The Curapipe solution is intended as a preventive measure to cure pinhole leaks and cracks in pipelines that fall "under the radar” of conventional monitoring systems. Such existing monitoring systems have inherent limitations preventing detection of small (pinhole) leaks despite the significant environmental and other collateral damage they may cause. Both operators and regulators are united in finding and taking proactive preventive measures to mitigate these effects, and Curapipe’s solution can be viewed as a significant development in this area.

Current procedures are applied after a leak has been detected. Existing monitoring systems typically detect leaks that release at least 1% of the pipeline flow. If the leak originated as a pinhole leak, as in the case of corrosion induced leaks, it potentially could be cured by Curapipe’s solution even at leak rates as low as 0.01% of the flow. For example, let's assume a leak in a pipeline carrying 600,000 barrels (~25 million gallons) of oil per day. If the leak could be cured at a leak rate of 2,500 gallons per day (0.01%) instead of at a leak rate of 250,000 gallons per day (1%), the impact would be significant.

Curapipe’s solution holds three important distinctions. It (a) is applied internally (as opposed to externally), (b) is inserted remotely through a pig launcher positioned upstream (as opposed to excavating in-situ), and (c) does not require prior knowledge of the location of the leak. Since Curapipe's internal approach is simple, elegant and not dependent on detection, it unlocks an intriguing potential to be applied periodically as a preventive mechanism, curing small leaks and cracks as they form. The preventive nature of the product also helps avoid negative political and regulatory implications.

As already mentioned, current detection methods do not detect leaks below 1% of the product flow, at which stage leaks are large enough to warrant pipeline shutdown for – what was up until now – unavoidable conventional leak repair. Curapipe's solution can cure leaks long before costly damage occurs, even addressing leaks as small as 0.001% of the flow. To achieve that goal, Curapipe has devised a unique internal repair approach, so that any number of leaks can be cured along the pigging route – without depending on prior detection of any of these leaks.

In the past, industry stakeholders such as the US Department of Energy have shown a concerted interest in repair methods that can be applied from the inside of transmission pipelines; such an internal application is an attractive alternative to conventional repair methods, since the need to excavate the pipeline is precluded.

Yes. As explained in FAQ 3 above, no physical intervention is required at the leak's location since the solution “seeks out” small leaks and cures them in its wake as it moves downstream. As a result, the Curapipe solution cures these leaks and prevents the occurrence of larger and more problematic leaks that would require pipeline shutdown and in-situ excavation.

Leak types include externally and internally induced corrosion leaks; flange, weld or seam-defect leaks; and seepage leaks associated with wall or weld cracks.

The Curapipe solution targets leaks ranging from minimally sized leaking cracks and pinholes to holes of around 15mm in diameter. However the optimal usage would be at the non-detectable lower diameter range. The solution is obviously not intended to cure catastrophic high-mass-rate releases resulting from punctures, tears or ruptures.

Pipeline diameters can range from 1 inch to 48 inches; the solution is also designed to handle multi-diameter pipelines.

Pipeline lengths are in the order of 30 to 40 kilometers. Special accommodation could be made for pipelines of up to 100 kilometers.

The solution is designed to be applied under the following wide-ranging conditions:
- temperature: +5ºC to +90ºC
- optimal differential pressure: 8 bar to 12 bar
- viscosity flow: 0.0004 m2/sec to 0.0009 m2/sec
- flow velocity: 0.2 m/sec to 2.0 m/sec
 

The solution does not require completely shutting down operation. However, internal pressure needs to be reduced to around 10 bars during the procedure for the curing substance to penetrate the leak effectively. Subsequently, normal operating pressures can be reapplied.

No. Any residual substances left over between the spheres of the pig train are extracted in their entirety when the pig train is removed from the pipeline via a standard pig receptor.

No. The solution has been designed to address both piggable and certain types of non-piggable pipelines.

This would be the case if the curing substance was attached to the pipeline cavity by way of adhesion. Curapipe’s solution, however, is designed to operate within the existent environment of the pipeline with crud, wax and other suspended materials in the way of the leak and in the presence of varying elements or contaminants such as basic sediment, water, H2S, CO2 and O2.

A steel pipeline can be inspected from the inside via pigging using ultrasonic, radiographic and pulsed eddy current inspection techniques applied for inspection of composite repairs. The curing substance can include a ferrous component that would show up on a pigging report. In non-piggable pipelines, validation can be carried out using a hydro-pressure test.

From a purely technological standpoint, the repair could typically outlast the remaining lifetime of the pipeline. Having said that, viewing Curapipe’s solution as a preventive measure will simplify its introduction from a regulatory standpoint.

Yes, the solution can be used both onshore and offshore (with the exception of offshore flow lines from oil wells with only one access point).

Yes. First, by shortening the "time to cure" (from leak inception to cure), the solution reduces the volume of spillage and associated pollution. Second, since all residual substances are extracted via the pig receptor, the solution has almost no environmental impact (with the exception of the immediate leak area); moreover, the hardened curing material in and around the leak does not exude any toxic waste. Third, the solution fully prevents environmental damage resulting from conventional excavations at the leak site.

The solution decreases downtime simply by avoiding shutdown due to conventional repair and cleanup.

Extension of existing pipeline life is closely associated with controlling risk (where risk = likelihood/probability of failure X consequence of failure). Of particular concern are cases of where the probability of a leak is relatively high (due to aging, corrosion, etc.) coupled with a high consequence if such a failure occurs. By mitigating the consequence of failure (via elimination of leaks and cracks while still small), Curapipe’s solution can contribute to risk reduction and pipeline life extension.