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Steel Process Vapor Line Repair
The United States currently operates 139 oil refineries, producing nearly 18 million barrels of crude oil daily. However, the country's vast pipeline network—spanning over 165,000 miles—is largely outdated, with most pipelines being at least 35 years old. As these systems age, their structural integrity weakens, increasing the risk of catastrophic leaks and spills. These incidents have already occurred in various parts of the world, and as the infrastructure continues to deteriorate, the problem is only going to worsen. The core issue lies in funding: pipelines are corroding faster than they can be replaced, leading to an ever-growing financial burden. Kent Moors, a respected expert in oil and gas policy, has pointed out that the global need for pipeline repairs is estimated at $500 billion—and this number increases by about $1 billion every week. So, how do we tackle this massive expense? The answer is HJ3’s carbon fiber technology.
At an Alaskan oil refinery, a critical ASTM A106 – Grade B steel vapor line header suffered from both internal and external corrosion. This led to significant steel loss, through-holes, and a complete loss of hoop strength. The repair required careful execution to avoid oxygen ingress, which could lead to dangerous combustion. The refinery had two options: replace the entire section, which would cause major downtime and high costs, or go for a more efficient and cost-effective repair solution.
They chose HJ3’s carbon fiber solution. Using the CarbonSeal™ system, the damaged vapor line header and attached 42-inch pipe were restored in just two days. Given the chemical exposure, a chemical-resistant base and topcoat were essential. The process began with thorough cleaning of the surface to achieve a white metal finish using mechanical tools. Through-holes and areas with steel loss were patched, followed by the application of the basecoat and primer. Then, saturated carbon fiber was applied, and finally, a protective topcoat was added.
What made this repair stand out was that it required no downtime, no hot work permits, and no welding. The structure’s hoop strength was fully restored, and the repaired area now offers excellent resistance to corrosion and chemicals. This approach saved the refinery $300,000 compared to replacement costs. Additionally, the energy used in the repair was 22% less than manufacturing a new pipe. It also prevented the waste of nearly 33,500 gallons of water, avoided over a ton of CO2 emissions, and kept more than 1,000 lbs of steel out of landfills.
If your steel pipes are showing signs of wear and need reinforcement, consider HJ3’s carbon fiber solutions. They offer a fast, safe, and sustainable alternative to traditional repair methods. Contact HJ3 today to learn more.