Online Leak Sealing • Composite Wrapping
Excel Stark delivers engineered online leak sealing and composite repairs that keep refineries, pipelines and utilities running safely without unplanned shutdowns.
Online Leak Sealing Design Flow (excerpt)
Based on classic Furmanite leak sealing methodology, adapted and extended for Excel Stark’s composite systems.
Trusted on critical assets worldwide
On-line & offline
Across MENA & beyond
Engineered repairs
Resin systems
Core Capabilities
From enclosures for live leaks to crack-resistant high modulus carbon systems, Excel Stark covers the full spectrum of clamp, wrap and hybrid repair solutions.
Design and installation of engineered enclosures and clamps on live systems — without shutdown.
Cold-applied glass and carbon fibre systems for process piping, pipelines and tanks.
Hybrid solutions combining mechanical clamps and long-life composite overwrap.
On-line valve gland packing and line killing to stop fugitive emissions and restore tight shutoff.
Ring-type and wire-type enclosures for leaking flange gaskets, even with minimal gaps.
High modulus carbon systems to reinforce cracks, dents, wrinkle bends and geotechnical loading.
Permanent composite sleeve and wrap systems for high-pressure pipelines and storage tanks.
Product Systems
Drawn from independently tested systems such as Iridium Wrap Carbon, Titanium Wrap Glass and HydroWrap – covering temperatures from -55°C to +550°C and pressures up to high transmission pipeline levels.
High-modulus carbon fibre wrap for high-pressure pipelines, cracks, dents and wrinkle bends.
Typical use: High-pressure transmission pipelines, crack-like features, dents and geotechnical movement.
Cost-effective glass fibre system for process piping, tanks and secondary containment.
Typical use: Process piping external corrosion, tank patches and general reinforcement.
Pre-impregnated, water-activated wrap for quick, simple leak repairs where speed is critical.
Typical use: Rapid leak reduction on small-bore piping and low-to-medium pressure lines.
Hand-mixable epoxy putty formulated to plug active leaks before overwrapping.
Typical use: Localised hole and weep sealing on crude oil lines, tanks and fire water systems.
Metal rubber, plates and ratchet straps to divert and contain leaks, combined with composite overwrap.
Typical use: Cooling water lines and process lines where metal plates and straps can be safely installed.
How It Works
Based on the classic Furmanite on-line leak sealing process, Excel Stark uses dimension sheets, FEA-verified clamp designs and UK-approved calculations to ensure each enclosure is safe before it ever touches your line.
Composite cold wrapping is one of the fastest ways to extend remaining life or arrest corrosion without hot work — using glass, carbon or water-activated wraps selected to your design envelope.
Note: Material selection is based on temperature, pressure, fluid contents, leak condition and whether the unit is online or offline, as outlined in your design parameters.
Case Studies
Real-world references drawn from tank farms, refineries, pipelines and flare systems – based on composite repairs and on-line leak sealing techniques used by Excel Stark and its technology partners.
Fire water storage tank • Texas, USA
Leaking fire water tank with through-wall corrosion on a tall shell (18 m height).
Conditions: Ambient temperature; fire water duty; in-service condition preferred.
Solution: Leak sealed with epoxy putty and fibre, followed by glass / carbon overwrap to reinforce the shell.
Outcome: Leak stopped without hot work and tank integrity restored while avoiding full drainage.
Cooling water line • Process plant
Internal corrosion with multiple leaks on cooling water piping.
Conditions: 7 barg design pressure, 60°C operating temperature.
Solution: Leaks sealed using metal rubber, metal plates and ratchet straps, then overwrapped with composite.
Outcome: Delivered a minimum 10-year repair life with no hot work and minimal downtime.
Hydrocarbon storage tank • Canary Islands
Lack of fusion in tank welds requiring long-length reinforcement.
Conditions: In-service tank; long weld seams totalling 114 linear meters.
Solution: Glass fibre repair designed to ISO 24817 / API 653 and installed with local support.
Outcome: 20-year design life achieved with in-service repair, avoiding costly out-of-service work.
Crude oil storage tank • Saudi Arabia
Leak indication from tell-tale hole and localised wall degradation on a 36.7 m diameter tank.
Conditions: Crude oil service, elevated temperature; tank in operation.
Solution: Approximately 25 m² of tank wall wrapped with composite designed to ASME PCC-2 / API 653.
Outcome: 20-year design life with local installation support and no hot work on the tank wall.
20” crude oil pipeline • North Africa
Severe external corrosion up to 66% through wall on high-pressure crude oil line.
Conditions: Design pressure 210 barg, 60°C operating temperature.
Solution: Three layers of carbon fibre composite wrap installed along the defect zone.
Outcome: Pipeline integrity restored with a composite repair designed in line with ISO 24817.
Flare drum vessel • USA
Severe internal corrosion expected to cause leaks before the next planned shutdown.
Conditions: High-temperature, cyclic service with limited outage available.
Solution: Entire vessel wrapped with four layers of carbon fibre composite to contain internal defects.
Outcome: Drum kept in reliable service for ≥8 years, aligning with shutdown strategy and avoiding unplanned outage.
Services & Systems
Design and installation of engineered enclosures and clamps on live systems — without shutdown.
Cold-applied glass and carbon fibre systems for process piping, pipelines and tanks.
Hybrid solutions combining mechanical clamps and long-life composite overwrap.
On-line valve gland packing and line killing to stop fugitive emissions and restore tight shutoff.
Ring-type and wire-type enclosures for leaking flange gaskets, even with minimal gaps.
High modulus carbon systems to reinforce cracks, dents, wrinkle bends and geotechnical loading.
Permanent composite sleeve and wrap systems for high-pressure pipelines and storage tanks.
Carbon Fibre Epoxy System
High-modulus carbon fibre wrap for high-pressure pipelines, cracks, dents and wrinkle bends.
Glass Fibre Epoxy System
Cost-effective glass fibre system for process piping, tanks and secondary containment.
Water-Activated System
Pre-impregnated, water-activated wrap for quick, simple leak repairs where speed is critical.
Epoxy Putty
Hand-mixable epoxy putty formulated to plug active leaks before overwrapping.
Mechanical + Composite Hybrid
Metal rubber, plates and ratchet straps to divert and contain leaks, combined with composite overwrap.
Why Excel Stark
With engineering completed in Europe and field teams across the Middle East, Excel Stark combines rapid calculation turnaround with on-site presence where it matters most.
FAQ
These questions come directly from plant managers, pipeline integrity engineers and offshore operators dealing with live leaks and integrity concerns.
Excel Stark seals leaks on process piping, pipelines, bolted flange connections, valves (gland leaks and non-seating valves) and selected tank nozzles. Feasibility depends on pressure, temperature, geometry and access – our engineers assess each case before proposing an on-line solution.
Our resin systems cover a range from approximately -55°C up to +550°C when correctly specified. Design pressure limits depend on the defect and geometry; our composite systems have been qualified for high-pressure transmission pipelines and operate up to 210 barg in reference projects.
Yes. Composite repairs and leak sealing solutions are designed and checked in accordance with ISO 24817 and ASME PCC-2 Article 4.1, with additional testing for cracks, dents and wrinkle bends. For tanks we also follow API 653 requirements.
For urgent leaks we can provide rapid assessment based on photos, process data and line drawings, followed by dispatch of on-line leak sealing teams. Simple metal-plate and HydroWrap solutions can often be implemented within hours once on site, while engineered enclosures require fast-tracked design and fabrication.
We typically require line size and schedule, design and operating pressures and temperatures, fluid service, defect description and dimensions, isometric or P&ID drawings, photos and any inspection data (UT, MFL or visual). Our team uses this to prepare dimension sheets and run FEA and composite calculations.
Share your line data, defect measurements and photos. We will respond with a standards-based repair concept and implementation plan.
Contact
Share your leak details, operating envelope and photos. Our engineering team will review and revert with a safe, standards-based repair concept.
We aim to respond to urgent leaks on the same day. For true emergencies, please follow your site escalation protocol alongside this form.
