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The United States currently operates 139 oil refineries, producing close to 18 million barrels of crude oil daily. However, the country’s extensive network of oil pipelines, spanning over 165,000 miles, is showing its age—most of these pipelines are more than 35 years old. As they continue to deteriorate, the risk of catastrophic leaks increases, causing environmental damage and economic losses. Kent Moors, an esteemed expert in oil and gas policies, has pointed out that the global cost for repairing oil pipelines stands at an estimated $500 billion and is rising by about a billion dollars weekly. Addressing this issue isn’t just a necessity; it’s urgent.
Take, for instance, an incident at an oil refinery in Alaska where an ASTM A106 – Grade B steel vapor line header experienced severe internal and external corrosion. This corrosion led to significant steel loss and through-holes, compromising the structural integrity of the pipe. The attached 42-inch diameter pipe also required reinforcement. The refinery had to make a tough call: either replace the damaged pipes, which would result in substantial downtime and high costs, or opt for repairs.
After careful deliberation, the refinery decided to repair the pipes using HJ3’s CarbonSeal™ system. The process was swift, completing the reinforcement in just two days without any downtime or the need for hot work permits. The repair began with a thorough cleaning of the pipe surface to achieve a white metal finish. Next, patches were applied to address through-holes and steel loss. A chemical-resistant basecoat and primer were then used on the exterior before saturating the carbon fiber and applying a protective topcoat.
What’s truly impressive is that this repair not only restored the pipe’s hoop strength but also made it resistant to further corrosion and chemical exposure. Compared to the cost of replacing the pipes, this repair saved the refinery $300,000. Moreover, the repair consumed 22% less energy than manufacturing a new pipe, conserved 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 waste.
If your facility is facing similar challenges, don’t overlook the benefits of HJ3’s carbon fiber solutions. Contact HJ3 today to learn how their innovative technology can help preserve your infrastructure while saving time, money, and resources.
June 18, 2025