Understanding Composite Repairs: Expert Insights from Brad Whelan, HJ3’s Senior Application Engineer
Composite repairs have become a go-to solution for many industrial applications. They offer an effective way to maintain operations and address pipeline defects like anomalies, dents, and more without causing costly downtime. To gain deeper insight into this growing field, we spoke with Brad Whelan, HJ3’s Senior Composites Application Engineer. With over a decade of experience in composite repair design, Brad shares his expertise on the application, benefits, and unique aspects of using fiber composites in pipeline repairs.
Can you tell us about your background and experience in composite fiber repairs?
Hi, I’m Brad Whelan, and I’ve been working as a Senior Applications Engineer at HJ3 for over 10 years. My focus has been on composite repair solutions for piping systems—whether it's process piping in plants or refineries, transmission pipelines, or pressure vessels. I also play a key role in developing our design calculators, which help ensure that every repair is tailored to the specific needs of the client. At HJ3, we don’t just sell materials—we provide real, reliable solutions that work under real-world conditions.
What type of pipe repairs do composite fiber products typically address?
Process Piping Repairs
Process piping often involves complex geometries like elbows, tees, and pressure vessels. In the petrochemical industry, where chemicals can be highly corrosive and operating conditions vary, we work closely with contractors worldwide to deliver custom-engineered solutions. Our goal is to handle unique challenges while maintaining safety and efficiency.
Transmission Pipeline Repairs
Transmission pipelines cover vast distances, so the focus here is on long-term, permanent repairs. These assets need to last for decades, and the repair must be both durable and efficient. Often, these repairs require quick action, as final inspections may reveal new details that affect the repair plan.
What defects can be addressed with composite fiber repairs?
Corrosion
Corrosion is one of the most common issues we tackle. For example, Corrosion Under Insulation (CUI) occurs when moisture forms beneath insulation, especially in petrochemical facilities. Another issue is coating failure, which can lead to rusting. Internal corrosion is also a concern, particularly in acid lines where stainless steel is expected but not always maintained properly.
Dents
In oil and gas transmission pipelines, dents are a frequent problem due to third-party damage, manufacturing flaws, or natural events. Repairing dents requires evaluating the cyclic loading of the pipeline, as pressure fluctuations influence the best repair approach.
What are the advantages of using composite repairs over traditional methods?
Minimized Downtime
The main goal of any repair is to extend asset life in the most cost-effective way. Shutting down operations is expensive, so using carbon fiber composites allows for quicker, less disruptive repairs.
Lightweight Solution
Composites are significantly lighter than steel clamps or closures, weighing just 10% of their alternatives. This makes them easier to transport and install, especially in remote locations.
Fast and Efficient
Unlike traditional repairs that can take months, composite repairs can be fabricated and installed on-site in a matter of hours. This reduces lead times and ensures faster return to service.
How does HJ3’s CarbonSeal™ stand out in the market?
Speed To Solutionâ„¢
HJ3 prides itself on fast delivery. We can ship materials same day and offer zero-cost inventory plans to keep supplies on-site, ensuring rapid response to emergencies.
Unmatched Strength Per Ply
Our system delivers superior strength per layer compared to other products on the market. The higher density material means fewer layers are needed, reducing installation time and costs.
Proven Performance
We conduct extensive testing, including long-term performance evaluations and full-scale tests for ASME PCC-2 compliance. For over 20 years, HJ3 has delivered engineered composite solutions across multiple industries, from tanks and vessels to concrete strengthening.
Can you share a notable project where composite repairs made a significant impact?
A few years ago, we helped a client repair a pressure vessel that had developed cracks near the weld seam, leading to a leak. The issue was discovered during a scheduled outage, and there was no time for replacement. Using a nested contractor, we wrapped the entire vessel head and added a 4-foot strength section of the shell. The repair was completed in just 48 hours, and the vessel was back in service without affecting the overall turnaround schedule. The design is expected to last until 2029, and it has performed flawlessly since then.
At HJ3, we’re committed to delivering high-quality, compliant solutions that meet the unique needs of each client. We see ourselves as a specialty provider of engineered systems, not just a supplier of materials. By working closely with operator engineers, we ensure that every repair is safe, sustainable, and meets industry standards.
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