The Problem

A natural gas pipeline, crucial for fueling a blast furnace at an aluminum plant, was suffering from severe corrosion, the natural gas pipeline needed repair. The situation was critical, as the pipeline not only needed corrosion-resistant repair but also required a buildup of wall thickness. An in-place repair was essential to avoid unscheduled outages, which could potentially cost the plant over one million in lost sales revenue.

The Substrate

The pipeline in question was made of metal, a common material in industrial pipeline construction for its durability and ability to withstand high pressures and temperatures. However, metal pipelines are prone to corrosion, especially in industrial environments.

The Solution

Unconventional Solutions devised an innovative in-place repair process, mindful of both the urgency and the safety requirements of the plant:

• Surface Preparation: Brass non-sparking tools and brushes were employed to achieve an SSPC-SP 2 surface profile. This method was chosen to ensure the safety of both personnel and the facility, as working in a natural gas environment presents significant risks.
• Cleaning and First Coating: The pipeline was thoroughly cleaned with USI Universal Cleaner. Following this, the pipe was coated with RESIMETAL 101 Metal Repair Paste, which provided the initial layer of protection and repair.
• Reinforcement: To strengthen the pipeline, Resimac 808 High Strength Reinforcement Mesh Tape was applied. This reinforcement tape is essential for enhancing the structural integrity of the pipeline.
• Final Coating: Another layer of RESIMETAL 101 Metal Repair Paste was applied over the reinforcement tape, ensuring a robust and durable repair.

Products Used

• USI Universal Cleaner: Used for cleaning the pipeline surface.
• RESIMETAL 101 Metal Repair Paste: Provided corrosion-resistant repair and wall thickness buildup.
• Resimac 808 High Strength Reinforcement Mesh Tape: Used to reinforce and strengthen the pipeline.

For sustainable and reliable repair solutions for natural gas pipelines and other industrial infrastructure, contact Unconventional Solutions today. Our innovative methods ensure your operations continue smoothly with minimal downtime.