As of today, the United States operates 139 functional oil refineries, producing close to 18 million barrels of crude oil daily. However, a major concern arises when we consider the state of the nation’s 165,000 miles of oil pipelines. A significant portion of these pipelines—many of which are over 35 years old—are nearing the end of their operational lifespan, if they haven’t already surpassed it. This aging infrastructure poses a serious risk, as catastrophic oil spills have already caused extensive damage globally. As these pipelines continue to deteriorate, such incidents will only become more frequent unless urgent action is taken.
The core issue here, as with so many challenges we face, boils down to funding. Pipelines are corroding faster than we can afford to replace them, creating an escalating financial burden. Kent Moors, a respected expert in oil and gas policies, highlighted the gravity of the situation: “The global demand for repairing oil pipelines is estimated at $500 billion… and this figure increases by roughly a billion dollars each week.†Given this daunting reality, how can we address such a massive expense? The solution might just lie in HJ3’s carbon fiber technology.
Take, for instance, an incident at an Alaskan oil refinery where an ASTM A106 – Grade B steel vapor line header experienced both internal and external corrosion. This necessitated reinforcement measures due to severe steel loss and the presence of through-holes, which compromised the header's hoop strength entirely. Internal repairs also needed careful execution to avoid oxygen ingress, which posed a combustion hazard. The refinery was left with a critical decision: either replace the pipes, which would involve significant downtime and high costs, or opt for a more cost-effective repair solution.
After weighing their options, the refinery decided on repairing the pipes using HJ3’s CarbonSeal™ system. In just two short days, the vapor line header and the connected 42-inch diameter pipe were successfully reinforced. To ensure long-term protection against chemical exposure, a chemical-resistant base and topcoat were applied. The repair process started with the meticulous cleaning of the pipe surface to achieve a white metal finish using mechanical hand tools. Areas with through-holes and steel loss were patched, followed by the application of a basecoat and primer on the exterior. Saturated carbon fiber was then carefully wrapped around the pipe, concluding with the application of a protective topcoat.
What made this repair truly impressive was that it required neither downtime nor hot work permits or welding. The hoop strength of the structure was completely restored, and the header now boasts enhanced resistance to corrosion and chemicals. This efficient repair not only saved the refinery $300,000 compared to replacement costs but also consumed 22% less energy than manufacturing a new pipe would have required. Additionally, it helped conserve nearly 33,500 gallons of water, reduced over a ton of CO2 emissions, and avoided the disposal of more than 1,000 pounds of steel in landfills.
If you’re dealing with corroded steel pipes requiring reinforcement, don’t hesitate to reach out to HJ3. Their innovative solutions could be the key to solving your pipeline challenges while saving both money and the environment.
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Guangdong Tonglian Pipeline Technology Co., Ltd , https://www.tonglianpipeline.com