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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 network of 165,000 miles of oil pipelines is aging rapidly—most are over 35 years old and nearing the end of their useful life. This aging infrastructure poses a growing risk, as catastrophic oil leaks have already occurred in various parts of the world. With the pipeline system continuing to deteriorate, these incidents are likely to become more frequent unless action is taken.
The core issue lies in funding. Pipeline corrosion and degradation are happening at a faster rate than we can afford to replace them, leading to an ever-increasing financial burden. Kent Moors, a respected expert in oil and gas policy, has highlighted that the global need for pipeline repairs is estimated at $500 billion—and this figure is rising by about a billion dollars every week. So, how do we address this massive challenge?
Enter HJ3’s carbon fiber technology. It offers a smart, cost-effective, and environmentally friendly solution for pipeline reinforcement and repair.
At an Alaskan refinery, a critical ASTM A106 – Grade B steel vapor line header suffered severe internal and external corrosion. The 20-inch header and the attached 42-inch pipe were compromised, with significant steel loss and through-holes that had completely weakened the hoop strength. Additionally, the internal repair required careful execution to prevent oxygen from entering, which could pose a combustion risk.
The refinery faced a tough decision: either replace the damaged sections, which would involve extensive downtime and high costs, or find a quicker and more economical alternative. They chose the latter and opted for HJ3’s CarbonSeal™ system.
The repair was completed in just two days, without the need for hot work permits, welding, or shutting down operations. The process began with thorough surface preparation using mechanical tools to achieve a white metal finish. Any through-holes and areas with steel loss were patched, followed by the application of a chemical-resistant basecoat and primer. Then, saturated carbon fiber was applied, and a protective topcoat was added to ensure long-term durability.
This innovative repair restored full structural integrity and provided exceptional resistance to corrosion and chemicals. Not only did it save the refinery $300,000 compared to replacement costs, but it also used 22% less energy and prevented the waste of nearly 33,500 gallons of water. It also avoided over a ton of CO2 emissions and the disposal of more than 1,000 lbs of steel in landfills.
If your facility is dealing with aging or corroded steel pipes, HJ3’s carbon fiber solutions offer a smarter, faster, and more sustainable way to reinforce and protect your infrastructure. Don’t wait—contact HJ3 today to learn how we can help you avoid costly replacements and reduce environmental impact.