In 2014, a client was looking to rehabilitate several long sections of a flare header system by encapsulating it with welded steel. The refinery's inspection department had identified wall thinning on several sections of pipe and determined that immediate repair was needed to prevent the possibility of a hydrocarbon leak. The client had already performed several welded repairs on this header in the past and knew that since the flare header could not be shut down, its repair would be a challenge while ensuring worker safety at all times.
The client received an estimate of $1.6 million to perform the welded repair. An alternative repair method was also discussed with the client – wrapping the exterior of the pipe with carbon fiber-reinforced polymer (CFRP). CFRP is a highly engineered and rigorously tested product, developed and installed by Fibrwrap Construction.
The client agreed to evaluate the alternative and Fyfe/Fibrwrap worked closely with the client to develop a solution that would both satisfy the client’s process safety requirements, and be cost effective to install. Ultimately, a high temperature Tyfo® Fibrwrap® system was proposed that met the client’s needs and specifications. The cost estimate for this solution was only $500,000.
After a comprehensive technical evaluation, the client awarded a contract to Fyfe/Fibwrap in September 2014, to repair 1,000 feet of 24-inch pipe and 500 feet of 16-inch pipe. In working in partnership with Brinderson, a sister company of Aegion, the project was completed on time and on budget.