The United States currently operates 139 oil refineries, producing nearly 18 million barrels of crude oil daily. However, much of the country's 165,000 miles of oil pipelines are over 35 years old, meaning they're reaching or have already passed their expected lifespan. Aging infrastructure is a growing concern, as leaks and spills have already caused environmental damage worldwide. With pipelines continuing to deteriorate, these incidents are likely to become more frequent unless action is taken.
This issue isn't just about aging equipment—it’s also about money. Maintaining and replacing this aging network is becoming increasingly expensive. Kent Moors, a respected expert in oil and gas policy, has highlighted that the global need for pipeline repairs is estimated at $500 billion, with costs rising by around $1 billion each week. The question now is: how can we reduce this financial burden?
Enter HJ3's carbon fiber technology. At an Alaskan refinery, a critical vapor line header made of ASTM A106 – Grade B steel was suffering from severe internal and external corrosion. The 20-inch header and 42-inch pipe had lost structural integrity, with through-holes and significant metal loss. This posed a serious risk, not only to operations but also to safety, especially since oxygen ingress could lead to combustion during repairs.
The refinery had two options: replace the damaged sections, which would mean long downtime and high costs, or repair them using a more efficient and cost-effective solution. 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 significant operational disruption.
The process began with thorough surface preparation, achieving a white metal finish using mechanical tools. Any through-holes were patched, and a chemical-resistant basecoat and primer were applied. Then, saturated carbon fiber was carefully wrapped around the structure, followed by a protective topcoat. The result was a fully restored pipeline with full hoop strength and excellent resistance to corrosion and chemicals.
This repair saved the refinery over $300,000 compared to replacement costs. It also used 22% less energy, prevented the waste of nearly 33,500 gallons of water, and reduced CO2 emissions by over a ton. Plus, it avoided the disposal of more than 1,000 pounds of steel in landfills.
If you're facing similar challenges with aging pipeline infrastructure, consider HJ3's advanced carbon fiber solutions. They offer a smart, sustainable, and cost-effective alternative to traditional repair and replacement methods. Contact HJ3 today to learn more about how their technology can protect your assets and reduce long-term costs.
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