A successful high-temperature trial proved CarbonSeal HT1 can deliver engineered composite repairs online without shutdown, previously a limitation in the industry!
Composite repairs at elevated operating temperatures have traditionally been a limiting factor for many asset owners. Conventional composite repair systems often require equipment to be taken offline or shut down before installation, resulting in significant production losses, extended maintenance windows and increased operating costs. HJ3’s CarbonSeal HT1 Engineered Composite Repair System has been proven and tested globally for application on high-temperature operating assets, delivering reliable high-temperature composite repairs in conditions where many alternative technologies have struggled or failed. This trial was designed to validate the system under realistic operating conditions by simulating a severe Type B through-wall defect on a DN300 spool operating at 85°C.
Our Solution
PipeServ partnered with HJ3 to validate the CarbonSeal HT1 Engineered Composite Repair System through a live high-temperature trial on a DN300 spool containing an 85 mm through-wall defect operating at 85°C. Following abrasive blasting and surface preparation, the engineered composite repair was installed in just over one hour, before being cured and successfully hydrostatically pressure tested at 1.5 times operating pressure. Comparable composite repair systems had previously required up to three days to complete under similar conditions and were unable to achieve the same outcome. The success of the trial provided the confidence to deploy the technology in the field, with PipeServ subsequently completing 14 live Amine line repairs and now scheduled to undertake two additional repair campaigns, demonstrating CarbonSeal HT1’s proven capability for high-temperature online composite repairs.
Results
The successful validation and subsequent field applications have demonstrated that HJ3 CarbonSeal HT1 delivers a step change in high-temperature composite repair technology. By enabling repairs to be completed online and in an exceptionally short timeframe, operators can maintain production while avoiding costly shutdowns that can result in millions of dollars in lost production. The rapid installation significantly reduces maintenance windows without compromising compliance with ASME PCC-2 and ISO 24817. Following the successful trial and multiple live process piping repairs, HJ3 CarbonSeal HT1 has established itself as the leading engineered composite repair technology for high-temperature process piping applications, providing asset owners with a safer, faster and more reliable alternative to traditional repair methods.
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