Extending the lifetime of a pipeline with ten years in 48 hours

Flare lines at refineries often suffer from corrosion. These lines are crucial for the refinery as these systems are used for safe disposal of waste gases by burning them under controlled conditions. Imagine the mixture of chemistry these lines face. Very susceptible for corrosion attacks, mainly internally but also external. The often high temperatures of the medium also accelerate corrosion. Blasting, cleaning and wrapping the lines by applying composite materials is a way to extend the lifetime. Composite materials have strong capabilities and it’s a durable and environmentally accepted method for repair. The engineered repair applied can withstand a 100% wall loss situation of a certain diameter.

Challenge

In this particular case blasting the pipe was not an option. The crew had to roughen and clean the flare line sections by hand(tools). In many instances a Bristle Blaster® of Monti may be the solution. Surface preparation is a key part of a successful wrapping project.

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Repairing a massive carbon steel pipe within 24 hours

A small leak under a metal sleeve at a 28” pipe is a problem and requests a fast and proper solution. The size of the sleeve basically would be considered as the defected area which required a repair of a reasonable size. By dropping the pressure in the pipeline the small leak was stopped and contained. Immediately after the leak was stopped the engineered carbon fiber epoxy based system was applied covering the sleeve and surrounding pipe area. The multi-layer carbon fiber solution will last for many years.

Challenge

The timeframe between starting preparation of the 100 kg repair kit, shipping from the Netherlands to Croatia, installing the wrap and curing of the epoxy was roughly 24 hours.

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Proactive corrosion protection for a carbon steel storage tank

Tank repair by applying composites is getting more and more popular. Often the roof of a tank is affected by corrosion. Corrosion due to the medium (might be aggressive) or exposing to the weather conditions. Also the tank wall itself might be exposed to corrosion. Often cracking or degradation of the wall is a problem. In the Netherlands and Belgium we as CTE BV are providing these services by installing carbon patches. The case study below is describing the repair of cooling water tanks suffering from internal corrosion at a steel plant.

Challenge

Cooling water is an important part of the process of making steel. Without proper cooling a plant can come to a standstill. Working inside a tank requires a special training (confined space) on top of the normal installation certificate.

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Repairing an active leak at a natural gas carbon steel pipeline

An active leak in a natural gas transmission pipeline is a nightmare for every gas distributor. It creates an environmental undesirable and dangerous situation that needs to be fixed as soon as possible. Stopping the leak was the first step in the process of repairing the pipeline. In this case the girth welds of the pipe were showing weak points and in one particular case there was a small leak. After the leak was stopped by using a low-profile leak sealing solution provided by CTE BV the engineered carbon fiber epoxy based system was wrapped around the repaired area. The particular area was secured for future leakages.

Challenge

Besides stopping an active leak also the winter circumstances did ask for a professional approach towards a successful repair according ISO 24817.

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