With a crude oil capacity of 247 million barrels per day, a major Gulf Coast refinery recognized that corrosion had occurred on two carbon steel pipes, each approximately 300 linear feet, which led to the cooling tower. Essential to the operation of the refinery, the pipes carried hot process water from the refinery to a large cooling tower. Over their 30-year life, the pipes had become corroded due to the constant moisture from the cooling tower and salt in the air from the Gulf Coast. A visual inspection by Structural Preservation Systems (SPS) noted heavy pitting on the steel after an organic coating had long flaked away. Further, certain sections of the pipe had started to fail and were leaking water. If the pipes completely failed, the plant would have to shut down because the cooling tower could not remain operational. SPS was able to secure the work, because their repair strategy allowed the plant to remain fully operational during repairs and would not require replacement of the pipe. Other contractors suggested taking the plant out of service and replacing the pipe, which would have been extremely costly to the owner.

The first task on the project was to stop the current leaks. The first option was to clamp a piece of steel that was the same diameter as the pipe around it. However, since the pipe was severely pitted, water squirted out of the sides of the clamp since it did not provide a tight seal. SPS then found a rubber gasket that could adhere to the clamp around the perimeter. Crews installed the clamp tighter and tighter until it molded into the shape of the pipe and stopped the water leaks. SPS was able to stop more than a dozen leaks on the pipes. A steel corrosion inhibiting primer was installed on the exposed pipe to penetrate and eliminate rust and stop further corrosion. Once the leaks were stopped and the primer installed, SPS' crews covered the entire pipe with an epoxy compound to make it smooth again. This process re-established the original surface contours of the pipe and mitigated voids under the fiber strengthening system. The fiber strengthening method used is a multidirectional fiberglass composite system that is impregnated with a hydrophobic urethane epoxy. It was used to increase the hoop strength of the pipe and designed to withstand hydrostatic pressures that are placed on the pipe. This system had the resin impregnated within the fiber, which only required water to cure the resin. This was the perfect application for this product, because there was a great deal of water in the area that could not be removed and the team did not need to be concerned as with normal epoxies that react negatively with the presence of water. Each section of the pipe had four layers of the fiber strengthening system and overlapped approximately 1-foot when a new section began.

Extremely satisfied with the results of the project, the owner appreciated that SPS' repair strategy avoided a costly plant shutdown. Special care was taken throughout the project to ensure the safety of all team members since crews were working with hot water and in limited visibility. One hundred percent tie-off was required at all times and crews wore waders to protect their lower extremities. SPS was able to complete the project with no safety incidents.