Problem Summary

Anomaly Description:
A leak occurred in the connection of the 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:
Deterioration of flange mating gasket

Integrity concerns:
Toxic and flammable H2S gas active leak.

  • Line Size: 38″

  • Design Pressure: 5 BAR

  • Operating Pressure: 1.5 BAR

  • Design Temperature: 343°C

  • Operating Temperature: 280°C

  • Material: SA-516 Gr 70N

  • Line Class: 175

The Beruseal Solution

Beruseal designed and manufactured a 4-piece clamp that would seal off the flange against burners 60” flange. The clamp was designed with an outer sealing groove; a sealant pocket situated at the leaking area as well as sealant pockets over the bolts (below picture). The particular clamp design aided in sealing off the leak whilst also acting as a strongback system to hold the burner flange in place should the bolts fail because of the stress from 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 catastrophic failure of the flange bolts and its effects on the clamp holding the system in place.

  • On-site repairs for maximum up-time productivity
  • Improved Safety by reducing noise & emissions
  • Equipment Integrity with international support & custom engineering

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