Mechanically Bonded Lined Pipe: Technology, Applications, and Industry Outlook

Mechanically bonded lined pipes are an advanced solution for transporting corrosive fluids in the oil, gas, petrochemical, and energy transition sectors. By combining the structural integrity of carbon steel with the corrosion resistance of a thin CRA liner, these pipes deliver long-term reliability at a fraction of the cost of solid CRA solutions.

This post explains what mechanically bonded lined pipes are, how they are manufactured, their technical advantages, and where they are being adopted across the global energy industry.

Table of Contents

• What Is a Mechanically Bonded Lined Pipe?
  • Definition and Structure
  • Manufacturing Techniques
• Why Use Mechanically Bonded Lined Pipe?
  • Corrosion Challenges in Energy Transport
  • Key Benefits
• Applications in Oil, Gas, and Beyond
  • Subsea Flowlines and Risers
  • Onshore Pipelines
  • Emerging Uses in CCS and Hydrogen
• Technical Considerations and Standards
  • Design Codes and Qualification
  • Installation Methods
  • Inspection and Integrity Management
• Comparison With Other Pipe Types
• Case Studies and Industry Adoption
• Future Outlook
• Conclusion – Key Takeaways
• References

What Is a Mechanically Bonded Lined Pipe?

Definition and Structure

A mechanically bonded lined pipe consists of:

• Outer pipe: Carbon steel provides mechanical strength and pressure containment.
• Inner liner: A thin sleeve of corrosion-resistant alloy (CRA) such as 316L stainless steel, Inconel, or Alloy 625.
• Bonding process: The liner is mechanically expanded against the host pipe using hydraulic pressure or thermal expansion, creating a tight fit without metallurgical welding.

This design reduces reliance on costly CRA while maintaining high corrosion resistance inside the pipe.

Manufacturing Techniques

Two main approaches are used:

• Hydraulic expansion: Pressurized water expands the liner into intimate contact with the outer pipe.
• Thermal expansion/contraction: Heating the outer pipe and cooling the liner before insertion allows shrink-fit bonding.

End sections (known as transition zones) are reinforced through welding or special end fittings to ensure leak-tight sealing.

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Why Use Mechanically Bonded Lined Pipe?

Corrosion Challenges in Energy Transport

Pipelines face aggressive service conditions — CO₂, H₂S, seawater injection, and high-temperature hydrocarbons. Conventional carbon steel corrodes quickly under these conditions, while full CRA pipes are often prohibitively expensive due to high alloy content.

Key Benefits

• Cost efficiency: Significant reduction in CRA usage compared to solid CRA or clad pipe.
• Flexibility: Customizable liner alloys for specific fluids (e.g., super duplex, Alloy 825).
• Lightweight: Reduced pipe weight aids transport and installation.
• Proven reliability: DNV and API standards support use in subsea and onshore service (DNV-ST-F101, 2021).

Applications in Oil, Gas, and Beyond

Subsea Flowlines and Risers

Mechanically bonded lined pipes are widely used in subsea tie-backs and deepwater projects where corrosion protection is critical. Reel-lay installation has been qualified for mechanically lined systems, with successful use in Brazilian Pre-Salt risers (OnePetro, 2019).

Onshore Pipelines

Onshore operators adopt mechanically lined pipe for sour service (high CO₂/H₂S) and aggressive produced water environments, offering cost-effective corrosion resistance.

Emerging Uses in CCS and Hydrogen

• Carbon Capture and Storage (CCS): CO₂ transport demands strong corrosion protection — MLP is a cost-effective option (Cladtek, 2025).
• Hydrogen pipelines: Ongoing R&D evaluates mechanical liners against hydrogen embrittlement challenges (Reda, 2024).

Technical Considerations and Standards

Design Codes and Qualification

• DNV-ST-F101 and API 5LD outline requirements for design, manufacturing, and qualification.
• Fatigue testing ensures mechanical liners can withstand dynamic subsea conditions.

Installation Methods

Compatible with:

• S-lay and J-lay techniques.
• Reel-lay, with qualification programs confirming liner stability during spooling/unspooling cycles (ASME OMAE, 2024).

Inspection and Integrity Management

Integrity is verified through:

• Non-destructive testing (NDT).
• Fatigue and pressure cycle testing.
• In-service monitoring for liner displacement at transition zones.

Future Outlook

As energy operators look for cost-effective, sustainable solutions, mechanically bonded lined pipes are positioned for growth:

• Oil & Gas: Continued adoption in subsea tiebacks and mature fields.
• CCS: Rising demand for CO₂ transport lines.
• Hydrogen: Potential role in global hydrogen backbone projects pending qualification.
• Standardization: Expanding DNV and API guidance will accelerate industry confidence.

Conclusion – Key Takeaways

• Mechanically bonded lined pipes deliver corrosion protection at significantly reduced cost.
• They are well-suited to subsea, onshore, CCS, and emerging hydrogen projects.
• Qualification programs confirm their fatigue and reel-lay compatibility.
• With decades of proven use, mechanically lined systems are set to play a major role in the energy transition pipeline infrastructure.

References

1. DNV. (2021). DNV-ST-F101: Submarine Pipeline Systems. DNV Rules
2. Proclad. (2024). Guide to Mechanically Lined Pipe. Proclad Blog
3. ASME OMAE. (2024). Full-Scale Testing of CRA-Lined and MLP Fatigue Performance. ASME Digital Collection
4. OnePetro. (2019). Mechanically Lined Pipe MLP with Improved Fatigue Resistance. OnePetro
5. Reda, A. (2024). CRA Clad Pipes vs. MLP Selection. Journal of Pipeline Science and Engineering. ScienceDirect

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