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There are currently 139 operating oil refineries in the United States, producing nearly 18 million barrels of crude oil daily.  Considering that a vast majority of the 165,000 miles of U.S. oil pipeline is at least 35 years old, the aging pipeline infrastructure is nearing the end of (or has already passed) its serviceable life.  Catastrophic oil leaks have already occurred all over the world, and leaks and spills will continue to occur as our pipeline continues to age.  The problem, like so many others that we face, is one of money.  Pipeline is corroding and aging faster than we can replace it, and it’s racking up a bill that no one can afford.  Kent Moors, an acclaimed oil and gas policy expert, says that “the immediate need worldwide [for oil pipeline repair] is put at $500 billion… and it’s growing by about a billion dollars every week.”  So how do we reduce this huge bill, you ask?  With HJ3’s carbon fiber, of course!


At an oil refinery in Alaska, an ASTM A106 – Grade B steel vapor line header corroded both internally and externally, requiring reinforcement.  The 20” vapor line header and attached 42”- diameter pipe required reinforcement due to steel loss and through-holes from extreme corrosion.  The entire structure had lost its hoop strength.  Additionally, the internal pipe repair had to be completed with extreme care to avoid oxygen ingression, as combustion was possible.  The refinery had the choice to replace the pipes, incurring downtime and extreme costs, or repair them.
Highly chemical-resistant base coat is applied


After reviewing their options, repairing the pipes with HJ3’s carbon fiber was a no-brainer.  The CarbonSealTM system repaired the vapor line header and attached pipe in only two days. Considering the constant exposure to chemicals, a chemical-resistant base and topcoat were vital for protecting the system. First, the pipe surface was cleaned to white metal using mechanical hand tools. Through-holes and other steel loss were patched, and the basecoat and primer were applied to the pipe exterior. Saturated carbon fiber followed, and the protective topcoat was applied last.
HJ3 primes the pipe


Saturated CarbonSeal fabric is applied to the pipe
HJ3’s carbon fiber is applied to the header


HJ3 applies the chemical-resistant topcoat
The finished structure’s hoop strength is restored


Repairing the pipe required no downtime, hot work permits, or welding. The structure’s hoop strength has been restored, and the header is now corrosion and chemical-resistant. The installation was completed within two days, and the refinery saved $300,000 compared to replacement costs. Furthermore, repairing the pipe required 22{f00316eaeff19fc4d3daa6454136ee4db9a0ad1868aa2a79e58a2db09827821d} less energy than would have been required to manufacture a new pipe. The repair prevented almost 33,500 gallons of water from being wasted, more than a ton of CO2 emissions from polluting our atmosphere, and more than 1,000 lbs of steel from potentially going to landfills. If you have a steel pipe that needs reinforcement, contact hj3 at info@hj3.com.