Kazakhstan
Summary
A 16” flare line suffered from severe internal degradation due to corrosion caused by a high concentration of sulfuric content in the process. The refinery had been forced to replace the entire 650-meter-long flare line every two years. To reduce costs and downtime, they sought an alternative solution that would extend the service life to a minimum of five years.
Benefits
- Extended the life of aging and corroded assets
- Prevented product loss
- Restored pipe integrity
- Enabled operation despite ongoing internal degradation
- Designed to withstand high concentrations of hydrogen sulfide
- Operated at temperatures up to 313°F (156°C)
- Eliminates unplanned down time of critical assets
- Simple installation and rapid curing
- No hot work required
- No VOCs
Challenge
The entire rehabilitation scope had to be executed without interrupting flow. This included surface preparation in an ATEX zone, lifting pipework at supports, and reinforcing complex geometries such as elbows and tees. These challenging conditions, combined with severe pipe degradation, required additional precautions. The contractor used non-sparking power tools to avoid accidental wall perforation and prevent forced shutdowns.
Solution
After reviewing the process content and conducting a thorough examination, CSNRI chemical engineers determined that the ThermoWrap MT system was compatible with the corrosive content and could be used as a long-term solution without risk of deterioration.
The in-house engineering team designed the repair to carry the piping loads independently of the steel substrate. This ensured continued operation even in the event of steel perforation, without the risk of product loss. A 14-layer system was applied over the entire length of flare piping, extending the design life from 2 to 10 years and significantly reducing the need for future shutdowns.
Results
This innovative, first-of-its-kind application demonstrated the outstanding performance of ThermoWrap MT. It proved to be a reliable and effective solution for extending asset life under the most demanding conditions—where conventional methods and materials failed to meet industry requirements.
The line was decommissioned after successfully completing its planned service life, achieving an 8-year leak-free operation. This set a new benchmark for flare line rehabilitation standards.
