Ht Pi e 12 09 Hydratight Process Integrity Brochure Uk

PROCESS INTEGRITY Engineering Solutions and On-Site Services

Pipe cutting and BevellingFlexible internal or external mount cutting and bevelling equipmentHigh quality pipe cutting, bore matching for connection of pipesSuitable for Onshore, Offshore or Subsea projects

On-Site MachiningHydratights On-Site, In-Situ Machining capability provides the services of a fully equipped machine shop direct to your site, including; Turning, Drilling, Milling and GrindingDismantling and transport of vessels/equipment is unnecessary, reducing plantdowntime to a minimum

Hot Tapping and Line PluggingTapping integrating tie-ins without production lossPlugging isolating product flow during normal productionTapping and plugging bypassing and replacing of damaged lines, defective valves etc

On-Line Thermowell InstallationInstallation of Thermowells under operating conditions to providetemperature data collection without production lossIdeal where temperature measurement of high temperature, abrasive or corrosive media may result in premature failure of an unprotected sensor

Specialised Engineering ServicesHydratight is an innovative provider of engineering solutions and on-site servicesdesigned to maintain the integrity of production and process plant and pipework.

On-Site BoltingIn-house designed and manufactured bolt tightening toolsCompetent supervisors and techniciansLeak-free start-up and production

On-Line Industrial Leak-SealingAvoid production losses and unscheduled plant shutdowns by using our on-line Leak Sealing serviceCost effective and safe sealing of flanges, bonnet, valves and fittings with around the clock availability

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On-Line Freeze PluggingFast, safe plugging of process lines without draining or interruption is possible with our on-line Freeze Plugging serviceLiquid nitrogen or carbon dioxide are expertly applied, freezing the process media to create a pressure tight plug, allowing efficient modification to plant with minimal disruption

On-Line Safety Valve TestingCutting the cost associated with Safety Valve Testing, verifying operation at production pressuresAvoids the cost of unnecessary valve removal and replacement and provides reassurance that safety systems are in good working order

Induction Heat TreatmentThrough the DL Ricci operation, Hydratight offer on-site Resistance and Induction Heat Treatment servicesModern portable equipment and experienced field technicians combine todeliver accurate and affordable in-situ heat treatment

Bolting and Process IntegrityHydratight offers a tailored solution to meet customers needs, with a range ofin-house manufactured productsAll products and services are carried out to the highest quality standards andbest practices worldwide

Largest Portable Tool Rental FleetWith the largest inventories of market leading products, Hydratight brings a truly flexible approach and outstanding value in both bolting and machining, underpinned with local technical support

On-Site Condenser and Heat-ExchangerRepair and Restoration

Hydratight offer Turnkey refurbishment and maintenance packages for Heat Exchangers and CondensersExperienced personnel efficiently restore components to original specificationand performance, on-site and on time

Sales and Rental Services

PROCESS INTEGRITY

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Whether the requirement is for torque or tensionequipment, Hydratight has extensive stocks of in-housedesigned and manufactured product available,ensuring leak-free bolted connections.

Selection of the required tooling may be influenced by:Access to the joints and bolt lengthAccuracy neededSite preference and experience of personnel

On-Site BoltingHydratight pioneers global standards, making leak-free bolted connectionssafely and competently with full regard to the environment.

Hydratights highly trained and competent serviceteams inspire confidence that all bolting operations,whether torque or tension, will be carried out efficientlyand safely, ensuring the correct bolt loads areachieved and not just applied.

Hydratight utilises innovative, purpose designed andmanufactured products and well trained crews toprovide an unrivalled quality of service and value formoney.

Technical SupportHydratight can quickly assess the suitabil-ity of equipment to fit particular jointsthrough its bolting calculation software In-formate and Boltup, or in more complexcases via the Technical Support teamsbased in the companys regional facilities.

Consideration is given to;Height restrictionsBolt pitch issuesProximity of bolt circle diameter to thebase of the hub or weld neck


Pipe Cutting & Weld PreparationDL Ricci portable Pipe Cutting and Weld Preparation machines have led the market for many years becoming an industry standard.

The companys extensive range of machines offers theperfect match for any application from the small to theheavy duty.

The patented bearing technology built into the DL Ricciclamshells, provide easy set-up and robust operationin any environment.

Examples ofapplications

Machining of weld excavations toremove defective material inpreparation for re-weldingInternal or external match boring toallow pipes with a different wallthickness to be paired togetherSingle V, double angle or J prepcan all be produced

PROCESS INTEGRITY


The CompanyDL Ricci is one of the more recent additions to the Hydratight business, addingnew capability in respect ofmanufacture and supply ofspecialist machines, in addition to a global on-siteservice operation.

BenefitsMinimum disruption to production or processSafe, efficient, non-destructive and cost-efficient sealing of flanges, bonnets,fittings, elbows etc.Rapid response with large stocks anddedicated in-house mechanical workshopsHigh quality standardsAround the clock advice and service

On-Line Industrial Leak-Sealing

Hydratights history of developinginnovative technologies continues with theaddition of On-Line Leak Sealing.

With continuous on-call availability, Hydratights specialiston-line leak sealing of flanges, bonnets, valves and fittingsoffer a fast, efficient and cost effective solution for leaks.

With a right first time philosophy, safety is ensured andenvironmental performance optimised whilst plantdown-time and costs are reduced to a minimum.

Using expert knowledge, the selection of the rightprocess and materials ensures leaks are efficientlyand permanently fixed.

(1) Broken down flange sealing(2) Compound (substitute sealant)(3) Injection adapter (closed)(4) Injection adapter (valve to inject compund)(5) Sealing clamp(6) Copper seal pipe(7) Bolted flange connection


On-Site MachiningModifications and repairswith portable machinery

Hydratight executes on-site repairs, improvementsand modifications to all kinds of equipment, plant andconstruction parts with a wide range of mobilemachinery. Highly qualified engineers and techniciansensure quality without compromise, comparable tostationary machining.

Portable machining is recommended for turning,drilling, milling and grinding of plant components,which either cannot or can only be disassembledand/or transported with great difficulty. Reducing costsfor dismantling, assembling, and transport of vesselsand equipment, on-site machining significantlyreduces downtime and increases plant safety.

TurningCapacity up to 5.500 mmFacing and grooving of flanges and heat-exchangersPipe cutting and weld preparation of pipe endsMachining of shafts

MillingPump, motor and machine bedplatesResurfacing, milling of profilesKeyways in bores and shaftsCNC-milling of threading upto 200 mm, depth 300 mm

Drilling and Line BoringMachining of bushes, bearingsand multiple in-line boringsDrilling up to 150 mm in solid materialMachining up to 800 mm of nozzles in vessels

GrindingLarge diameter rotating equipmenteg: dryers and turn furnaces

BenefitsHydratight offers all the facilities of afully equipped machine shop rightwhere it is needed on-site.

Significantly reducing;Plant down-timeCost of dismantling/re-assemblyTransport costs

PROCESS INTEGRITY


Hot Tapping of PipelinesTapping of pipelines at full operating pressure

Meet deadlines safely and with minimum disruption toproduction; Hydratights Hot and Cold Tapping serviceprovides the solution to plant and pipelinemodifications without the need to decommission, thusmaximising plant up-time. It is a precise process ofdrilling a hole in a piping system under pressure,without draining or spilling the products inside.

A valve (3) is mounted on the fitting (4) welded to theline. The tapping machine (1) installed on top of thevalve drills through (2) the opened valve into the pipe(5) and retains the coupon. Once retracted the valveis closed and the machine removed.

Safe, fast tie-ins, repairs, modifications and bypassof faulty or damaged systems all under full operatingconditions provides exceptional value and efficiency.

Benefits

On-line integration of tie-ins orbypass lines withoutproduction lossInstallation of thermowells withminimum disruption


On-Line Thermowell InstallationInstallation of thermowellsat full operating pressure

Hydratights technique of On-Line Thermowellinstallation is approved by the TUV, offering assuranceof safe and efficient performance.

The connection of resistance thermometers orthermocouples to existing pipelines under pressurerequires qualified engineers and special tappingequipment.

Thermowell installation offers precise, robust andpermanent temperature measurement of processmedia where the media may be corrosive, abrasiveor at high pressures.

ProceduresWelding of tapping nozzle to pipeAssembly of gate valve and adaptersAssembly of tapping machineHot-Tapping of product pipelineDisassembly of tapping machinePositioning of thermowell on the machineAssembly of tapping machineInstalling thermowellDisassembly of tapping machineAssembly of cap with thermosensorAssembly of thermosensorLimitations

Operating temperature up to 315 COperating pressure up to 48 barThermocouples up to 50 mm

BenefitsInstallation of Thermowell at operating pressureMinimum disruption toprocess/productionIdeal for temperature measurement of media wherethe abrasive or corrosive nature of the media can limit sensor life

PROCESS INTEGRITY


On-Line Mechanical PluggingEmergency and scheduled stopping of a liquid or gas flow in a pipeline at full operating pressure

Purpose designed equipment in the hands of highlyskilled technicians enables fast and safe MechanicalLine Plugging at full operating pressure.

Hydratights Line Plugging service is ideal for temporaryor permanent isolation of pipe work, allowing repair ormodification without the need for plant shut-down or theloss of production or process media.

Benefits

Isolate, repair or modify pipe-work without production lossPlug and bypass without interruption to process flow


On-Line Freeze PluggingCryogenic freezing of process or production media at full operating pressure to provide temporary isolation of pipe work

A non-invasive alternative to Mechanical Pluggingsuitable for pipelines up to 48 diameter.

Freezing the media down to form a plug allowsmodifications or repairs downstream without the needto drain the pipeline.

Benefits

Continued production during pipework modification or repairIntegrity of pipe work maintained no need to re-test plug locationDrainage of media avoided,production performance maintained

This process requires the operator to stop the flowof media through the pipeline to allow freezing totake place.

Isolation of the downstream pipe is achieved by fittinga purpose made enclosure through which cryogenicLiquid Nitrogen or Carbon Dioxide are piped.

Rapid cooling of the process media inside the pipequickly follows forming a pressure tight frozen plug.

With no pipe modifications necessary, this temporaryplugging method offers a solution to maintenance orrepair needs.

PROCESS INTEGRITY


On-Site Condenser and Heat-Exchanger RestorationRepair and restoration ofcondensors and heat-exchangers

Extend life of Heat Exchanger and Condensers by costeffectively returning their tubes to optimumperformance using the CTI Shield/Seal Service.

The CTI Shield/Seal is a high grade alloy thin-walledtube insert which prevents erosion and repairsdamage at the inlet and outlet of the tubes. Thisprocess can in many cases return leaking tubes to fullservice at a fraction of the cost of a full tubereplacement.

Close tolerance machining and the thin-wall design ofthe insert prevent turbulence normally associated withthis type of repair.

ApplicationsErosion at the tube end, pitting corrosionBig corrosion cracksGaps due to corrosionImproper tube wideningWeak tube to tube connections

CTI Full Length Tube LinerTM

as tube insertIf damage to the tubes is more extensive, the patentedCTI Full Length Tube Liner offers an effective solutionto erosion, corrosion wall thinning and pluggedleaking tubes.

BenefitsOn-site cost and disruption ofplant transportation avoidedFast, economic re-instatement tooriginal specificationThe real alternative to full tube replacement


On-Line Safety-Valve TestingSafety-valve tests undernormal operating conditions

Hydratight is able to test the response pressure ofsafety relief valves under normal operating conditions.This TV-approved computerised test system doesnot require any increase of operating pressure.

Hydratights state of the art technology provides theassurance and meets the obligation to regularly testthe operation of safety valves.

This market leading process enables testing withoutthe need to increase line pressure and eliminates theneed for unnecessary valve replacement.

Test procedureThe difference between operating and nominalresponse pressure is simulated by a pulling force in aspecial procedure. Applying this test procedure, noincrease of the operating pressure is required. Thismethod is applicable to all manufacturers and nominaldiameters of spring-loaded full-stroke or proportionalsafety relief valves.

Benefits

Test procedure applicable for all sizesTV approved certification for all tested valvesEnables testing of response pressures without increasing the operationalpressureAvoids down time and labour costs associated with valve removal/replacementEliminating costs for transport of the valves, avoids transport damageEfficient management of test data including settings and resultsReducing costsSuitable for gas, steam, condensate and water

PROCESS INTEGRITY



Qualification ManagementAn overview of Hydratights Approvals and Certificates.Hydratight utilise quality standards and best practises worldwide.

German Certificate ofApproval DIN EN ISO 9001

German Certificate ofApproval SCC** German Certificate for

on-line leak-sealing

Netherlands Certificate ofApproval VCA

British Certificate of ApprovalBS EN ISO 9001:2000

British Certificate ofApproval ISO 14001:2004

PROCESS INTEGRITY


German Certificate forsafety-valve-testing

German Certificate forinstalling thermowells

German Certificate ofApproval SCC**

British Certificate of ApprovalBS EN ISO 18001:1999

Norweigan Certificate ofApproval DNV

US Certificate ofApproval ABS

Global Standards Local Delivery

Email us at: [email protected] find your local representative at:

hydratight.com/contact

Material sourced from fully sustainable, managed forestsusing Elemental Chlorine Free fibre. HT/PI/E/12-09

Our global network means you can rely onthe right people, products and services wher-ever you are in the world.

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Ht Pi e 12 09 Hydratight Process Integrity Brochure Uk

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