38″ Boiler Flange Clamp

Client: Tengizchevroil

Problem Summary

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Anomaly Description:
A leak occurred in the connection of 38” piping attached to a reactor furnace burner. It was leaking hazardous H2S gas through both bolt holes and the flange mating surface.

Root causes:
Deteriration of flange mating gasket

Integrity concerns:
Toxic and flammable H2S gas active leak.

Technical Details

Line Size:
Design Pressure:
Operating Pressure:
Design Temperature:
Operating Temperature:
Material:
Line Class:
38″
5
1.5
343
280
SA-516 Gr 70N
175
38
38.1

The Beruseal Solution

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Beruseal designed and manufactured a 4piece clamp that would seal off the flange against burners 60” flange. The clamp was designed with a outer sealing groove, a sealant pocket situated at the leaking area and sealant pockets over the bolts. (below picture) This clamp design aided in sealing off the leak and at the same time act as a strongback system to hold the burner flange in place should the bolts fail due to stress corrosion and cracking from being exposed to leaking sour service.
A FEA stress analysis was performed according to the rules of ASME VIII Div2 using allowable stresses from ASME VIII Div1 to simulate the event of catastrphic failure of the flange bolts and its affects on the clamp holding the system in place.

38.2
38.1
38.4
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