Beruseal Case Studies

14″ Crude Line Support Wraps

The 14” Crude line that supplies to the refinery was inspected and it was noted that severe external pitting corrosion was found on the contact areas where the pipe meets the concrete sleepers. 178 support sections were identified with 27 of them having major wall thinning. Major findings had wall losses of approximately 70 percent.
2,7mm wall left from an original 9,52mm

Flange Surface Clamp

A leak has been detected on the body flange of a vessel during gas regeneration process. The vessel flanges had a diameter of 2700mm.

3/4″ Clamp Enclosure

A leak was detected on an old clamp but a shutdown for replacing the line and removing the clamp was not possible.

3/4″ T-Piece Enclosure and Restraint

Through hole found in T-piece welding resulting in steam leak, a polymer compound was injected into a sealing groove to avoid sealant entering the line through the defect. A safe and successful repair was implemented that allowed the client to operate at full capacity until the next planned shutdown.

38″ Boiler Flange Clamp

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.

Large through-wall defect on a 36” Sulphur Degassing Unit

Visual inspection found through-wall damage on a section of the line. Damage was located near tie-in 6” nozzle attachment weld of exhaust gasses line from Sulphur Degassing Unit. UT scanning was performed to determine the condition of the area of damage and 6” nozzle. In accordance with inspection results, wall residual thickness in the area of damage was ≈4.7mm, in the adjacent areas. Т-min was 5.0mm, nominal thickness was 7.9 mm. Wall residual thickness of 6” nozzle was 5.8mm, nominal thickness was 7.11 mm.

Failed Gasket on Heat Exchanger

H2S gas leaking from heat exchanger shell flange with bolts that were unsuccessfully re-tensioned in an attempt to eliminate leakage.

Partially Submerged 26” Riser Repair

The riser had a slight leak and was deformed. Numerous attempts were made by different vendors to repair damage to a platform riser by means of composite repair systems. The repairs however were unsuccessful. Beruseal was called upon to perform on-line leak sealing.

Mixed Sour Gas Manifold-Weld-O-Let Cracks

Axial-orientated cracks were found in one butt-weld and one fillet-weld on a 2” pipe with RT on the U300 Mixing Manifold.

Pre-heater Flange Clamp

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.

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