The United States currently operates 139 oil refineries, producing nearly 18 million barrels of crude oil daily. However, the country's vast network of 165,000 miles of oil pipelines is aging rapidly—many of these lines are over 35 years old and nearing the end of their useful life. As a result, the risk of catastrophic oil leaks is increasing, with incidents already causing environmental damage around the world. The problem isn't just about aging infrastructure; it's also a financial crisis. Pipelines are corroding faster than they can be replaced, leading to an ever-growing repair bill. Kent Moors, a respected expert in oil and gas policy, has pointed out that the global need for pipeline repairs is estimated at $500 billion—and this figure increases by about a billion dollars every week. So, how do we tackle this massive cost? The answer lies in HJ3’s advanced carbon fiber technology.
At an Alaskan refinery, a critical ASTM A106-Grade B steel vapor line header was suffering from severe internal and external corrosion. The 20-inch header and its attached 42-inch pipe had lost structural integrity due to significant metal loss and through-holes, compromising the hoop strength of the entire system. The internal repair required careful execution to prevent oxygen from entering, which could lead to dangerous combustion. The refinery had two options: replace the pipes entirely, which would mean costly downtime, or choose a more efficient and economical repair solution.
They opted for HJ3’s CarbonSeal™ system, which restored the vapor line header and connected pipe in just two days. Given the constant exposure to chemicals, a chemical-resistant base and topcoat were essential to protect the repaired section. The process began with thorough surface preparation using mechanical tools to achieve a white metal finish. Any holes or areas with missing steel were carefully patched, followed by the application of a base coat and primer. Then, saturated carbon fiber was applied, and a protective topcoat completed the repair.
What made this repair stand out was the absence of downtime, hot work permits, and welding. The structure’s hoop strength was fully restored, and the repaired section is now highly resistant to corrosion and chemical damage. This innovative method saved the refinery over $300,000 compared to replacement costs. Additionally, the process used 22% less energy than manufacturing a new pipe, prevented the waste of nearly 33,500 gallons of water, reduced CO2 emissions by over a ton, and avoided the disposal of more than 1,000 pounds of steel in landfills.
If your facility is facing similar challenges with aging steel piping, consider HJ3’s carbon fiber solutions. They offer a fast, safe, and sustainable alternative to traditional repairs. Contact HJ3 today to learn more about how they can help you save time, money, and resources while protecting your infrastructure.
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