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Composite repairs have become a go-to solution in many industrial settings. They offer an efficient and effective way to address pipeline issues without causing costly downtime. Whether it's corrosion, dents, or other defects, composite materials provide a reliable alternative to traditional repair methods. To gain a deeper understanding of the benefits and applications of composite fiber repairs, we sat down with Brad Whelan, HJ3’s Senior Composites Application Engineer, to get his expert perspective.
Can you tell us about your background and experience in composite fiber repairs?
I’m Brad Whelan, and I’ve been working in the field of composite repair design for over 10 years. At HJ3, my role involves designing and implementing composite solutions for piping systems, including process piping in plants and refineries, transmission pipelines, and pressure vessels. I also play a key role in developing our design calculators, which help ensure accurate and efficient repair solutions. What I love most is that we don’t just sell products—we provide real, working solutions that meet the needs of our clients and keep their operations running smoothly.
What type of pipe repairs do composite fiber products typically address?
Composite fiber products are used across a wide range of applications, depending on the environment and the type of asset being repaired.
Process Piping Repairs
In the petrochemical industry, we often deal with elbows, tees, and pressure vessels. These systems handle a variety of chemicals under lower pressures and temperatures. Our team works closely with contractors around the world to develop custom solutions that fit specific geometries and operational requirements.
Transmission Pipeline Repairs
For transmission pipelines—often spanning thousands of miles—the focus is on long-term reliability. These repairs need to last for decades, so we prioritize durability and sustainability. Additionally, because these pipelines are critical infrastructure, quick response times are essential. The final inspection can sometimes change the repair plan, so flexibility is key.
What defects can be addressed with composite fiber repairs?
Composites are particularly effective at handling a variety of common pipeline defects.
Corrosion
One of the most frequent issues we see is corrosion. In petrochemical environments, moisture trapped under insulation can lead to Corrosion Under Insulation (CUI). Coating failures can also cause rusting, and internal chemical exposure, like in acid lines, may lead to internal corrosion if the material isn't suitable.
Dents
Dents are more common in oil and gas transmission pipelines due to third-party damage, manufacturing imperfections, or natural events. Repairing dents often involves similar techniques to corrosion repair, with a focus on evaluating the cyclic stress profile of the pipeline to determine the best approach.
What are the advantages of using composite repairs over traditional repair methods?
There are several clear benefits to choosing composite repairs over conventional methods.
Minimized Downtime
The goal of any repair is to extend the life of the asset in the most cost-effective way. Shutting down a system can cost millions per day, so composites allow for faster, less disruptive repairs that keep operations running.
Lightweight Solution
Composites are significantly lighter than steel clamps or closures, which are commonly used as alternatives. This makes installation easier and reduces logistical challenges.
Fast and Efficient Solution
Unlike traditional replacements that may take months to fabricate and ship, composite repairs can be deployed on the same day. This speed is especially valuable in emergency situations where time is critical.
How does HJ3’s CarbonSeal™ stand out in the market?
HJ3’s CarbonSeal™ has earned a strong reputation for its performance and efficiency.
Speed To Solutionâ„¢
One of our key differentiators is our ability to deliver materials quickly. We can ship carbon fiber products anywhere in the world the same day, and we also offer zero-cost inventory plans to keep materials on-site for immediate use.
Unmatched Strength Per Ply
Our products are made from higher-density materials, which means fewer layers are needed for the same level of strength. This not only speeds up installation but also reduces overall costs.
Proven Performance
We conduct extensive testing, including long-term performance evaluations and full-scale tests for ASME PCC-2 compliance. With over 20 years of experience, HJ3 has built a comprehensive range of composite repair systems for various industries, from tanks and vessels to concrete structures.
Can you share a notable project where composite repairs made a significant impact?
A few years ago, we were called in to repair a pressure vessel that had developed cracks near the weld seam. The issue was discovered during a scheduled maintenance window, and there wasn’t enough time to replace the entire unit. Using a combination of welding and composite wrapping, we were able to restore the integrity of the vessel within 48 hours. The repair was completed without affecting the overall schedule, and the vessel has been in service since then, with an expected lifespan through 2029.
At HJ3, we pride ourselves on delivering high-quality, compliant solutions that meet the unique needs of each client. We’re not just a supplier—we’re a partner in engineering and problem-solving. Our commitment to innovation, safety, and performance ensures that every repair we perform is both effective and sustainable.