Robert J. Smyth, P. Eng., and Harold Lee, C.E.T., Technical Support Manager, T.D. Williamson, discuss a pipeline repair solution that offers quick deployment, safe installation, and reliable performance.
Circumferential cracking (commonly referred to as CSCC) is a significant threat to pipeline integrity, often caused by external forces, natural soil settlement, bedding support loss, or corrosive environments. Historically, inline inspection tools have focused on more common failure mechanisms but are now being designed to detect cracking in the circumferential direction. Any crack left unaddressed poses a risk to the environment and public safety and can lead to substantial financial losses for operators. The unique nature of CSCC requires a close examination of the effectiveness of pipeline repairs.
Standard repair methods for CSCC involve either the complete removal and replacement of the cracked section or the installation of a Type B sleeve. However, both approaches come with significant costs of their own and can introduce additional risks.
Removing and replacing a pipeline segment requires depressurisation of the line and extensive excavation, resulting in operational shutdowns and an increased potential for environmental impact. Type B sleeves are a less expensive workaround, and although effective when installed flawlessly, welding-related failures – such as hydrogen-induced cracking or accidental burn-through – remain a major concern.
Modern pipeline inspection technologies have improved CSCC detection across the industry, but this also means operators will likely need to address these traditionally elusive defects more frequently in the future.
To explore alternatives to Type B sleeves, C-FER Technologies organised a Joint Industry Project (JIP) with four pipeline operators to test six different non-intrusive repair technologies, focusing on their ability to arrest CSCC growth. Among the products tested, the PETROSLEEVE®, T.D. Williamson’s steel Type C (compression) sleeve, demonstrated its effectiveness across multiple testing phases.
A non-intrusive repair solution
The PETROSLEEVE repair system is designed to permanently restore pipeline integrity. While it is steel-based, technicians do not have to apply welds directly to the carrier pipe during installation. Instead, two half sleeves encircle the defective area after applying a layer of epoxy onto the pipe. Welded sidebars then secure the device in place. The system’s proprietary Engineering Installation Parameters (EIP) software assists technicians by calculating installation settings, taking into account factors such as the pipeline’s internal pressure, grade, thickness, temperature, and the installation operating and design pressures of the pipeline – to achieve the correct compression.
Typically, the installation process takes less than an hour to complete. Technicians begin by grit-blasting the defective area to remove debris and prepare a clean bonding surface. The high-strength epoxy used in this process is formulated to cure at the pipeline’s normal operating temperature, ensuring optimal adhesion. Once the epoxy is applied, the two half sleeves are set into position around the pipe and mechanically compressed, forming a tight interference fit. To secure the final assembly, only the sidebars are welded to the top shell – eliminating the risks associated with in-service welding. Finally, the EIP software analyses post-installation stress conditions and generates a detailed report confirming the repair’s integrity.
Although the PETROSLEEVE was originally designed to reinforce pipelines compromised by axial cracks, corrosion, gouges, dents, and manufacturing defects, the compression it provides also resists the tensile stresses that drive circumferential crack growth. The C-FER JIP offered an opportunity to evaluate its limitations in this application.
Read the latest issue of World Pipelines magazine for pipeline news, project stories, industry insight and technical articles.
World Pipelines’ December 2025 issue
The December 2025 issue of World Pipelines explores how the global pipeline sector is adapting to the energy transition, with a strong focus on CCS readiness, digital transformation, integrity management, and operational resilience. Articles span Asia’s CCS pipeline build-out, energy market dynamics, high-precision repair and integrity solutions, repurposing existing pipelines for CO2 service, cybersecurity, autonomous operations, and the shift from traditional to cloud-based training and competency frameworks.