During a project in (2001), insulation was applied on a cold equipment as follows:

• Surface preparation and blasting completed.
• Vapor stop applied at all terminations.
• First layer of PIR insulation applied and inspected.
• Vapor barrier applied, first layer inspection passed.
• Second PIR layer applied, final inspection completed and accepted.

After a few months of plant operation, I observed a leak near a support area with heavy ice formation.

Possible causes I suspect include:

• Breach or discontinuity in the vapor barrier.
• Mechanical stress or vibration at support points.
• Thermal bridging or gaps in insulation layers.

I am seeking expert advice on repair options while the plant is live. Is it necessary to wait for a shutdown, or are there methods to repair the insulation online?

Any insights or suggestions would be highly appreciated.