‍In 2023, over a quarter (28.2%) of pipeline incidents were caused by corrosion. As a time-dependent threat, early detection and mitigation are key to minimizing the impact corrosion has on pipeline integrity. If corrosion progresses too much, the pipeline can have through-wall failures from metal loss. To combat this, composite repairs are a cost-effective, permanent, and compliant solution to restore the pipeline’s serviceability compared to traditional steel sleeves.    

Understanding the Threat: Why Corrosion Demands Proactive Solutions

As corrosion develops, the pipeline begins to lose strength due to metal loss. This can eventually lead to failures and high costs associated with damages and repairs. Two primary types of corrosion exist on pipelines: external and internal.  

External corrosion occurs due to chemical reactions between the steel and its environment. Internal corrosion occurs from a chemical attack on the interior of the pipe from products transported in the pipe..  

Composite repairs have become a widely accepted repair method for both internal and external corrosion.  It should be noted that an external repair will not address internal corrosion directly; therefore, a composite repair is not a permanent solution for internal corrosion.  

Key Benefits of Composite Repairs

Benefit 1: Cost-Effectiveness  

A standard composite repair requires a 2-to-3-person crew and no heavy machinery or welding. In contrast, a steel sleeve requires larger crews of 4-5 people, including a qualified welder. Depending on the size of the line, a crane may be needed, which drastically increases costs.  

Benefit 2: Corrosion Resistance

Steel sleeves are still susceptible to corrosion if not properly coated and maintained. Composite materials, on the other hand, are corrosion-resistant. By creating a barrier between the pipe and the external environment, the corrosion is isolated and inhibited from further progressing. They also provide structural reinforcement, if the system is properly designed and implemented.

Benefit 3: Long-Term Reliability

In most cases, the repair can be completed in one or two shifts, including surface preparation, application, and curing. This results in reduced downtime and faster backfills.

CarbonSeal™: A Compliant Repair Solution  

With the advances in composite repair methods and comprehensive testing, including long-term cyclical fatigue testing for corrosion, dents, and cracks conducted by HJ3 and third-party evaluators, operators can trust the durability and effectiveness of HJ3's CarbonSeal™ for pipeline repairs. As the strongest per-ply system in the industry, CarbonSeal™  is designed to reduce costs and installation time while providing a permanent ASME-PCC 2-compliant repair for corrosion.  

Pipeline corrosion remains a persistent challenge for operators, threatening the integrity of the line and increasing the risk of costly failures. By implementing composite repairs, operators can receive an innovative, compliant, and cost-effective approach to mitigating corrosion. Overall, these repairs reduce downtime while offering long-term reliability. To learn more about how HJ3 can help you prevent corrosion damage, contact us today.