Case Study
A production facility in West Texas identified internal corrosion during ultrasonic inspection of several 4-inch, 45° elbows on an inlet header. Wall loss exceeded 20% in critical areas, with minimum thickness readings as low as 0.145″. Due to widespread degradation and the lead time required for spool fabrication, XCorr® 100 was applied to reinforce the degraded elbows and maintain operational integrity until permanent replacement could be completed.
Elbow Challenges
- Inlet header elbows are highly susceptible to internal corrosion due to turbulent flow and fluid impingement.
- Corrosion often concentrates at the entrances and exits, leading to localized wall loss.
- Elbow geometry complicates the application of traditional welded or clamped repairs.
- Shutdowns for spool replacement interrupt production.
- Custom elbows require specialized fabrication with extended load times.
Project Needs
- Restore pressure containment on corroded elbows with wall loss exceeding 20%.
- Provide mechanical reinforcement compliant with ASME PCC-2 standards.
- Minimize operational disruption by avoiding hot work and immediate replacement.
- Maintain safe operating pressure until full pipe replacement is possible.
XCorr® 100 Restores Integrity to Corroded Elbows on Inlet...
Provided Protection
Following discover of advanced internal corrosion and sub-MOP wall thickness in multiple 4-inch 45° elbows, the XCorr® 100 composite wrap provided immediate structural reinforcement and restored mechanical integrity.
By redistributing hoop and axial stresses, the composite system maintained containment and mitigated the risk of failure during the operational window prior to spool replacement. The repair enabled continued service without hot work or system shutdown.
