case studies
14” Flare Line Elbow Repair (Refinery)
PSI is known for our ability to evaluate and solve critical problems, often coming up with unexpected workable solutions. A major US-based refinery chose to work with PSI on one such project.
Aggressive corrosion from chemicals entering the flare line was causing ongoing internal thinning. Plant crews recognized that if further damage occurred, the system could fail catastrophically, leading to an expensive shutdown.
Working with Citadel Technologies’ team of engineers, PSI recommended the use of DiamondWrap® to encapsulate the elbow. The use of this technology, installed by PSI’s trained and certified installers, allowed the line to remain in operation with zero disruption in production. In addition, no heavy equipment or hot work were required for the installation.
This solution was safe, cost-effective and allowed the refinery to maintain full operation until the next scheduled turnaround.
The use of this technology, installed by PSI’s trained and certified installers, allowed the line to remain in operation with zero disruption in production.
Half-Inch Line-to-Line Enclosure
Rarely are problems faced by plants and refineries easy or convenient. For one such customer, numerous obstructions to a pipe with an almost paper-thin wall had them dialing PSI for help.
The PSI technician assessed the situation, noting a half-inch valve directly in the path of closing. In determining a solution, he noted the enclosure had to be small enough to fit within the limited space, light enough to avoid stressing the damaged pipe, but solid enough to seal off product should erosion occur. It was also critical, given the service area, that it meet stringent codes.
After evaluating the best options, Plant Services, Inc. went to work. Carefully notching the line allowed the enclosure to be installed despite tight conditions, while an injection of an industrial strength resin epoxy provided both strength and sealing elements. The result was not only a successful installation; it was completed quickly and at a fraction of the cost of other, more aggressive solutions.
1”-16” Geometry Piping Repair (Sour Water, 700 psi)
When poor heat treating led to failing welds in the Heat-Affected Zone (HAZ) at a Wyoming refinery, the company opted to wrap the welds with a discount fiberglass repair product. It quickly proved inadequate and leaks became significantly worse.
PSI was called in to see if options existed that would allow the lines to stay in production until an upcoming turnaround. In evaluating the pipes, PSI noted that the leaks were occurring in multiple sections of piping, including elbows, reducers, tees, straight runs and flanges. That meant that in some sections, there would be no way to use clamps to assist in sealing the leaks.
PSI recommended the use of DiamondWrap® to repair the leaks and allow the piping to remain in production. Consulting with engineers, it was determined that four layers of the carbon-fiber wrap, installed by PSI, would allow the pipes to maintain full flow and pressure. No outage was required, and the solution installed by PSI performed flawlessly until the scheduled turnaround.
No outage was required, and the solution installed by PSI performed flawlessly until the scheduled turnaround.
