Understanding Composite Repairs: Expert Insights with 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 fix various pipeline defects—like dents, anomalies, and corrosion—without shutting down critical systems. To gain a deeper understanding of this method, we spoke with Brad Whelan, HJ3’s Senior Composites Application Engineer, who shared his experience and perspectives on the use, benefits, and unique features of composite fiber 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 role involves designing composite repair solutions for piping systems, including process piping in plants or refineries, transmission pipelines, and pressure vessels. I also contribute to the development of our design calculators, which help ensure that every repair is tailored to the specific needs of our clients. At HJ3, we don’t just sell materials—we provide real, functional solutions that meet the highest standards of performance and reliability.
What type of pipe repairs do composite fiber products typically address?
Process Piping Repairs
Composite fiber products are commonly used for repairing elbows, tees, and pressure vessels in process piping. In the petrochemical industry, these systems often handle a variety of chemicals under lower pressure and temperature conditions. We collaborate with contractors worldwide to deliver custom-engineered solutions that can handle complex geometries and operational challenges.
Transmission Pipeline Repairs
For transmission pipelines, which stretch across thousands of miles, the focus is on long-term durability. These repairs must be classified as permanent and last for decades. They also require quick response times, as final inspections can lead to changes in repair designs and lengths. Speed and precision are key when dealing with such large-scale infrastructure.
What defects can be addressed with composite fiber repairs?
Corrosion
One of the most common issues we see is corrosion. In petrochemical environments, corrosion can occur under insulation due to moisture, known as Corrosion Under Insulation (CUI). Coating failures can also lead to rusting, especially in areas where chemicals interact with the pipe’s surface. Acid lines, for instance, are usually made of stainless steel, but internal corrosion can still develop if not properly managed.
Dents
Oil and gas transmission pipelines are generally well-protected, but they’re still vulnerable to dents caused by third-party damage, manufacturing flaws, or natural events. Repairing dents involves assessing the cyclic profile of the pipeline, as pressure fluctuations affect the integrity of the system. The repair approach is similar to that used for corrosion, ensuring structural stability and safety.
What are the advantages of using composite repairs over traditional methods?
Minimized Downtime
One of the biggest benefits of composite repairs is that they allow for minimal downtime. Shutting down an asset can cost millions per day, so extending its life with carbon fiber is both efficient and cost-effective. This makes composites an ideal choice for time-sensitive operations.
Lightweight Solution
Compared to traditional clamps or steel-based solutions, composites are significantly lighter—often weighing just 10% of their alternatives. This makes installation easier, reduces transportation costs, and minimizes the load on the structure being repaired.
Fast and Efficient
Unlike traditional methods that may take months to implement, composite repairs can be deployed on the same day. Field-fabricated sleeves and pre-engineered systems allow for rapid deployment, making them a preferred choice for emergency situations and time-critical projects.
How does HJ3’s CarbonSeal™ stand out in the market?
Speed To Solutionâ„¢
HJ3 prides itself on delivering solutions quickly. Our materials can be shipped to any job site the same day, and we offer zero-cost inventory plans to keep supplies on-site. This ensures that repairs can begin immediately without delays.
Unmatched Strength Per Ply
Our products are engineered with higher density materials, offering greater strength per layer than many competitors. This means fewer layers are needed, reducing installation time and overall costs while maintaining superior performance.
Proven Performance
We have conducted extensive testing, including long-term performance evaluations for dents, corrosion, and crack-like defects, as well as full-scale tests for ASME PCC-2 compliance. For over 20 years, HJ3 has provided reliable composite repair systems across multiple industries, from tanks and vessels to concrete strengthening applications.
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 of the head, causing a leak. The issue was discovered during a scheduled maintenance outage, and there was no time for a full replacement. Working with a nested contractor, we wrapped the entire vessel head and a 4-foot section of the shell in just 48 hours. The repair was completed without disrupting the turnaround schedule, and the vessel has been in service since then, with an expected lifespan until 2029.
At HJ3, we believe in providing more than just materials—we offer engineered solutions that meet strict compliance standards and ensure long-term reliability. Our team works closely with operator engineers to find viable, safe, and sustainable repair options that protect both assets and operations.
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