Marun Petrochemical Company 88-inch Pipeline Repair Project

The 88-inch cooling pipelines at Marun Petrochemical Company suffered a thickness reduction of more than 80% in various sections. This was due to years of operation in harsh industrial conditions and exposure to corrosive chemicals. This significant thickness reduction not only severely decreased the pipe’s mechanical strength but also led to two dangerous leakage points along the pipeline’s path. Furthermore, the 24-inch and 12-inch branches connected to the main pipe also required immediate repair due to erosion. These conditions made it impossible to continue operating the pipeline without immediate action.

Project Specifications

Project Execution Process

Following the precise identification of critical points, the repair process began with the complete removal of the pipe’s coating. Old coatings and corrosion-related contaminants were removed using sandblasting and chemical methods to create a clean surface ready for composite adhesion. Next, using ultrasonic and radiographic devices, the exact wall thickness of the pipe was measured at each point, and areas with more than 80% thickness reduction, along with the leakage points, were identified.

To repair these areas, 16 to 20 layers of composite coating were designed and applied based on the operating pressure, ambient temperature, and the type of chemicals present in the pipeline. These coatings were made from a combination of high chemical resistance epoxy resins and reinforcing fibers (carbon fiber) to not only compensate for the lost thickness but also to ensure resistance to future corrosion. The 24-inch and 12-inch branches were also repaired with the same technology and with high precision to ensure the complex connections were completely sealed.

Project Results

After the completion of the repairs, the pipeline underwent a hydrostatic test at 1.5 times the operational pressure, and no leakage was reported. Furthermore, non-destructive testing (NDT) inspections, such as ultrasonic and magnetic particle testing, confirmed the complete integrity of the coatings and the absence of hidden cracks. This project not only restored the pipe’s thickness to a safe level but also resulted in significant financial savings for Marun Petrochemical by preventing a full pipeline replacement.

Pipe Thickness Restoration

Compensating for an 80% thickness reduction and restoring mechanical strength.

Complete Elimination of Leaks

Precisely sealing critical points and preventing environmental hazards.

Branch Repair

Restoring the functionality of 24-inch and 12-inch branches without the need for replacement.

50% Cost Reduction

Achieving financial savings compared to the full pipe replacement method.

Technical Approval of the Marun Petrochemical Pipeline Repair Project

Manshoor Composite Sanat Asia Company successfully completed the repair project of Marun Petrochemical Company’s 88-inch cooling pipelines using modern composite technologies. This project involved restoring the lost thickness of the pipes and fixing critical leaks. The technical approval issued by the Technical Services Management of Marun Petrochemical indicates full compliance with technical, safety, and environmental standards during the execution process. The use of advanced composite coatings not only increased the lifespan of the pipelines but also significantly reduced maintenance costs and operational risks. This collaboration is a successful example of the company’s commitment to quality and innovation in heavy industries.

Summary

This project is not only a technical success in the field of industrial pipeline repairs but also demonstrates the company’s ability to manage complex challenges using modern technologies. The combination of engineering precision and advanced materials has created a model for future projects in the oil, gas, and petrochemical industries.