NASA and Kansas City Students Work Together to Understand Corrosion in Space
June 22 03:26:36, 2025
The United States currently operates 139 oil refineries, producing close to 18 million barrels of crude oil daily. However, much of the nation’s 165,000 miles of oil pipelines are over 35 years old, nearing or exceeding their functional lifespan. The consequences of aging pipelines are well-documented, with catastrophic oil spills having devastated environments worldwide. As our existing pipeline infrastructure continues to deteriorate, these incidents are bound to increase unless urgent action is taken. Kent Moors, a respected expert in oil and gas policy, estimates that the global cost of repairing pipelines is approximately $500 billion, a figure that increases by about a billion dollars weekly. The challenge lies in finding a way to address this issue without breaking the bank.
At an oil refinery in Alaska, an ASTM A106 – Grade B steel vapor line header experienced both internal and external corrosion, compromising its structural integrity. The 20-inch diameter header and the connected 42-inch pipe were severely affected, leading to significant steel loss and through-holes. This damage not only jeopardized the header’s hoop strength but also posed risks related to oxygen ingress, which could lead to combustion hazards. The refinery had to decide between the costly option of replacing the pipes—resulting in extended downtime—or opting for a more practical repair solution.
After weighing their options, they chose to reinforce the pipes using HJ3's CarbonSealâ„¢ system. This innovative approach successfully restored the vapor line header and the attached pipe within just two days. To ensure protection against chemical exposure, a chemical-resistant basecoat and topcoat were applied. The process began with 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. Saturated carbon fiber was then applied, completing the restoration with a protective topcoat.
What makes this repair particularly impressive is that it was done without requiring any downtime, hot work permits, or welding. The hoop strength of the structure was fully restored, making the header resilient to corrosion and chemical exposure. This cost-effective solution saved the refinery $300,000 compared to the price of replacing the pipes. Moreover, the repair consumed 22% less energy than manufacturing new pipes would have required. It also conserved nearly 33,500 gallons of water, reduced over a ton of CO2 emissions, and prevented the disposal of more than 1,000 pounds of steel in landfills.
If you're facing similar challenges with your steel pipes, don’t hesitate to reach out to HJ3. Their expertise in carbon fiber technology offers a sustainable and efficient way to extend the life of critical infrastructure. Let’s work together to reduce waste, lower costs, and protect our environment. Contact HJ3 today at [insert contact information].