LEAK SEALING OF 6 ”NB WELDOLET ON A SUB SEA 36 ”NB PIG BARREL ON PLEM -

Overview A 36 ”NB Pig Barrel Place on Sub -Sea PLEM had a leak from welding joint of the Bottom Drain 6” NB line. The pig barrel was installed at water-depth of 35 meters. Replacement of pig barrel implied complete dismantling and removal of pig barrels for repairs. Leak sealing onsite was possible only with a tailor-made clamp. The dimensions were taken in poor visibility conditions. Adequate margins and tolerances were provided.

Solution & Implementation VKVC designed, manufactured, tested and delivered the Clamp to seal the drain line. Result The Pig Barrel on PLEM has been used for Pigging the Pipeline. The Pig Barrel is used intermittently, it was decided not to replace the Pig Barrel.

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OFF-SHORE CRUDE OIL PIPELINE FLANGE LEAK

Overview A 48 ”NB Pipeline from SBM to the tank farm developed a leak on one of the flange joints on a spool piece near the SBM. The water depth was approximately 35m. The leakage Point in the Gasket face could not be located due to poor visibility. VKVC was called in to provide a leak sealing solution on emergency basis.


Solution & Implementation Flange leak sealing involves Leak sealing in 2 Stages. Stage-1 Installation of Clamp. Stage-2 Injection of sealant to seal the annulus between studs and nuts of Flange Joint. Stage-1 Installation of Clamp was completed without any complication. During Stage-2 injection of sealant the viscosity of sealant prevented it from being injected from a distance of approximately 60 meter. 35 meter water depth and 25 meter hose leeway. The first attempt was abandoned as sealant did not reach the Clamp. A low viscosity Epoxy sealant was tested at VKVC Works for Pumping from 100 meter distance into an artificially pressurized chamber containing a dummy Clamp. The trials were successful. The low viscosity Epoxy sealant was then injected into the Clamp at site.

Result The Flange joint is operating successfully with VKVC Clamp till date approximately 3 years in service. Also we did Offshore Subsea Pipeline Structural leak repair clamp for another client.

                            Read  More from here  http://vkvc.com/case-studies/offshore-crude-oil-pipeline-flange-leak-repair-sub-sea/

ON-SHORE GASLINE FLANGE LEAK REPAIR CLAMP

Overview Middle East Gas Company operates a 48 ”NB ANSI 600 Gas Pipeline to transmit Gas from the fields to a central gas plant.This 48 ”NB Pipeline is the trunk line of the company. A Sectionalizing Valve Flange Gasket developed a leak. The leakage was minute when detected. Leakage rate was lower at a pressure between 80-90 Bar but would leakage rate would increase rapidly above 90 Bar. Replacement of Gasket meant a shutdown of the 48 ” NB Pipeline.Operational and functional Constrains ruled out an immediate non planned shutdown.

Solution & Implementation VKVC was contacted on a weekend to provide an emergency leak sealing solution. A Flange Leak Repair Clamp 48 ”NB ANSI 600 was Fabricated,Pressure Tested and air freighted within 96 hours. Leak sealing compound injection ports were installed at site. After installation of Clamp the compound was injected to seal the leakage through the studs and nuts. A pressure gauge was also installed on the Clamp to monitor the pressure built up due to leakage in the Clamp annuls. A VKVC Technician was available at site for supervision of Clamp installation. Result The Pipeline was kept safely Operational with VKVC Flange leak repair Clamp till a scheduled shutdown. 24 months later.

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LEAK SEALING OF MONOLITHIC ISOLATION JOINTS IN MIDDLE EAST/INDIA

Overview Monolithic Isolation Joints on Pipelines often develop leaks over a period of time. This happens mainly due to soil settlement causing metal erosion. The leaks need to be encapsulated to keep the Pipeline Operational till Permanent repair is carried out by replacing the Monolithic Insulation Joints. The Clamp for each Monolithic Isolation Joint is designed and manufactured with actual site dimensions. The material of flange is compatible with Monolithic Isolation joint. The annuls between Monolithic Isolation Joint and Clamp is filled with an epoxy grout and internal non conductive liner is provided for electrical isolation. Composite material wrap can be provided for permanent installation.

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NON PIGGABLE DE-COMMISSIONING ON-SHORE

Overview 3 Pipelines 16 ” NB 12km long were installed Parallel in 1980 to transport Crude from Jetty to a tank farm. Rapid Urban development led to the Pipeline ROU being severely encroached. The Pipelines were not designed to be pigged and could not be inspected by Intelligent Pigging. No as built drawing were available. Space constrains ruled out Pig Barrel installation.


In 2013 it was noticed that several houses located in the vicinity of the Pipelines weregetting Oil droplets in their water supply.The authorities ordered the product to be evacuated and Pipeline decommissioned immediately. The initial proposal was to evacuate the product with water however the volume of water required and subsequent disposal procedure ruled out this option. The only solution was to evacuate product with pigs that would negotiate reduced bore valves, miter field bends. As the Pipelines were known to be leaking the pigs were to run at very low pressures. Further leakage was to be avoided.

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COMBINING PIPELINE PIGGING + LEAK REPAIR CLAMP + PIPE COUPLING

Overview At a marine terminal, a20” NB Napthapipeline had been km long operational, transporting Naptha from the Jetty to a tank farm. The line passes under various highways, railway lines and crossings. The line is operated only during unloading of cargo at the port. A highway located on the pipeline route was being expanded. During excavation, an excavator damaged the pipeline, creating a 3cm wide and 15cm long gorge. The Pipeline was non-operational during this accident.

 The excavator operator backfilled the area and did not intimate the authorities. A tanker arrived at the port a few days later. Naptha was pumped thru the Pipeline as per normal procedures. A leakage occurred through the gouge and leak continued for a few hours before being detected, a fire erupted thereafter. On detection the pumping was shut down immediately. VKVC was contacted to provide a solution for leak sealing and repair of Pipeline.

  Solution and Implementation VKVC mobilized equipment and manpower at site within 24 hours. Stage- 1 The Leakage location was excavated. A ‘T ’Clamp was installed with Hose. Two CDI non-intrusive signals were installed on either side of Clamp. The hose was connected to a tanker. Batching Pigs were launched with Nitrogen from Jetty. Pigs pushed the product in Pipeline to the tanker. Their passage across the leak point was detected by the CDI non-intrusive Pig Signals.

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LEAK SEALING OF 2 ”BRANCH PIPE IN MIDDLE EAST

Overview A Station Plant Piping of a 20 ”NB Sour Gas Pipeline developed a leak on 2 ” NB Branch Pipe.The branch Pipe could not be isolated as no Valve had been provided to isolate the 2 ”NB Pipeline from 20 ”NB Pipeline.VKVC was contacted for an emergency leak Sealing Operation.


Solution & Implementation A 2” NB Horse Shoe Clamp was installed on the 2” NB leaking bend. This immediately sealed the leak, enabling the 20” NB pipeline to remainoperational. Horse Shoe Clamps are temporary onsite fabricated Clamps and may not be very reliable to be used over a long period of time. It was decided to provide an encapsulation Clamp on the Horse Shoe Clamp.

  Result VKVC manufactured and supervised installation of an Encapsulation Clamp on the Horse shoe Clamp.The 2 ”NB Branch was replaced 2 years after Clamp installation.

Read More from here http://vkvc.com/casestudies/leak-sealing-of-2-branch-pipe/Z