Understanding Composite Repairs: Expert Answers with Brad Whelan, HJ3’s Senior Application Engineer

Composite repairs have become a more common repair method for many industrial applications. They are a proven solution to keep lines in operation and for repairing many defects for pipelines such as anomalies, dents, and other features without downtime. We sat down with Brad Whelan, HJ3’s Senior Composites Application Engineer, to get his insights on the application, benefits, and unique aspects of composite fiber repairs. 

Can you tell us about your background and experience in composite fiber repairs?

I’m Brad Whelan, a Senior Applications Engineer at HJ3 with over 10 years of experience in composite repair design. At HJ3, I primarily focus on repairs involving piping, including process piping at a plant or refinery, transmission pipelines, and pressure vessels. Additionally, I have helped develop many of our design calculators. We have very high commitments to our clients and customers. It’s not just about selling the material; it’s about selling a solution that actually works. 

What type of pipe repairs do composite fiber products typically address?

Process Piping Repairs

Process piping repairs generally look at elbows, tees, and pressure vessels. In the petrochemical market, you see a wide variety of chemicals, alongside lower pressures and temperatures. We work closely with contractor partners all over the world to provide custom-engineered solutions to accommodate a wide range of services and geometric challenges.

Transmission Pipeline Repairs

Since transmission pipelines traverse thousands of miles at once, the focus is more on asking, “Can we classify these repairs as permanent repairs?” Longevity is the focus. These repairs need to be sustainable for many decades for these assets. Many of these repairs also require quick response times as repair lengths and designs can change upon final inspection of an indication.

What defects can be addressed with composite fiber repairs?

Corrosion

A common defect that can be addressed is corrosion. Corrosion can be caused by a multitude of issues. For example, for petrochemical assets, when the line is insulated, corrosion can happen due to moisture forming under the insulation. This defect is known as CUI—Corrosion Under Insulation.  

Another common defect often occurs around the coating of the pipe. The coatings can fail and start to rust. Additionally, chemicals on the inside of the line can cause defects. Acid lines, for example, should be stainless steel, but problems can occur that may cause internal corrosion on the steel.

Dents

Oil and gas transmission pipelines are a bit of a different story. They are very well protected due to being highly regulated. However, they are more subject to dents due to third-party damage, manufacturing, natural phenomena, etc. To repair dents, a process similar to corrosion repair is implemented. With pipelines, the cyclic profile is evaluated and used to calculate the best repair, as the pressure fluctuates in the line.

What are the advantages of using composite repairs over traditional repair methods?

Minimized Downtime

In all instances, the goal is to extend the life of the asset in the most cost-effective and efficient way. Shutting assets down is not an option, as this can cost the user millions of dollars each day. Extending the life of the assets by carbon fiber is the way to go.

Lightweight Solution

Composites’ main competition is clamps and closures in the petrochemical market; however, these tend to be much heavier, as they are made of steel. Composite repairs weigh just 10% of their alternatives. 

Fast and Efficient Solution

Pipeline repair sleeves are fabricated in the field and can take hours to install. Complex replacement vessels can take months, with many of these new assets being shipped from overseas. With long lead times, composites have become a great alternative as they can be deployed same day. 

How does HJ3’s CarbonSeal™ stand out in the market?

Speed To Solution™

Where HJ3 stands out is the speed of delivery, materials can be shipped out to any job same day. We also offer zero-cost inventory plans to keep materials on-site. 

Unmatched Strength Per Ply

HJ3 offers the strongest repair system per layer in the industry. Our products are made of a higher density material than others. This means fewer layers are needed, leading to faster installation times and lower overall costs.

Proven Performance

We have performed long-term performance testing for dents, corrosion anomalies, and crack-like defects in addition to full-scale testing for ASME PCC-2 compliance. For over 20 years, HJ3 has been providing engineered composite repair systems for a wide range of industries and applications, including tanks, vessels, and concrete strengthening applications. As a multi-disciplined engineered firm and manufacturer, HJ3 offers the widest range of repair systems and solutions in the industry.

Can you share a notable project where composite repairs made a significant impact?

A few years ago, we worked on a pressure vessel that was experiencing cracking near the weld seam of the head, resulting in a leak. The damage was discovered in the middle of a scheduled outage. Due to timelines, there was no option for replacement. The turnaround was coming to an end, and the client was looking for an emergency solution that would restore integrity to the vessel. They were able to weld plates around the leaks so we could come in and wrap the entire vessel head in addition to the 4-foot strength section of the shell. We were able to make the repair within 48 hours by working through a nested contractor. In the end, there was no negative impact to the turnaround schedule, the design is projected to last until 2029 and has been in service for several years now.

HJ3 takes pride in the work we provide to our clients and customers, specifically our knowledge of industry guidelines and compliance. We consider ourselves a specialty provider of engineered solutions, not just a material manufacturer and supplier. HJ3 works closely with operator engineers to navigate a viable solution while ensuring compliance and longevity of the repair.

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