ProAssure™ Version 2 – Enhancement Initiative

Repair and rehabilitation efforts for the ageing onshore and offshore pipelines are crucial for PETRONAS’ operation.

For more than 15 years, composite repairs have been increasingly applied for the maintenance and rehabilitation of piping, pipelines, and vessels in the oil and gas industry.

Composite repairs restore the integrity of assets, effectively and economically extending operational life and prevents loss of containment. The repair method provides strength as well as corrosion protection and live repair for the assets.

PETRONAS developed its in-house composite overwrap repair system called ProAssure™ Wrap for offshore and onshore application in 2008. ProAssure™ Wrap is an overwrap composite repair system made of non-crimp fabric composites that provide high strength, ease of handling, and low manufacturing costs. It is highly flexible and, hence, can overcome the issue of tight access and complex-shaped pipelines. Upon application, the wrap can harden through curing in ambient conditions.

ProAssure™ can be used to repair and restore corroded and leaking pipelines whilst providing protection against further corrosion.

Piloted at SK Oil Tukau-B riser, PETRONAS Carigali Sdn Bhd (PCSB) in 2010, the product was deployed in 2012 for repair and mitigation of piping, pipeline, risers, and caissons across PCSB.

The application of ProAssure™ Wrap became broader in 2014 to cover repairs at onshore plants and pipelines such as for Malaysia Liquified Natural Gas (MLNG), PETRONAS Gas Bhd (PGB), and Malaysian Refining Company Sdn Bhd (MRCSB), amongst others.

PETRONAS has achieved substantial value creation amounting to millions of dollars by avoiding shutting down and eliminating the need for pipeline/piping section replacement. The identified cost avoidance from the loss of production, piping, and pipeline replacement was approximately RM508 million, based on more than 1,000 successful repairs recorded from 2016 to 2021.

An enhancement to Pressures Wrap was initiated in 2022 to ensure the product remains competitive against other composites in the market.

Various fabrics were assessed in terms of their specification, pricing, and material. A total of twelve (12) qualification tests were successfully conducted with third-party approved certification. 

The fiber glass fabric was replaced with an enhanced material in accordance with ISO 24817 and ASME PCC2.

The result showed a new fabric with similar resin formulation was able to improve ProAssure™ performance where between 30-45% reduction of layers was achievable for leak repair (Type B). This shows that cost is optimised when ProAssure™ is applied as a repair method to address both wall thinning and leaks. 

The newly improved ProAssure™ is ready for deployment and commercialisation by the fourth quarter of 2023.

Snapshot of ProAssure™  Wrap application process flow.
 

Snapshot of ProAssure™ repair before and after application using wrapping method, non-standard geometry and patching method.  
 

Certification Program for ProAssure™ Applicator

Internal customer response on ProAssure application: 
 

“ProAssure is always our preferred repair solution and trusted brand. It provides flexibility that can accommodate the surface profile of the pipeline, is cost-effective, technically  proven with good track record and readily available when required.” 
– Asset Delivery Integration Value Assurance (IVA), Upstream Malaysia Assets 

‘ProAssure helps PGB in asset management whilst fulfilling our obligations as  responsible corporate citizens in meeting Operational Responsibility, Business  Responsibility and Environmental Responsibility’ 
- Head of Pipeline & Civil Integrity, PETRONAS Gas Bhd, Gas Transmission  & Regasification. 

‘ProAssure application exceeds client expectations and is continuously improve based  on our feedback.’ 
- Staff Engineer, PETRONAS Gas Bhd, Gas Transmission & Regasification.  

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