The oil and gas industry is under constant performance scrutiny from all sides. Regulators ensure operators follow increasingly rigorous rules and procedures during operations. Consumers demand uptime, as they utilize oil and gas resources to go about their daily routines. Advocacy groups are on the lookout for environmental oversights, as operators balance expansion efforts with environmental protection obligations.
On top of this, assets are aging. Pipelines, storage tanks, and process equipment routinely operate under difficult conditions and are subjected to performance stresses that accelerate their deterioration. Threats to integrity can include defects such as corrosion, through-wall failures, dents, cracks, and gouges. In many cases, these issues develop in critical assets where shutdowns are costly and replacement is impractical.
Carbon fiber composite repair systems and high-performance coatings are proven reinforcement solutions for high-consequence infrastructure. Operators that leverage these solutions benefit from corrosion protection and long-term reliability.
Demonstrated Success in Oil & Refined Product Applications
Below is a compilation of projects from oil & gas and refined product applications where composite repair systems and advanced coatings provided effective, long-term solutions without the cost and disruption of full asset replacement.
Abrasion-Resistant Coating for Steel Tank
A carbon steel tank removed from a drilling rig showed severe internal corrosion along with a localized through-wall failure. The failure was repaired using a ceramic repair putty, followed by the application of a high-performance, abrasion-resistant coating system. Installed in a single day and in humidity conditions exceeding 95%, the solution restored the tank’s integrity and delivered long-term protection against further degradation.
Advanced FRP Systems provided a coating solution for an energy services provider that was looking to protect its secondary containment system at its fracking fluid fill station.
Secondary Containment Protection from Acidic Fracking Fluids
An energy services provider required protection for a secondary containment system at a fracking fluid fill station. To prevent chemical attack on its concrete surfaces, a chemical-resistant composite coating system was installed, including a non-skid layer for improved worker safety. This solution ensured durability and long-term resistance to aggressive acidic fluids in a high-demand operating environment.
Bolted Oily Water Tank Corrosion Reinforcement
A large, bolted storage tank used for oily water service experienced multiple leaks and through-wall failures due to corrosion and microbial activity. A comprehensive repair strategy was implemented, including carbon fiber composite patch repairs, leak-tight bolt reinforcement, and a corrosion-resistant coating system applied across the entire surface. The solution effectively stopped leaks, mitigated microbial corrosion, and extended the service life of the asset.
Refined Product Pipeline Corrosion Reinforcement
Severe corrosion was discovered at the ground-to-air interface of a refined product transfer pipeline. A four-layer carbon fiber composite repair system was applied both to reinforce the pipe and create a protective barrier against further corrosion. The repair restored pipeline integrity without requiring shutdown or replacement.
Corrosion Repair for Underground Pipeline
An in-line inspection identified corrosion on a buried pipeline. To reinforce the corrosion feature and prevent potential leaks of flammable materials, a four-layer carbon fiber composite system was installed. The repair provided integrity reinforcement and halted further corrosion, delivering a long-term, maintenance-free solution for this critical pipeline.
Advanced FRP helped convert a 195 ft x 145 ft tank to a more environmentally friendly fuel with an oil tolerant coating system.
Cleaning and Oil-Tolerant Coating for Biodiesel Tank
A massive storage tank previously holding #6 fuel oil presented significant cleaning challenges prior to biodiesel conversion due to residual oil contamination. After segmenting, cleaning, and preparing the surface, an oil-tolerant primer and immersion-grade epoxy coating system were applied. Despite complex geometry and initial adhesion challenges, the project successfully delivered long-term corrosion protection and enabled conversion to a more environmentally friendly fuel.
Resource Roundup: Repairing Various Defects, Case Studies, and Choosing Composites or Steel Sleeves
Advanced FRP continues to develop and publish insights based on real-world applications and field experience in oil & refined product applications. The resources below highlight key learnings and technical guidance for composite repair systems in these critical operating environments.
This article explores how composite repair systems address a wide range of pipeline defects, including external corrosion, internal corrosion, crack-like defects, dents, and gouges. It highlights the ability of composites to provide substantial system reinforcement, inhibit further corrosion, and tolerate installation while assets remain in service. The discussion also emphasizes the importance of proper material selection and comprehensive validation testing to ensure long-term performance in demanding operating environments.
This article compares traditional steel sleeve repairs with modern composite wrap systems, outlining the advantages and limitations of each approach. While steel sleeves remain a reliable option for certain high-pressure applications, composite systems are highlighted for their adaptability, lightweight properties, and ability to conform to complex geometries. The article also explains how composite repairs reduce installation resource complexity, eliminate welding hazards, and provide long-lasting reinforcement for a wide range of pipeline conditions.
Advanced FRP Systems consulted with a company in the oil and gas industry specializing in wellsite wastewater removal and processing on how to repair through-wall failures and leaks of oily water in one of their storage tanks.
This case study documents the evaluation and repair of a leaking bolted storage tank affected by microbially induced corrosion (MIC). It provides insight into failure mechanisms such as coating degradation, bolt corrosion, and gasket issues, and outlines a multi-step repair strategy to address these challenges. The comprehensive repair approach included thorough decontamination of microbes, installation of carbon fiber patches to contain through-wall failures, and immersion-grade epoxy to reinforce tank floor bolts.
Let’s Rehab Your Infrastructure
For operators across oil & refined product applications operating aging, high-consequence infrastructure, composite repair systems and high-performance protective coatings provide field-proven solutions for extending asset life and avoiding premature and costly system replacements.
Meeting High Expectations: Reliable Repairs in Oil & Refined Product Applications
The oil and gas industry is under constant performance scrutiny from all sides. Regulators ensure operators follow increasingly rigorous rules and procedures during operations. Consumers demand uptime, as they utilize oil and gas resources to go about their daily routines. Advocacy groups are on the lookout for environmental oversights, as operators balance expansion efforts with environmental protection obligations.
On top of this, assets are aging. Pipelines, storage tanks, and process equipment routinely operate under difficult conditions and are subjected to performance stresses that accelerate their deterioration. Threats to integrity can include defects such as corrosion, through-wall failures, dents, cracks, and gouges. In many cases, these issues develop in critical assets where shutdowns are costly and replacement is impractical.
Carbon fiber composite repair systems and high-performance coatings are proven reinforcement solutions for high-consequence infrastructure. Operators that leverage these solutions benefit from corrosion protection and long-term reliability.
Demonstrated Success in Oil & Refined Product Applications
Below is a compilation of projects from oil & gas and refined product applications where composite repair systems and advanced coatings provided effective, long-term solutions without the cost and disruption of full asset replacement.
A carbon steel tank removed from a drilling rig showed severe internal corrosion along with a localized through-wall failure. The failure was repaired using a ceramic repair putty, followed by the application of a high-performance, abrasion-resistant coating system. Installed in a single day and in humidity conditions exceeding 95%, the solution restored the tank’s integrity and delivered long-term protection against further degradation.
An energy services provider required protection for a secondary containment system at a fracking fluid fill station. To prevent chemical attack on its concrete surfaces, a chemical-resistant composite coating system was installed, including a non-skid layer for improved worker safety. This solution ensured durability and long-term resistance to aggressive acidic fluids in a high-demand operating environment.
A large, bolted storage tank used for oily water service experienced multiple leaks and through-wall failures due to corrosion and microbial activity. A comprehensive repair strategy was implemented, including carbon fiber composite patch repairs, leak-tight bolt reinforcement, and a corrosion-resistant coating system applied across the entire surface. The solution effectively stopped leaks, mitigated microbial corrosion, and extended the service life of the asset.
Severe corrosion was discovered at the ground-to-air interface of a refined product transfer pipeline. A four-layer carbon fiber composite repair system was applied both to reinforce the pipe and create a protective barrier against further corrosion. The repair restored pipeline integrity without requiring shutdown or replacement.
An in-line inspection identified corrosion on a buried pipeline. To reinforce the corrosion feature and prevent potential leaks of flammable materials, a four-layer carbon fiber composite system was installed. The repair provided integrity reinforcement and halted further corrosion, delivering a long-term, maintenance-free solution for this critical pipeline.
A massive storage tank previously holding #6 fuel oil presented significant cleaning challenges prior to biodiesel conversion due to residual oil contamination. After segmenting, cleaning, and preparing the surface, an oil-tolerant primer and immersion-grade epoxy coating system were applied. Despite complex geometry and initial adhesion challenges, the project successfully delivered long-term corrosion protection and enabled conversion to a more environmentally friendly fuel.
Resource Roundup: Repairing Various Defects, Case Studies, and Choosing Composites or Steel Sleeves
Advanced FRP continues to develop and publish insights based on real-world applications and field experience in oil & refined product applications. The resources below highlight key learnings and technical guidance for composite repair systems in these critical operating environments.
Article: Composite Repairs Effective for Various Pipeline Defects
This article explores how composite repair systems address a wide range of pipeline defects, including external corrosion, internal corrosion, crack-like defects, dents, and gouges. It highlights the ability of composites to provide substantial system reinforcement, inhibit further corrosion, and tolerate installation while assets remain in service. The discussion also emphasizes the importance of proper material selection and comprehensive validation testing to ensure long-term performance in demanding operating environments.
Article: Pipe Repair Sleeves or Composite Wrap for Effective Pipeline Repairs
This article compares traditional steel sleeve repairs with modern composite wrap systems, outlining the advantages and limitations of each approach. While steel sleeves remain a reliable option for certain high-pressure applications, composite systems are highlighted for their adaptability, lightweight properties, and ability to conform to complex geometries. The article also explains how composite repairs reduce installation resource complexity, eliminate welding hazards, and provide long-lasting reinforcement for a wide range of pipeline conditions.
Case Study: Bolted Oil Water Tank Repair
This case study documents the evaluation and repair of a leaking bolted storage tank affected by microbially induced corrosion (MIC). It provides insight into failure mechanisms such as coating degradation, bolt corrosion, and gasket issues, and outlines a multi-step repair strategy to address these challenges. The comprehensive repair approach included thorough decontamination of microbes, installation of carbon fiber patches to contain through-wall failures, and immersion-grade epoxy to reinforce tank floor bolts.
Let’s Rehab Your Infrastructure
For operators across oil & refined product applications operating aging, high-consequence infrastructure, composite repair systems and high-performance protective coatings provide field-proven solutions for extending asset life and avoiding premature and costly system replacements.
Contact Advanced FRP to learn how composite solutions can support your critical infrastructure when replacement is not feasible.