Technowrap™ Composite Repair – Air Buffer Bottle (FPSO) Service Line

Overview

Gecric Integrity, in collaboration with ICR Integrity, successfully restored the integrity of an air buffer bottle aboard an FPSO offshore Ghana. The asset had experienced significant wall loss due to external corrosion, with remaining thickness reduced to approximately 1.8mm. The client required a fast, reliable, and cost-effective repair solution with a 10-year design life—without shutting down operations.

Planning

Joint engineering collaboration between Gecric Integrity and ICR Integrity
Detailed assessment of corrosion severity and remaining wall thickness
Selection of Technowrap™ composite repair system for high-temperature application
Development of execution plan to ensure no shutdown and minimal operational disruption
Mobilization of local Ghana-based technicians and materials

Execution

Surface preparation to ST3 standard with minimum roughness of 54 microns
Application of Technowrap™ 2K cloth with high-temperature resin
Installation of 15 engineered composite layers
Continuous quality assurance checks throughout the repair process
Completion of installation across five-day shifts offshore

Operational Challenge

Significant wall loss (down to 1.8mm thickness)
Offshore FPSO constraints with limited access
Requirement to execute repair without shutdown
Need for a durable, long-term solution (10-year design life)

Outcome

Successfully restored structural integrity of the air buffer bottle
Achieved full 10-year design life requirement
Completed repair safely with zero shutdown
Delivered a fast, cost-effective solution minimizing production impact