Case Study
A produced water system operated in West Texas was experiencing accelerated internal degradation across multiple fittings—primarily elbows—due to high-solids loading and turbulent flow. Wall losses as high as 62% were confirmed via radiographic imaging. To prevent through-wall failure while deferring costly replacement, InduMar’s WRC composite paste provided wear resistance while an overwrap with the Stop It® fiberglass composite enhanced structural integrity.
Before
After
Internal Erosion Challenges
Produced water systems handling solids and debris create high-velocity impingement zones, particularly at pipe elbows and fittings. In this project:
- Nominal wall thicknesses of 0.253″ were reduced to 0.096″ (~62% loss).
- Internal erosion at 90°, 45°, and tee fittings created deep pits and thin-wall zones.
- Sections remained in active service, requiring field-applied, quick-cure solutions.
- Heat and environmental factors (>100°F) limited working times.
Project Needs
- Rebuild wall thickness lost due to erosive produced water flow.
- Protect elbows and fittings where turbulence accelerates material degradation.
- Enable repairs under low pressure (10 psi) without requiring asset shutdown.
- Extend the service life of fittings experiencing through-wall risk.
- Ensure structural reinforcement in localized high-wear regions.
Field-Applied Wear Resistant Composite Systems Mitigate...
Provided Protection
The combined composite solution protected severely eroded elbows and restored mechanical strength. The system provided:
Each application involved precision surface preparation, manual patching of deep erosion sites with WRC30, and subsequent wrapping with Stop It® for hoop strength.
The composite system enabled asset owners to safely extend the operational life of critical infrastructure in erosive service environments without downtime.
