Supplying Corrosion-Resistant Pipe Fittings for a Gas Processing Facility in Nigeria’s Niger Delta
Client Overview
Our client is a mid-sized gas processing company operating in the heart of Nigeria’s Niger Delta. With rising domestic demand for cleaner fuel and Nigeria’s push to reduce gas flaring, the company recently expanded its processing infrastructure to boost capacity and comply with environmental regulations.
Project Background
Located in a high-salinity, high-humidity environment, the facility’s pipeline network required a complete overhaul of its outdated carbon steel fittings. Frequent leakage, joint failure, and corrosion-related shutdowns had become a major operational challenge. The maintenance team reported that flange connections and elbows in high-pressure lines degraded rapidly due to exposure to corrosive condensates and moisture-laden air.
The client approached us with a clear requirement.
Deliver high-grade, corrosion-resistant pipe fittings that meet ASME B16.11 and ASTM standards, suitable for sour gas service.
Challenges
1. Aggressive Environmental Conditions:
The facility’s proximity to the coast meant elevated salt exposure, which accelerates rusting and pitting—especially at weld seams and threaded joints.
2. High-Pressure, Sour Gas Service:
The fittings had to withstand H₂S-laden gas streams and maintain integrity under high operating pressures.
3. Bulk Requirement with Tight Timeline:
The project demanded a bulk order of over 18,000 forged fittings with full QA/QC documentation, delivered within 5 weeks, including packing, testing, and inspection.
Our Solution
We recommended a material supply of 316L stainless steel and ASTM A182 F51 duplex forged pipe fittings, chosen for their exceptional resistance to pitting, crevice corrosion, stress corrosion cracking, durability in sour gas environments, and long-term performance under pressure.
Products Supplied:
• 7,500 pcs Socket Weld Elbows (1” to 4”)
• 3,200 pcs Threaded Couplings and Tees
• 2,800 pcs Forged Reducers and Swage Nipples
• 4,600 pcs Flange-adapter fittings for line transitions
• 150 pcs Special custom-machined fittings for compressor skids
All fittings were manufactured to ASME B16.11 specifications, hydro-tested, and supplied with:
• Full MTC (EN 10204 3.1)
• Third-party inspection (as requested by the client)
• Heat number on each fitting
• ISO 9001:2015 compliance
Packing and On-Time Delivery
We deployed a dedicated production line to meet the fast-track delivery schedule. All pipe fittings were:
• Packed in seaworthy wooden crates with corrosion inhibitors
• Labelled with item codes, heat numbers, and purchase order references
• Shipped in two partial consignments via air and sea freight from India to Port Harcourt, Nigeria
Despite the logistics complexity, the entire 18,000+ pipe fittings were delivered in full within 34 working days.
Results and Impact
Zero Leak Failures:
Six months post-installation, the facility has reported no leakage or corrosion at any joint, even in previously vulnerable sections.
Extended Maintenance Cycle:
The client increased maintenance inspection intervals from 3 to 12 months—significantly reducing downtime.
Regulatory Compliance Achieved:
The successful installation helped the client meet environmental safety compliance set by Nigeria’s Department of Petroleum Resources (DPR).
Repeat Business Secured:
Impressed with our technical support and delivery reliability, the client placed a second bulk order for an upcoming LPG terminal project.
Client Feedback
“We were impressed by both the product quality and the speed of execution. The fittings arrived with full documentation, and installation was seamless. This partnership has helped us meet operational and regulatory goals without compromise.”
— Engr. Chinedu Okafor
Head of Maintenance, Gas Processing Facility, Niger Delta
“We were dealing with a tight deadline and strict inspection needs. Your team delivered on every front—from metallurgy to packaging to documentation. It’s hard to find that kind of reliability today.”
— Mr. Tunde Akinwale
Procurement Manager, Gas Processing Facility, Niger Delta
Conclusion
This project stands as a strong example of how the right material selection and manufacturing precision can solve complex operational issues in challenging environments. From technical consultation to on-time delivery, we provided more than just fittings—we delivered reliability.
If you’re managing a pipeline or gas processing facility in a corrosive environment like Nigeria’s coastal zones, reach out to us for engineered solutions that last.
Contact us today to learn how our corrosion-resistant pipe fittings can improve the safety and efficiency of your next project.
