ADVANCED ONLINE LEAK SEALING...

1www. sc-intra.ru/en

ADVANCED ONLINE LEAK SEALING TECHNOLOGIES

2009

2013

INTRA Services is a hi-tech company with their primary goal to promote advanced repair & maintenance technologies for oil & gas, chemical, petrochemical, oil refining industries in Russia and in neighbour countries.

Process piping repair and maintenance standard for oil refining and petrochem-ical plants at pressures up to 10 MPa (100 kgf/cm2) authorised by Central Directorate of the Federal Service for Environemntal, Engineering and Nuclear Supervision (FSETAN) of Russia (Rostekhnadzor).

Best service company in the industry according to World Refining Association.

Endorsement by Agency for Strategic Initiatives in ‘New Business’ category.

Leak sealing technology standard for in-house up-time maintenance of pipe-lines, vessels and pressure equipment developed by Company and approved by FSETAN.

PROJECT DEVELOPMENT

ABOUT US

2007

TEAM MEMBERS 15IN CITIES

OF RUSSIA, CIS, EU COUNTRIES, THE MIDDLE EAST

REPRESENTATIVE OFFICES AND BRANCHES OPERATE

COMPANY FOUNDATION

2

2014 2015

2016 2017

Project team establishment. Testing of item models in Ansys system.

Online repair equipment manufacture launched in Miass.

Production of INTRA compounds Successful pilot testing at hazardous assets Manufacture certified as per ASME Endorsement by Industrial Development Fund (IDF) of innovative online repair and maintenance technology introduction project for oil&gas industry complex enterprises.

Pilot testing of IntraCase selfsealing clamps.

INTRA Service Company is the only company in Russia that provides the full scope of online repair & maintenance services:

• online leak sealing;

• hot tapping and line stopping;

• composite repair.

SUBSTITUTION IMPORT

100%

Design Technology Production Promotion


OVER

150MLN USDSAVED

INTERRUPTION COSTS

44

Any incidents at a hazardous asset result in:

• extra costs associated with maintenance and recovery of equipment;

• disruption of annual production schedule (profit loss).

Unscheduled maintenance results in disrupted profit schedule (medium efficiency plant):

Estimated loss per a single leak:

low pressure

low pressure

high pressure

high pressure

(reduc t ion of ammonia production by 2 tons per day)

MLN USDSAVED

2000 – 3000 K

600 – 1400 K

130 – 160 K

USD/DAY

USD/DAY

USD/DAY

USD/DAY

USD/DAY

USD/DAY

USD/DAY

Refinery

Petrochemical

Chemical Production

500 – 700 1500 – 2500

2000 – 5000 3000 – 10000

Steam, water

Hydrocarbons (natural gas)

1.

2.

3.


4 HOURSTO MOBILISEPERSONNEL ANDEQUIPMENTС МОМЕНТА ПОСТУПЛЕНИЯ ЗАПРОСАДО НАЧАЛА РАБОТ

2014 20172016

400JOBSPER YEAR

MORETHAN

18 HOURSTO COMPLETETHE TASK

2 DAYS TO REPAIR A LEAKINGDN1400 FLANGE

1+JOBS

HAZARDOUSASSETSFACILITIES

63

129 LEAKS REPAIRDIN 30 DAYSAT AN OILREFINERY

2600 LEAKS REPAIREDIN THE LAST3 YEARS

4

LOCATIONSOF RUSSIA28

PROJECTSCOMPLETED IN

NEIGHBOURCOUNTRIES

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1 *Ðàçìåðû èñïîëíèòåëüíûå, îñòàëüíûå äëÿ ñïðàâîê.

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ÃÎÑÒ 9066-75

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DATA IN FIGURES

6

4 HOURSTO MOBILISEPERSONNEL ANDEQUIPMENTС МОМЕНТА ПОСТУПЛЕНИЯ ЗАПРОСАДО НАЧАЛА РАБОТ

2014 20172016

400JOBSPER YEAR

MORETHAN

18 HOURSTO COMPLETETHE TASK

2 DAYS TO REPAIR A LEAKINGDN1400 FLANGE

1+JOBS

HAZARDOUSASSETSFACILITIES

63

129 LEAKS REPAIRDIN 30 DAYSAT AN OILREFINERY

2600 LEAKS REPAIREDIN THE LAST3 YEARS

4

LOCATIONSOF RUSSIA28

PROJECTSCOMPLETED IN

NEIGHBOURCOUNTRIES

(1:4)

1

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È02.06.201702.06.2017

Ðóê.íàïð. Âåñåëîâñêèé 02.06.2017

02.06.2017

1 Îìåëå÷êî 13.06.2017-

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1 *Ðàçìåðû èñïîëíèòåëüíûå, îñòàëüíûå äëÿ ñïðàâîê.

2 Ìàðêèðîâàòü óäàðíûì ìåòîäîì:1248-Äó150Ó-881-17 .

3 Îñòàëüíûå òåõíè÷åñêèå òðåáîâàíèÿ ïî 4834-014-82162778-2015.ÒÓ.


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ÃÎÑÒ 9066-75

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To repair a leak of flammable medium under pressure (development of documentation, fabrication of a split ring clamp, arrival of technicians to the site).

from request to start of work.


Preparation and reinforcement of the damaged pipeline area for further work (replacement of fasteners, installation of ring adapters, installation of a clamp to strengthen the flange joint)

Based on the medium pressure and the leak size various containment methods can be used to ensure the service is uninterrupted

Installation of impres packing and bandInstallation of sealant along the perimeter of a damaged pipeline areaInstallation of a ring clamp

Installation of a split ring clampInstallation of a peripheral clampInstallation of a sectoral clampInstallation of an enclosure clamp

LEAK SEALING IS DONE IN A FEW SIMPLE STEPS:

THE TECHNOLOGY

Online leak sealing is an advanced method of equipment maintenance without interruption of service.

PREPARATION

PRESSURE PRESSURE

LEAK AREA CONTAINMENT

8

Installation of injection adapters in the leak area for subsequent compound injection.

Compound injection (resin based filler with properties based on the media parameters) with an injection gun.

As the compound has cured a band or a clamp with injected sealant becomes a part of the pipeline, the leak has been sealed.

Application of band and unique compounds (synthetic resin fillers with varying properties based on leak temperature, medium, pressure, type and equipment design).A special clamp is installed in the leak area creating a seal. A special hydraulic tool is used to generate a higher pressure than in the system followed by

injection of a compound into the void. The higher pressure and the cured compound form a new sealing structure.Leak sealing is performed on a working pipeline or pressure vessel without interruption of service and provides a 100% seal.

THE CORE IDEA

PREPARATION FOR COMPOUND INJECTION

COMPOUND INJECTION


APPLICATION PARAMETERS

DEFECT TYPES: Defects in flange gaskets including pipeline fitting caps, welded joints and base metal defects in pipeline elements, equipment, vessels and tanks, gland valves, wellhead equipment elements and fittings at upstream facilities.

Oil and oil products

1200 °C 350 АТМ.

-196 °C 0.01 АТМ.

Chemically aggressive media

Associated gases

Natural gas

Ammonia, acids and alkalies

Chemicals

Steam and water

TECHNOLOGY APPLICATIONS

10

TECHNOLOGY BENEFITS

Emergency leak response ensures mitigation of incident/accident risks

Extended service life of fixed assets, material saving.

Lower emissions and oil spills (environemntal friendliness)

Lower product loss and reduced power consumption.

Lower costs associated with equipment downtime and service interruption

Safer operation in the uptime.

PRODUCTION AND TRANSPORTATIONCHEMICALPETROCHEMICALOIL REFINING

3.58%12.1%15.1%

69.22%

Projects completed

at upstream sites,oil refining, petrochemical

chemical, nucelar, food plants.

68%

22%

10%

AREA OF APPLICATION

Flange joints

Welded joints

Gland valves

1.

4.

2.

5.

3.

6.


Work methods and tools are defined by a combination of factors:

• working and rated parameters of conveyed medium;• design and operating indicators;• expert review reports;• defect progression modelling and current condition of the equipment

Clamps are engineered in the in-house engineering design department. The design engineers use ANSYS technolgoies to model innovative products.

Design of split clamp models as per existing standards:

• ASME PCC-2 Repair of pressure equipment.

• GOST R 52857.1-2007 Vessels and apparatus. Norms and methods of strength calculation. General requirements;

• STO 82162778-004-2013 Corporate Standard. Guidelines to application of leak sealing technology during in-house uptime maintenance of piping, vessels and equipment under pressure.

• Testing of mathematical and physical models of split clamps by finite element element method with Ansys Professional (excluding the field test phase).

• Standard design solution data base created.

• Engineering design departments classified as to their areas of expertise.

• Multi-level control system.

ENGINEERING PHASES

PHASE 1 DESIGN

PHASE 2 TESTING

ENGINEERING AND MANUFACTURE

12

Inquiry prioritisation system developed:

• the least load level;• the least dimensions;• the least material consumption;• shorter lead time and fewer phases.

• State-of-the-art clamp manufacture equipment: MAZAK, five-coordinate robotic turning circular milling

machining center.

• Production of consumables: 80+ varities of compounds.

PHASE 3 ANALYTICS

PHASE 4 MANUFACTURE

Split ring clamp of flanged joint

Reinforced ring clamp of flanged joint

Split box-shaped clamp of knuckle bend

Sector box-shaped clamp (tie-in)

Split peripheral clamp of flanged joint

Split box-shaped clampof rectilinear pipeline section

Split box-shaped clamp of T-joint (tie-in)

Sector clamp of flanged joint

Non-typical box-shaped clamps


• Low pressure (up to PN16);• High pressure (up to PN100).

Design and testing of split clamps with FEA Professional (ANSYS Professional):

• Testing of elements;• Testing of fasteners;• Claculation of fastener torques;• Material analysis;• Structure analysis

Testing at 1.5 x working pressure (maximum values) 10 mm through-wall defectNo visible leaking No visivle damage

Test at operation values during 12 hours. 10 mm through-wall defect No visible leakingAssessment crteria: maximum allowable pressure drop as per class “A”

CLAMP TYPES

PHASE 1 DESIGN

PHASE 2 TESTING

INTRACASE SELF-SEALING REPAIR CLAMPS

STRUCTURAL STRENGH TEST

INTEGRITY TEST

14

Test at operation values during 12 hours. Full pipe collapse simulationNo visible leaking

• Welded joints of pipe sections.

• Straight pipe sections

• Short-radius elbow, Tee, incut.

Applied on the following defects:

• Process• Mechanical• Corrosion and erosion

PHASE 3 APPLICATION

INTRACASE-M (mechanical), compression-type clamp

INTRACASE-S (subsea), underwater clamp

INTRACASE-W (welded), combined type clamp (compression, welded)

INTRACASE-C (cross-asset), can be adjusted to pipe ovality

GRIPPER STRENGTH TEST


64 АТМ.

420 C°

HYDROCARBON GASES

FLANGED JOINTDN1200

PRESSURE

TEMPERATURE

Operating parameters:

Transported medium:

Engineered items:

Pipeline element and valve type

AFTER

16

BEFORE

38 АТМ.

250 C°

STEAM

FLANGED JOINTDN1200

PRESSURE

TEMPERATURE


Transported medium:

Engineered items:


AFTER


BEFORE

17 АТМ.

85 C°

NATURAL GAS

WELDED JOINT (TIE-IN)

DN50/250

PRESSURE

TEMPERATURE


Transported medium:

Engineered items:


AFTER

BEFORE

18

20 АТМ.

100 C°

HYDROGEN- CONTAINING GAS

WELDED JOINT (KNUCKLE BEND) DN100

PRESSURE

TEMPERATURE


Transported medium:

Engineered items:


AFTER

BEFORE


63 АТМ.

102 C°

FEED WATER

FLANGED JOINTDN80

PRESSURE

TEMPERATURE


Transported medium:

Engineered items:


AFTER

BEFORE

20

46 АТМ.

350 C°

HYDROGEN- CONTAINING GAS, GAS-OIL

WELDED JOINT (CONCENTRIC REDUCTION) DN450

PRESSURE

TEMPERATURE


Transported medium:

Engineered items:


AFTER

BEFORE


25.7 АТМ.

200 C°

HYDROGEN, WATER, CARBON OXIDES

WELDED JOINT(T-JOINT)

DN50

PRESSURE

TEMPERATURE


Transported medium:

Engineered items:


AFTER

BEFORE

22

25.7 АТМ.

200 C°

HYDROGEN SULPHIDE GAS

FLANGED JOINTDN400

PRESSURE

TEMPERATURE


Transported medium:

Engineered items:


AFTER

BEFORE


80 АТМ.

50 C°

SULFUR DIOXIDE

WELDED JOINT(TIE-IN) DN20/1000

PRESSURE

TEMPERATURE


Transported medium:

Engineered items:


AFTER

BEFORE

24

37 АТМ.

247 C°

CONDENSATE

WELDED JOINT (KNUCKLE BEND) DN150

PRESSURE

TEMPERATURE


Transported medium:

Engineered items:


AFTER

BEFORE


37 АТМ.

960 C°

METHANE

FLANGED JOINTDN15

PRESSURE

TEMPERATURE


Transported medium:

Engineered items:


AFTER

BEFORE

26

16 АТМ.

850 C°

HYDROGEN,POTASSIUM CARBONATE

FLANGE WELDED JOINTDN25

PRESSURE

TEMPERATURE


Transported medium:

Engineered items:


AFTER

BEFORE


42 АТМ.

-70 C°

CRACKING GAS

FLANGED JOINTDN50

PRESSURE

TEMPERATURE


Transported medium:

Engineered items:


AFTER

BEFORE

28

18 АТМ.

12 C°

AMMONIA (LIQUID)

WELDED JOINTOF BENDDN300

PRESSURE

TEMPERATURE


Transported medium:

Engineered items:


AFTER

BEFORE


120 АТМ.

110 C°

FEED WATER

FLANGED JOINTDN150

PRESSURE

TEMPERATURE


Transported medium:

Engineered items:


AFTER

BEFORE

30

10.5 АТМ.

50 C°

FLUORHYDRIC ACID

FLANGED JOINTDN40

PRESSURE

TEMPERATURE


Transported medium:

Engineered items:


AFTER

BEFORE


140 АТМ.

150 C°

FEED WATER

WELDED JOINT(T-JOINT) DN25

PRESSURE

TEMPERATURE


Transported medium:

Engineered items:


AFTER

BEFORE

32

0.7 АТМ.

40 C°

FLARE GAS

WELDED JOINT(T-JOINT) DN600

PRESSURE

TEMPERATURE


Transported medium:

Engineered items:


AFTER

BEFORE


24 АТМ.

174 C°

HYDROGEN-CONTAINING GAS, METHANE, CARBON OXIDES

PIPELINE VALVESDN400

PRESSURE

TEMPERATURE


Transported medium:

Engineered items:


AFTER

BEFORE

34

ONLINE REPAIR

MANUFACTURE

INTELLIGENT SERVICES

INDUSTRIAL SERVICES

REPAIRTECHNOLOGIES

Hot tapping and line stopping Leak sealing

Composite repair

Recovery of equipment operation

Inspection control and leak detection

Testing of safety valves

Manufacture of hot tapping and line stopping equipment and fittings

Manufacture of leak sealing clamps and compounds

Miscellaneous online maintenance equipment and consumables

Intrasoft Reliability Management System

Supervising of fixed asset construction

Supervising of turnaround maintenance

Bolting

Technical University

Corrosion under insulation

Thermal spray metal coating

Chemical cleaning of pipelines and equipment

Cleaning of tanks and reservoirs

Cleaning of heat exchangers

Flange facing

Stud extraction

Cutting of pipes, end cutting

Maintenance of heat exchangers

Tube bundle extraction

Turn-key maintenance

Welding, repair of welded joints

INTRA SERVICE COMPANY: BUSINESS AREAS

10IN THE MARKET

YEARSMORE THAN


HEADQUARTERS:

St. Petersburg,

17, Magnitogorskaya Str.

+7 (812) 313-50-92/93

[email protected]

www.sc-intra.ru/en

ADVANCED ONLINE LEAK SEALING...

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