Pre-heater Flange Clamp

Client: Tengizchevroil

Problem Summary

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Anomaly Description:
A small leak was detected on the body flange of vessel 1E-405.2. The gasket and studs are over 20 years old. The existing studs were corroded and could not be re-tightened. The existing sheet gasket is completely confined and can withstand a higher compression gasket load.
a bolt change out procedure was completed by the client yet the leak of H2S was still present.

Root causes:
Deterioration of the Gasket and studs that have been in service for 20 years without replacement.

Integrity concerns:
Further degradation of gasket and bolting leading to increased exposure of H2S into the environment. H2S exposure to human health is hazardous and large amounts of exposure could be fatal. There was also a risk of Stress Corrosion Cracking due to bolting being exposed to sour service.

Technical Details

Line Size:
Design Pressure:
Operating Pressure:
Design Temperature:
Operating Temperature:
Material:
Line Class:
3410 x 320mm
4 BAR
0.48 BAR
260°C
166°C
ASTM A350 LF2 CL.1
Special-Tubesheet/Channel
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The Beruseal Solution

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Clamp Design:
Beruseal designed and manufactured a 8 Part flange insert lip clamp that would clamp around the vessel flange. Due to the sheer size of the ring clamp, The design underwent an FEA analysis to accurately determine the stresses the clamp would be exposed to.

Due to the clamp design having a seating area on top of the vessel flange precise measurements had to be made to ensure the clamp sits flush on the 3400mm vessel flange and create an effective seal. The enclosure was also CNC machined from the 3D model to have the dimensions exactly accurate as per the design.

Seal:
A PTFE based sealant was injected into the cavity of the flanges, with high precision measuring and machining a successful seal was obtained.

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