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Site Technical Practices

EP 5-11-3

On-Stream Leak Repairs of Piping


Components

Page 1 of 54

August 2007

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TABLE OF CONTENTS
SCOPE .......................................................................................................................................................3
1.0
2.0
REFERENCES ...........................................................................................................................................3
3.0
DEFINITIONS.............................................................................................................................................3
4.0
GENERAL REQUIREMENTS....................................................................................................................5
5.0
REPAIRS OF FLANGE LEAKS ................................................................................................................5
5.1
OVERVIEW.............................................................................................................................................5
5.2
TONGUE CLAMP...................................................................................................................................6
5.3
PACKING CLAMP..................................................................................................................................7
5.4
TUBING CLAMP ....................................................................................................................................7
5.5
CRUNCH GROOVE CLAMP..................................................................................................................7
5.6
TONGUE AND PACKING CLAMP ........................................................................................................8
5.7
CLAMPS FOR FLAT FACE FLANGES.................................................................................................8
5.8
WIRE WRAPPING..................................................................................................................................8
5.9
FLANGE PEENING ................................................................................................................................9
5.10
FLANGE BANDING............................................................................................................................9
5.11
CAUSES OF FLANGE LEAKAGE.....................................................................................................9
6.0
REPAIRS USING ENCLOSURES (BOXES) ...........................................................................................11
6.1
OVERVIEW...........................................................................................................................................11
6.2
PIPE AND PIPE FITTING ENCLOSURES...........................................................................................11
6.3
VALVE ENCLOSURES........................................................................................................................12
6.4
EXPANSION JOINT ENCLOSURES ...................................................................................................12
7.0
REPAIRS TO VALVES ............................................................................................................................13
7.1
VALVE PACKING LEAKS ...................................................................................................................13
7.2
VALVE SEAT LEAKS ..........................................................................................................................14
7.3
PRESSURE SEAL BONNET LEAKS ..................................................................................................14
8.0
TUBE CRIMPING.....................................................................................................................................15
8.1
OVERVIEW...........................................................................................................................................15
8.2
GENERAL REQUIREMENTS ..............................................................................................................15
9.0
DOCUMENTATION AND RECORD RETENTION ..................................................................................15
9.1
REQUIREMENTS FOR NEW LEAK REPAIR DEVICES (LRD)..........................................................15
9.2
RECORDS RETENTION ......................................................................................................................16
10.0
SAFETY................................................................................................................................................16
10.1
OWNER RESPONSIBILITIES ..........................................................................................................16
10.2
LEAK REPAIR CONTRACTOR (LRC) RESPONSIBILITIES..........................................................16
11.0
MATERIALS .........................................................................................................................................17
11.1
METALLIC MATERIALS ..................................................................................................................17
11.2
SEALANTS AND PACKING MATERIALS ......................................................................................17
12.0
DESIGN ................................................................................................................................................18
12.1
GENERAL REQUIREMENTS...........................................................................................................18
12.2
REQUIREMENTS FOR STRONGBACKS .......................................................................................19
12.3
REQUIREMENTS FOR WIRE WRAP DESIGNS.............................................................................19
13.0
FABRICATION .....................................................................................................................................19
13.1
GENERAL REQUIREMENTS...........................................................................................................19
13.2
WELDING .........................................................................................................................................19
13.3
HEAT TREATMENT .........................................................................................................................20
14.0
INSPECTION ........................................................................................................................................20
14.1
GENERAL REQUIREMENTS...........................................................................................................20

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EP 5-11-3

On-Stream Leak Repairs of Piping


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14.2
14.3
15.0
15.1
15.2
15.3
15.4
15.5
16.0
16.1
16.2
16.3
16.4
16.5
16.6
17.0
18.0

Revision 0.0

INSPECTION OF NEW LEAK REPAIR DEVICES (LRDS) .............................................................20


INSPECTION PRIOR TO INSTALLATION OF A LEAK REPAIR DEVICE (LRD)..........................20
INSTALLATION OF ONSTREAM LEAK SEALING DEVICES.........................................................21
OWNER RESPONSIBILITIES ..........................................................................................................21
LEAK REPAIR CONTRACTOR RESPONSIBILITIES.....................................................................21
STOP GAP REPAIRS.......................................................................................................................22
REQUIREMENTS FOR BOLTING ...................................................................................................22
SEALANT REINJECTION ................................................................................................................22
DATA SHEET INSTRUCTIONS...........................................................................................................22
GENERAL.........................................................................................................................................22
INSTRUCTIONS FOR EP 5113 DS..............................................................................................22
PART I - OWNER SUPPLIED INFORMATION:...............................................................................23
PART II - LEAK REPAIR CONTRACTOR (LRC) SUPPLIED INFORMATION...............................23
PART III - DESIGN/INSTALLATION REVIEW, OWNERS ENGINEER .........................................24
PART IV - LRD REMOVAL AND REPAIR, OWNERS ENGINEER................................................24
TABLES................................................................................................................................................25
FIGURES ..............................................................................................................................................26

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EP 5-11-3

On-Stream Leak Repairs of Piping


Components

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1.0 SCOPE
1.1 This Practice covers requirements for performing onstream repairs to leaking piping components such
as flanges, pipe and pipe fittings, expansion joints and valves. In addition, the onstream repairs for pipe
flanges in this Practice can also be used for pressure vessel nozzle and girth flanges.
1.2 Any deviation to this Practice shall be in accordance with the procedure given in EP 1-1-3.
1.3 An Asterisk (*) indicates that a decision by the Owners Engineer or Owner is required, or that additional
information is furnished by the Purchaser.
2.0 REFERENCES
The latest edition of the following standards and publications are referred to herein.

STANDARDS AND PUBLICATIONS


Site Technical Practices
EP 113
EP 552
EP 553
EP 554
EP 562
EP 571
EP 5113 DS
EP 715
EP 1021
EP 1023
EP 1514

Deviations to Site Technical Practices


Welding Requirements for Piping
Piping Erection and Testing
Bolting Procedures for Flanged Connections
Piping for Rotating Equipment
Hot Taps
OnStream Leak Repairs of Piping Components Data Sheet
Welding Requirements for Pressure Vessels
Material Requirements for Aggressive Environmental Services
Material Hardness Requirements
Positive Materials Identification (PMI)

ASME Code
Sec. III
Sec. VIII
B16.5
B31.3

Rules for Construction of Nuclear Power Plant Components


Pressure Vessels, Division 1
Pipe Flanges and Flanged Fittings NPS Through NPS 24
Process Piping

ASTM Specifications
A193

Standard Specification for AlloySteel and Stainless Steel Bolting Materials for
High Temperature Service or High Pressure Service and Other Special Purpose
Applications

3.0 DEFINITIONS
3.1 Aggressive Environmental Service (AES) - Process services which result in material degradation such as
cracking, scaling, blistering, and severe pitting and/or corrosion. Examples of such services are hydrogen
service, wet hydrogen sulfide, cyanides, caustic, amine, and hydrofluoric acid. AES process fluid are
defined in EP 10-2-1

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On-Stream Leak Repairs of Piping


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3.2 Category D Fluid Service - A fluid service in which all the following apply:
1) The fluid handled is nonflammable, nontoxic and not damaging to human tissues as defined in
ASME B31.3, paragraph 300.2.
2) The design gage pressure does not exceed 150 psig.
3) The design temperature is from 20F through 366F.
3.3 Certificates of Compliance - A document by which the material manufacturer (or Seller to the extent that
the Code allows) certifies that the material represented has been produced and tested in accordance with
the requirements of the basic material specification shown on the certificate. Objective evidence of
compliance with the requirements of the material specification shall be maintained in the records of the
material manufacturer. However, certificates of compliance shall include reports or results of tests
required by the material specification or the Order.
3.4 Certified Material Test Report (CMTR) - A document, or documents, on which are recorded the results of
tests, examinations, repairs, or treatments required by the Material Specification. Supplementary or
special requirements, in addition to the requirements of the Material Specification, as required by the
Purchase Order shall also be included on the CMTR. The specification of the material being represented
including the year of issue, and the material heat number shall also be included on the CMTR. All such
documents shall identify the applicable Material Specification and shall be identified to the material
represented.
3.5 Inspector - A Toledo Refinery appointed engineer or inspector.
3.6 Leak Repair Contractor (LRC) - The company or business that agrees to furnish materials and personnel
at a specified price and/or rate to the Owner in order to perform an onstream leak repair.
3.7 Leak Repair Device (LRD) - A generic term used to describe a component that is utilized to seal an on
stream leak on a piece of equipment or piping. This device may be a standard clamp design offered by
many manufacturers or a customized fabricated clamp, box, or other enclosure.
3.8 Mainlining - A term used to describe seepage of sealant into the process stream during the sealant
injection phase of a LRD installation. Introduction of sealant into the process stream may cause problems
with valves and instruments; therefore, the potential of seepage must be minimized.
3.9 Manufacturer - The recipient of a direct or indirect purchase order for materials and/or equipment. In this
context, a direct order is one issued to a manufacturer by a contractor or the Owner. An indirect order is
one issued to a manufacturer by a vendor (recipient of a direct order) for materials, fabricated
components, or subassemblies.
3.10 OnStream - Equipment containing any amount of a process fluid including Category D Services.
3.11 Owner - The Toledo Refinery.
3.12 Owners Engineer - A Toledo Refinery appointed engineer.
3.13 Repair - The work necessary to restore piping to a condition suitable for safe operation at the design
conditions. If any restorative changes result in a change of design pressure and temperature, the
requirements for Rerating shall also be satisfied.
3.14 Temporary Repair - Repairs made to components in order to restore sufficient integrity to continue safe
operation until permanent repairs can be made and accomplished within a time frame acceptable to the
Inspector or Owners Engineer.

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On-Stream Leak Repairs of Piping


Components

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4.0 GENERAL REQUIREMENTS


4.1

(*)To control and eliminate leaks or prevent leaks at locally thinned areas in pressurized piping
components that are in service, onstream repair may be made by utilizing the repair techniques in this
Practice. All of these techniques are considered temporary in nature. Other repair techniques not
specially cited in this Practice may be used if approved by the Owners Engineer.

4.2

(*)During the next turnaround or other appropriate opportunities, all leak sealing and leak dissipating
devices, excluding packing repairs made to valves, shall be removed and appropriate actions made to
restore the original integrity of the component. Valve packing repairs shall be evaluated on a caseby
case basis to determine if re-packing or valve replacement is required. The Inspector shall insure that the
leak seal or dissipating device is removed and repairs are made, and the Owners Engineer shall be
involved in determining appropriate repair methods and procedures.

4.3 Drilling holes for the purpose of sealant injection into valve bodies, pipe fittings, or other components will
be permitted only after review and approval of the Owners Engineer. The LRC shall prepare calculations
to verify that the drilled holes will not threaten the integrity of the component and submit the calculations
to the Owners Engineer for approval prior to drilling activity.
4.4 All hydraulic sealant injection pumps shall have a calibrated pressure gauge to indicate the hydraulic
pressure required to inject the sealant. The LRC shall determine maximum sealant injection pressures for
each leak to protect piping components from damage during the repair process.
5.0 REPAIRS OF FLANGE LEAKS
5.1 Overview
5.1.1

Flange clamps can be used to achieve an onstream repair to a leaking flange. Alternatively, other
procedures such as wire wrapping and flange bands can also be used to seal leaks depending on
the operating conditions.

5.1.2

Flange clamps are split rings designed to encircle the flange, see Figure 1. The clamp is installed by
bolting the two halves of the clamp together. The clamp then forms a sealant cavity between the
flange faces and provides the means of injection of sealant through injection ports in the clamp ring.

5.1.3

The design of the clamp includes a seal on the inside of the ring. The seal is designed to make
contact with the flange when the clamp halves are bolted together. The purpose of the seal is to
contain the sealant and prevent extrusion during injection. The sealant can then fill the sealant
cavity and seal off the leak completely.

5.1.4

There are two distinctly different designs of flange clamps: the insert clamp and the peripheral
(outside diameter fitting) clamp. The size of the gap between the two flanges is the primary
determining factor in selecting the type of clamp. Peripheral clamps are used where the flange gap
is insufficient to accommodate an insert clamp blade or tongue.

5.1.5

The insert clamp is manufactured to fit precisely in the gap between the flanges. Some key
advantages to this type of clamp are:
Little or no mechanical work is required on the flange. Flange studs changeout is not typically
required, injection holes need not be drilled into the flange, and little or no peening is required.
Being manufactured to fit, the clamp can be tolerant of flange misalignment, outofroundness,
or differing diameters.
Many applications permit the use of standard clamp rings held in readiness in a finished or
semifinished state, requiring that only the insert be machined to the measured gap size.

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On-Stream Leak Repairs of Piping


Components

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Clamps are selfrelieving and will vent should flange separation take place as a result of bolt
relaxation. As the relaxation occurs, the leak will probably restart and serve as a warning that
additional actions are necessary.
The quantity of sealant is reduced.
Pressurized area between flanges is reduced.
A high degree of success has been experienced.
5.1.6

Peripheral clamps can be used as a simple ring to enclose the outside of the flanges with injection
ports through the ring. The outside of the flanges can also be enclosed with packing that is
compressed onto the flange periphery when the bolts on the clamp split line are tensioned.
Additionally, these clamps are frequently used in conjunction with a lowviscosity compound to
establish a homogeneous molding within the narrow flange gap. The major advantages of the
peripheral clamp are:
The clamp can be used for narrow gap flanges where an insert clamp is impractical.
The technique requires fewer injection points when used with low viscosity compound.
Leak sealant work on site is reduced.
No drilling or peening of flange surfaces is required.

5.1.7

Peripheral clamps require careful and accurate flange measures, and subsequent marking to correct
flange misalignment. Also, because there is not direct means of pressure release, it is advisable to
check the ability of the joint fasteners to withstand fullline pressure over the total flange area. The
maximum injection pressure should be analyzed by the LRC in relation to bolt stress to ensure that
overloading does not occur.

5.1.8

High tensile strength flange bolting (A193 Grade B7 or B16) is known to be susceptible to stress
corrosion cracking. The bolting in flanges in services that can contribute to stress corrosion cracking
should be replaced with new bolting before injection of sealant. Similarly, bolting which has been
previously encapsulated in sealant or when a corrosive service leak has recurred should be replaced
with new bolting prior to reinjection of additional sealant. The replacing of the bolting shall be
reviewed and approved by the Owners Engineer. If required, the replacing of the bolting onstream
shall be in accordance with EP 5-5-4

5.1.9

An overview of the attributes of the various clamps described below is given in Table 1. Numbers
appearing before the name of each clamp in Table 1 refer to the paragraph numbers below.

5.2 Tongue Clamp


5.2.1

A tongue clamp is an insert clamp type that is generally used for sealing leaks when the flange gap
is 0.375 inches or more, see Figure 2. It can be used on gaps less than 0.375 inches, but an
alternate means of sealant injection such as injection nuts or rings must be provided. These clamps
have a high rate of success for sealing flange leaks on very high temperature, high pressure and
high velocity leaks. They are relatively easy to install since the tongue aligns the clamp to the flange
during installation.

5.2.2

The crunch teeth on the tongue are not designed for an interference fit but are designed to achieve
metal to metal contact with the flange faces. The bore of the clamp ring does not contact the flange
outside diameter. Therefore, this type of clamp can compensate for flange mismatch or out of
roundness of the flange outside diameter. In addition, tongue clamps can be used on flanges that
have unequal diameters.

5.2.3

The tongue clamp seal is created with the crunch teeth against the flange faces and extends down to
the flange stud. This feature results in a reduction of the amount of sealant required to fill the cavity
and seal the leak.

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On-Stream Leak Repairs of Piping


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5.3 Packing Clamp


5.3.1

The packing clamp is a periphery clamp type which utilizes square braided packing installed in the
inside diameter of the clamp ring, see Figure 3. The packing is compressed as the clamp halves are
drawn tightly together and seals on the outside diameter of the flanges. The sealant then bridges
against the packing when injected. Again the bore of the clamp ring does not contact the outside
diameter of the flange.

5.3.2

The packing clamp is limited in use to a service pressure of 300 psig and less. It is not used on
severe leaks because the high velocity of the leak may roll the packing out of the packing groove.
The service temperature of the packing clamp is limited by the packing material. Typical packing
materials are limited to approximately 1200F to 1300F.

5.3.3

The packing clamp is preferred on large diameter flanges (sizes NPS 16 and larger) since less bolt
torque is required to achieve a seal than for any other type peripheral clamp. The packing size and
extent of compression is necessary to compensate for mismatch and surface irregularities at the
flange outside diameter.

5.3.4

This clamp can be reused if the packing material is replaced after each use.

5.4 Tubing Clamp


5.4.1

The tubing clamp is a periphery type clamp where metal tubing is used rather than packing to
achieve a seal, see Figure 4.

5.4.2

The clamp is normally used at pressures above 300 psig, but is also used at lower pressures when
leakage is severe. The maximum service pressure is limited to approximately 2000 psig.

5.4.3

A greater clamp bolt torque is required to compress and achieve a seal than that required to
compress packing. For this reason, a soft tubing is typically used for the peripheral seal.

5.4.4

(*)Copper tubing may be used as a standard for design temperatures up to a maximum of 450F.
Stainless steel tubing shall be used for design temperatures above 450F and for all clamps installed
on services which are categorized to be in AES, unless otherwise specified by the Owners Engineer.
Tubing clamps may be used at temperatures as high as 1500F, depending on the limits of the
tubing material used.

5.4.5

All tubing shall be connected to the clamp (silver brazing, tack welding or equal) to insure that the
tubing will not become dislodged while attempting to seal leaks with a high velocity.

5.4.6

As with packing, the size of tubing used depends on the size of the clamp and the amount of
mismatch or surface irregularity measured by the LRC.

5.4.7

This clamp can also be reused if the tubing is removed, the clamp cleaned, and new tubing installed
per paragraph 5.4.5.

5.5 Crunch Groove Clamp


5.5.1

The crunch groove clamp is a periphery clamp type that utilizes a tooth shaped labyrinth to achieve a
metaltometal seal on the outside diameter of the flange, see Figure 5.

5.5.2

This clamp can be used for any combination of high pressure, high temperature and severe leaks.
However, its use is limited to flanges that have machined surfaces on the flange outside diameter
and are aligned with very little mismatch. The crunch groove clamp is normally used only when
there is a combination of high temperature, very high pressure (above 2000 psig), and/or severe
leakage.

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On-Stream Leak Repairs of Piping


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5.5.3

Revision 0.0

Like the tongue clamp, the crunch teeth are 0.110 inches deep and are not designed for an
interference fit. The crunch teeth should contact the flange outside diameter at the same time as the
clamp ring splitlines make contact.

5.6 Tongue and Packing Clamp


5.6.1

The insert and periphery clamp types can be combined to achieve designs that have primary and
secondary seals, see Figure 6. In the tongue and packing clamp, the tongue forms the primary seal
in the flange gap and the packing is used to form a secondary seal on the flange outside diameter.

5.6.2

This clamp has similar service restrictions as those cited for the tongue clamp.

5.7 Clamps for Flat Face Flanges


5.7.1

Flat Face Flanges with full-face gaskets cannot be sealed using only a clamp at the flange outside
diameter, see Figure 7. If a flange clamp were installed on this flange to seal a leak at the gasketed
joint the leak path would move to a bolt hole. The resulting leak at a bolt hole could not be sealed by
injection of additional sealant into the clamp because the sealant would be unable to travel from the
clamp to the bolt hole because of the full face gasket.

5.7.2

To achieve a leak seal for a full-face gasket, injection nuts or rings are installed and sealant is
injected into the bolt holes. During this process, if seepage of sealant is noted at the flange outside
diameter, a tensioned cable or clamp can then be installed around the flange to allow bridging of the
sealant.

5.8 Wire Wrapping


5.8.1

In the wire wrap procedure, stainless steel wire is wrapped in the flange gap until the gap is filled
with wrapping wire, see Figure 8. Sealant is then injected through injection nuts that are installed
prior to the wire wrap, see paragraph 5.8.3. Sealant travels through the injection nut, through the
stud hole and into the flange gap area. The wire retains the sealant and allows the entire gap as well
as all stud holes to be filled with sealant. This seals off the leak completely when the sealant is
compressed.

5.8.2

(*)The following service and geometry limitations shall be used for the wire wrap procedure unless
the LRC can demonstrate suitable experience with other criteria. This experience shall be presented
to the Owners Engineer for approval prior to the commencement of the repair procedure.
0.375 inch maximum gap between flanges
650 psig service pressure
NPS 30 inch maximum flange diameters
ANSI Flanges (4 bolt minimum)

5.8.3

Prior to installation of the wire wrap, bolt tension is checked to verify uniform tension on all bolts.
Then a nut is removed from one of the bolts and replaced with an injection nut. The stud may be
replaced with an injection stud to provide additional sealant travel if the gap between the stud and
the stud bore is so restrictive as to limit sealant travel through the nut only. The injection nut is
tightened to the required bolt tension, and another nut is then replaced with an injection nut. This
procedure is repeated until injection nuts have been installed (evenly distributed) on at least half of
the flange bolts.

5.8.4

The use of wire wrapping to effect onstream repair of flange leaks has been widely used for many
years and is proven to be an effective repair method for flange leaks. It affords the LRC the ability to
repair flange leaks immediately with materials that are readily available. It is an inexpensive repair
procedure and does not require peening or drilling of the flanges in order to achieve a seal.

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On-Stream Leak Repairs of Piping


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5.9 Flange Peening


5.9.1

In the peening procedure, the inside edges of the flanges are mechanically peened to create a cavity
for the sealant, see Figure 9. Sealant is then injected through injection nuts that are installed prior to
the peening operation (see paragraph 5.8.3). Sealant travels through the injection nut, through the
stud hole and into the flange gap area. The peening retains the sealant and allows the entire gap as
well as all stud holes to be filled with sealant. This seals off the leak completely when the sealant is
compressed.

5.9.2

Peening the edges of a flange to create a cavity for sealant is not recommended for most
applications. This is because the flange may become distorted to the point where machinery in the
field is required to affect boltup after the repaired joint is dismantled. Peening may also result in
excessive vibration and additional stress on the component being repaired.

5.9.3

Peening is typically limited by the gap between the flange surfaces. The maximum permitted gap
should be less than 0.125 inches. If a larger gap is used, an insert wire shall be used to minimize
the peening required to affect a seal, see Figure 9.

5.9.4

(*)For carbon steel and low alloy materials, the minimum operating temperature of a flange that can
be sealed using the peening technique shall be 120F, unless otherwise approved by the Owners
Engineer. This temperature limitation is set to minimize the potential for a brittle fracture during the
peening process. Peening shall not be performed on low alloy materials in Hydrogen Service due to
the possible loss of toughness resulting from temper embrittlement.

5.10 Flange Banding


5.10.1

(*)Flange leakage can be sealed by welding a steel band around the perimeters of the flanges and
then seal welding around the nuts to prevent further leakage, see Figure 10. Because of the welding
involved, this technique is recommended only for limited to ASME B31.3 Category D Services. It
should not be used for onstream repairs of hydrocarbon lines unless the hot work can be safely
performed and is approved by the Owners Engineer.

5.10.2

Size is not a limitation with this technique since the band can be as thick as necessary to contain the
line pressure and any flange circumference can be banded.

5.10.3

The use of carbon steel bands above 800F is not recommended since the strength and oxidation
resistance decrease rapidly above this temperature. However, higher grade materials such as
stainless steel can be used for higher temperature applications as long as they are weldable, and
differential thermal expansion considerations are evaluated.

5.10.4

While the band should be designed to withstand the internal pressure from the point of view of the
circumferential stresses, it is generally impractical to design the band to take the full axial hydraulic
pressure loads (assuming the bolts do not exist.) Consequently, if the bolts are subject to
deterioration in service due to corrosion, erosion, oxidation or stress corrosion cracking, this
technique should not be used.

5.11 Causes of Flange Leakage


5.11.1

Understanding the causes of flange leakage is a major factor in evaluating effective repair
techniques. Some of the most common causes of leakage are described in this Section.

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On-Stream Leak Repairs of Piping


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5.11.2

Low Bolt Tension - In most flanged joints, tension in the bolts is used to resist the internal pressure
and provide adequate seating loads for the gasket. If the bolts are not adequately tensioned,
leakage will result. In many cases, only some of the bolts will have inadequate tension and
consequently the flange will only leak in areas close to these bolts. Leakage can often cause
changes in flange temperature around the leak that can lead to further leakage by causing increased
flange bending and further loosening of the bolts. Where nonmetallic gaskets are used, low bolt
tension can sometimes result in blowing out sections of the gasket because the loss of the gasket
seating force (which accompanies bolt loosening) reduces the restraining friction force between the
gasket and the flange faces.

5.11.3

High Stud Tension - Excessive stud tension can cause flange leakage by either damaging the gasket
or the flange itself. An initial bolt tension equivalent to a stress of 40,000 to 50,000 psi is normally
required to prevent flange leakage. Higher bolt tension can lead to excessive loading of certain
types of gaskets to a point where they no longer have sufficient elasticity to prevent leakage even
under minor changes of temperature or pressure. In addition, high bolt tension can also overload the
flange itself and cause excessive rotation. Large flange rotations can redistribute the flange loading
across the gasket width and reduce the seating area, giving a shorter leakage path and possibly
crushing the outer edge of the gasket. Hot bolting tightening of already overtensioned bolts can
increase leakage by further damaging the gasket and flanges and consequently is not
recommended.

5.11.4

Damage to Flange Faces and Gaskets - Defects to flange faces and gaskets such as scratches and
gouges can create leakage paths and allow fluid to escape. In some cases, erosion or corrosion of
the gasket and/or the flange face can occur which will eventually lead to the formation of a leakage
path. For example, external steam rings have caused erosion/corrosion of solid soft iron gaskets
that subsequently led to major leakage. Many steam leaks are initiated by low bolt tension, and as
soon as a leakage path is formed, erosion of the flange face and gasket will occur and result in
greater leakage. In the event of damage to flange faces and gaskets, hot bolt tightening is unlikely
to prevent leakage and another technique should be employed. However, a careful evaluation of the
possible consequences of not fully repairing a leak where erosion/corrosion could occur is required.

5.11.5

Varying Operating Conditions - Alterations in operating temperature and pressure cause changes to
the gasket seating load and bolt tension. These changes can sometimes lead to flange leakage.
Rapid temperature changes commonly produce flange leakage as they can significantly alter the bolt
load and gasket seating load. However, very often the leakage stops when the flange and bolts
reach steady state conditions. In some units operating procedures have been altered to reduce the
rate of temperature changes to flanged joints and thereby solve leakage problems. Reducing
temperature changes to a rate of less than 100F/hr. should prevent most cases of leakage due to
temperature transients. However, in the long term, severe cyclic temperatures will lead to leakage
since the joints may be overstressed and a loss of elasticity eventually leads to leakage. Tightening
of the bolting onstream is frequently successful in preventing flange leakage due to long term
temperature cycling. Care should be taken when using other techniques to prevent leakage to
ensure that any leakage that occurs as a result of an operating condition change does not go
undetected.

5.11.6

Improper Flange Alignment - Improper alignment, especially lack of flange face parallelism, can
cause uneven bolt loading and gasket compression, local crushing and subsequent leakage. Proper
centerline alignment of flanges is also important to assure even compression of the gasket. Flange
alignment criteria are cited in EP 5-5-3.

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5.11.7

Improper Gasket Centering - A gasket that is installed so that its centerline does not coincide with
the flange centerline will be unevenly compressed with the possibility of subsequent leakage. Spiral
wound and double jacketed asbestos gaskets are provided with a centering ring or gasket extension
to the inside diameter of the bolt circle to facilitate gasket centering. Even so, the gasket should be
centered with respect to the bolt circle. Sheet gaskets should be cut so that the outside diameter
extends to the inside diameter of the bolts for centering considerations.

5.11.8

Excessive Bending Moments in Piping Systems - This can occur because of improper piping
flexibility design, or by excessive application of force to attain flange alignment. Improper location of
temporary or permanent restraints or supports can also cause high flange bending moments. A
method which can be used to evaluate the potential for flange leakage due to an applied bending
moment is given the ASME Code, Section III. In this method, a piping stress analysis is utilized to
determine the bolt and flange stresses acting on the flanged joint.

5.11.9

Improper Bolting and Gasket Size or Material - Since the bolting and gasket materials are major
factors in a flange joint design, improper selection can have a major impact on joint reliability.
Requirements for bolting and gasket selection are covered in EP 5-2-2.

5.11.10 Improper Flange Facing - EP 5-2-2 stipulates that raised face flanges shall have a finish meeting the
requirements of ASME B16.5. This finish has 30 to 55 grooves per inch, cut spirally or concentrically
with a round nosed tool. In addition, a 125-250 micro inch roughness is also a requirement in EP 52-2 (as compared to a 125-500 roughness permitted by ASME B16.5). This surface roughness is
stipulated in EP 5-2-2 because it is the roughness recommended by most spiral wound gasket
manufacturers. For ring type joint flanges (RTJ), the grooves must be cut to very close tolerances
and finished to 63 RMS. In older flanges, RTJ gaskets often must be lapped into the groove to
ensure a tight fit and leak tightness.
6.0 REPAIRS USING ENCLOSURES (BOXES)
6.1 Overview
6.1.1

Enclosures are used to fully enclose (box) a leaking or substantially thinned component to affect a
onstream repair. When the enclosure is installed, a sealant cavity is created surrounding the leak.
In general, the cavity then has to be injected with sealant to seal the leak (expansion joints are an
exception).

6.1.2

Enclosures are available in many forms (depending on the leaking component) as prefabricated
standard stock items that can be installed on the leaking component by bolting. The end plates on
an enclosure create the sealant cavity and are the feature that distinguishes enclosures from flange
clamps. The nomenclature used for bolted enclosures is depicted in Figure 11.

6.1.3

(*)Enclosures can also be made by fabricating a custom box that is designed to fit around the leaking
component configuration. Custom designed boxes can either be installed by bolting or welding
directly to the leaking component. Installation of a box by welding directly to the leaking component
is limited to ASME B31.3 Category D Services. It should not be used for onstream repairs of
hydrocarbon lines unless the hot work can be safely performed and is approved by the Owners
Engineer.

6.2 Pipe and Pipe Fitting Enclosures


6.2.1

A full flange enclosure is shown in Figure 12. Note that with this type enclosure, a strongback is
provided in the event of failure of the bolts by means of the sealant and end plates.

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6.2.2

A typical straight line enclosure that may be used to enclose a weld joint or a leak through the wall of
the pipe is shown in Figure 13. In the enclosure shown, packing is used in this enclosure to seal
against the pipe. The packing that is installed in the end plates is compressed against the pipe when
the enclosure halves are bolted together. The enclosure is designed for clearance at the closure
point and does not make metal to metal contact with the pipe.

6.2.3

A full tee enclosure is shown in Figure 14. The injection ports and the bolting which holds the
enclosure halves together are also shown in this figure. Enclosures are also commonly used to
totally enclose 45 or 90 elbows. The one shown in Figure 15 is a single miter 90 enclosure. For
enclosing 90 long radius weld ells a double miter enclosure is used.

6.2.4

Packing for an enclosure seal is used below 300 psig design pressures to allow the sealant to bridge
over the leak and fill the void cavity. When the service pressure is above 300 psig, tubing and
crunch teeth seals are used. These three seal types are shown in Figure 16.

6.2.4.1

(*)Copper tubing may be used as a standard for design temperatures up to a maximum of 450F.
Stainless steel tubing shall be used for design temperatures above 450F and for all clamps installed
on services which are categorized to be in AES, unless otherwise specified by the Owners Engineer.

6.2.4.2

Crunch teeth are used to seal severe, high pressure leaks. It is important to note that crunch teeth
are not designed to bite into the pipe during installation. The crunch teeth bore is made to the same
dimension as the pipe diameter and no interference is intended.

6.2.5

A full packing or packing gland type enclosure is shown in Figure 17. This type of enclosure is used
to repair leaks in nonmetallic pipe made from PVC, fiberglass, clay, concrete or glass. Since only
the packing material is in contact with the pipe, the force against the pipe is uniformly distributed and
would not cause breakage of the fragile pipe.

6.2.6

Pipe and pipe fitting enclosures can typically be reused if the tubing and packing are changed each
time.

6.3 Valve Enclosures


6.3.1

A perimeter seal type enclosure can be used when enclosing valves, see Figure 18. When the
perimeter seal design is used, it must be designed recognizing that the void cavity in the enclosure
will be pressurized with line pressure and filled with the service fluid. Therefore, materials for the
enclosure must be compatible with the fluid service.

6.3.2

Considerations should also include whether the service is susceptible to freezing. Since the
enclosures void area will fully contain the fluid in a pressure boundary outside its normal flow path,
there will be a dead area that could freeze and rupture during cold weather.

6.4 Expansion Joint Enclosures


6.4.1

Expansion joint enclosures must utilize a perimeter seal type because the enclosure cavity must not
be filled with sealant. If it were, sealant pressure in the cavity would collapse the metal bellows and
flow through the line would be restricted.

6.4.2

An enclosure for expansion that utilizes a perimeter seal is shown in Figure 19. In this design, a
double row of packing is used with a sealant groove between the two rows of packing. This type
enclosure will effectively seal the leak, but any significant movement of the pipe at the closure point
will break the seal and resealing requires reinjection of sealant.

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6.4.3

If welding is permitted, an enclosure or box can be prefabricated and fitted around the leaking
expansion joint and the perimeter seal can be made by welding, see Figure 20. Alternatively, the
expansion joint cover can be utilized as the box if it has ample strength. When this type of enclosure
is used, it should be installed while the expansion joint is in the operating condition. This is because
the enclosure will restrict all movement at the expansion joint. Extreme care should be exercised
when removing the enclosure during a shutdown because energy stored in the piping system will
be released when the enclosure is removed.

6.4.4

As an alternative to an enclosure or box with a perimeter seal, clamshell repairs have also been
used to repair expansion joints onstream, see Figure 21.

6.4.4.1

A typical clamshell is a formed bellows element that is cut into two or more sections for field
installation. Clamshells are formed to a diameter large enough to completely enclose the leaking
bellows expansion joint.

6.4.4.2

The clamshell installation requires a metal surface to which the bellows element must be attached.
The attachment surface is usually a set of rings that are installed in segments around the pipe and
then butt or fillet welded to the pipe surface.

6.4.4.3

The clamshell sections are installed around the leaking bellows, tack welded together, the bellows
assembly is attached to the rings, and then the complete assembly is welded in place.

6.4.4.4

The clamshell is the best alternative for enclosing an expansion joint because after installation,
movement of the expansion joint is still possible.

6.4.5

Expansion joints designed in accordance with EP 5-4-1 have external covers which can be seal
welded in the event of a leak. Seal welding of this cover will result in restriction of expansion joint
movement. Type 3 piggy back expansion joints per EP 5-4-1 are designed with a secondary seal
bellows. In the event of a leak, this bellows is jacked into place and seal welded. The advantage of
this design is that the enclosure used to seal the leak is made using an expansion joint; therefore,
bellows movement is permitted after installation of the enclosure.

6.4.6

If the design of the expansion joint enclosure or box requires removal of tie rods, hinge joints or other
external hardware which is used to provide support for the axial pressure thrust load, the enclosure
shall be designed to fully support this load.

7.0 REPAIRS TO VALVES


7.1 Valve Packing Leaks
7.1.1

As a first attempt to eliminate valve packing leaks, adjust the packing gland as follows: retorque
gland bolts to their recommended value, add a lubricant to the packing material around the stem (for
example, CLIMAX, DEMNUM, etc.) and stroke the valve five times retorquing the gland bolts after
each stroke. Be sure the lubricant is compatible with the service media and temperature.

7.1.2

Valve packing and seat leaks may be sealed onstream using a sealant injection method similar to
the one used for flanges.

7.1.3

Leaking valve packing glands shall be repacked using injected packing material rather than a
sealant. The valve packing material shall not cure or otherwise solidify, and shall have compliance
throughout its useful life.

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7.1.4

A valve packing leak may be sealed by injecting packing material into the existing valve stuffing box.
The means for injection of the packing material is provided by drilling a small hole into the packing
area. This hole is tapped and a shutoff adapter is threaded into the tapped hole. The valve stuffing
box is then repacked by filling it full of packing material by the injection process, see Figure 22. The
valve packing gland should be left in the fully extended position to allow for future adjustment.

7.1.5

The holes drilled for injection of the packing shall be drilled and tapped into the packing box wall
exercising care not to drill into the pressurized packing until the injection valve has been threaded
into the tapped hole.

7.1.6

If further usage of the injection valve is expected, the injection valve can remain on the packing box
of the repacked valve. Otherwise, the injection valves shall be removed after the valve is repacked
and the injection hole plugged with an appropriate drillthrough safety plug.

7.1.7

The Leak Repair Contractor shall warrant that all valves will remain fully operable after repacking
and that steps are taken during the repair procedure to prevent extrusion of valve packing material
into the process stream.

7.2 Valve Seat Leaks


7.2.1

Valve seat leaks may also be sealed by drilling and tapping an injection port into the body of the
valve. Seat leaks are internal rather than external leaks but can adversely affect plant operations.
Occasionally, seat leakage may contribute to package gland leakage. The following procedures for
valve seat leakage repair shall be used only to prolong valve operation until the next maintenance
opportunity. At that time, the valve must either be repaired and the injection ports plugged, or
replaced with a new valve.

7.2.2

Gate valve seat leaks may be sealed when the leak occurs in the bottom portion of the gate.
Injection ports must be installed and sealant, rather than valve packing material, is injected while the
valve is in the closed position, see Figure 23.

7.2.3

(*)Ball valve seat leaks are injected with a packing material between the two seals, in the valve body,
with the valve in the open position, see Figure 24. The valve is then closed to isolate the process.
The drilled hole for the shutoff adapter should be in the center position. The injected material should
be the same as the packing material. A sealant that will not adhere to the ball may be used with the
approval of the Owners Engineer.

7.2.4

For globe valves, seat leaks can only be sealed by killing the valves or making them inoperable.
This is accomplished by injecting sealant into the valve inlet to block the flow to the valve seat.
Similarly, ball valves may be killed or rendered inoperable when sealant is injected into the valve
body with the valve in the closed position. Gate valves are killed by injecting a sealant upstream into
the valve bonnet area and all around the gate, see Figure 25.

7.3 Pressure Seal Bonnet Leaks


7.3.1

The bonnet seat rings on pressure seal bonnet valves can also be sealed using an injection method,
see Figure 26. However, achieving a seal is difficult due to the small space available at the tip of the
seal ring into which compound can be injected.

7.3.2

Exact dimensions must be provided by the valve manufacturer to determine the correct drill point for
the shutoff adapter. On larger valves, more than one injection point may be required. Once the
adapters are in place, a sealant compound is injected around the small gap at the tip of the seal ring.

7.3.3

Some valve designs lend themselves to the success of this technique more than others. Many
designs have virtually no gap at the tip of the seal ring and an alternative cavity, such as a thread
relief must be injected.

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7.3.4

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(*)The valve should not be injected in the area of the knockout segmented ring or directly below
the bonnet retaining ring without a thorough engineering evaluation and the approval of the Owners
Engineer.

8.0 TUBE CRIMPING


8.1 Overview
8.1.1

Tube crimping can be used to seal off leaking tubes in reformer fired heaters while in operation. In
this method, a mechanically actuated crimp block is placed on the reformer tube inlet and outlet
pigtails. The tube is then crimped to choke off flow.

8.1.2

There are two basic methods employed for tube crimping. In the first method, single crimp blocks
are used on the inlet and outlet pigtails to achieve a seal. In the second method, dual crimp blocks
with an intermediate injection clamp ring are used to achieve a seal. The injection clamp is utilized
for injection of a sealant to insure a leak tight seal. The second method is recommended for
hydrogen and steam reformer heaters.

8.2 General Requirements


8.2.1

Depending on the material of the pigtail, a minimum metal temperature must be maintained to insure
that sufficient ductility exists to crimp the tube without causing cracking. For Inconel 600 pigtails, the
minimum recommended temperature is 700F. For other alloys, the minimum temperature shall be
established by considering the material property and the condition of the pigtail.

8.2.2

Adequate cooling must be provided to insure that relaxation of the crimp block studs does not occur.
Relaxation will result in leakage at the crimp location.

8.2.3

After the tube has been crimped, the loss of fluid flow will result in an increase in the tube metal
temperature. Therefore, tube supports may have to be adjusted to accommodate the associated
additional thermal expansion of the tube.

8.2.4

If the tube is being isolated because of catalyst blockage (as opposed to an external leak), the pigtail
should be hot tapped after the crimping operation to bleed off any remaining pressure inside the
tube. This precaution will help to minimize the risk of a fire inside the heater in the event of a tube
rupture due to overheating of the tube material.

9.0 DOCUMENTATION AND RECORD RETENTION


9.1 Requirements For New Leak Repair Devices (LRD)
9.1.1

The following drawings, calculations and material data shall be supplied along with each LRD:

9.1.1.1

A crosssectioned drawing with all dimensions required for fabrication showing the following:
design pressure and temperature
maximum sealant injection pressure to be used during installation and the volume of sealant
corrosion allowance
materials of construction
weld details
total weight (including estimated weight of sealant) and support structure design if necessary
sealing device identification number
plant identification, unit number and description of clamp location
sealant or packing material
strong-back drawing (including location with respect to clamp)

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field sketch with measured critical dimensions


9.1.1.2

A completed OnStream Leak Sealing Data Sheet. Any exceptions to the requirements of this
Practice must be indicated on the data sheet.

9.1.1.3

All mechanical design calculations required to demonstrate the structural adequacy and compliance
to this Practice, see section 12.0.

9.1.1.4

Welding Procedure Specifications (WPS) and Referenced Procedure Qualification Records (PQR)
for all fabricated LRDs.

9.1.1.5

Certified Material Test Reports or Certificates of Compliance.

9.1.1.6

Welding inspection records.

9.1.2

One copy of all drawings, calculations and material data shall be submitted and delivered to the
Owner along with the LRD.

9.1.3

(*)All comments and unresolved issues cited by the Owners Engineer, if any, shall be resolved by
the Leak Repair Contractor

9.2 Records Retention


9.2.1

All documentation including the information in paragraph 9.1.1 shall be submitted to the Owners
Engineer for review and approval. After approval is obtained from the Owners Engineer, see
paragraph 9.1.3, all documentation shall become part of the permanent equipment records until that
time when the LRD is removed from service, and suitable repairs are performed to restore the full
integrity of the component.

9.2.2

The LRC shall retain all documentation outlined in paragraph 9.1.1 for a minimum of five years.
Copies of these records shall be made available to the Owner on request.

10.0 SAFETY
10.1 Owner responsibilities
10.1.1

All work associated with sealing onstream leaks shall be performed in accordance with the local
refinery Safety Practices and Procedures Manual, and the additional requirements of this Practice.

10.1.2

All work associated with sealing onstream leaks shall be performed in accordance with the local
plant Safety Practices and Procedures Manual, and the additional requirements of this Practice.

10.1.3

For leak sealing involving welding and/or cutting, precautions should be taken for proper grounding
during electric welding and for the cutting of pipelines with cathodic protection systems, if the system
cannot be disengaged.

10.2 Leak Repair Contractor (LRC) Responsibilities


10.2.1

The LRC shall be fully responsible for the safety of his employees and shall provide them with
appropriate protective clothing, goggles, face shields, hard hats, safety shoes and gloves. The LRC
shall furnish additional safety equipment if the nature or condition of the work requires it.

10.2.2

The LRC shall be responsible for ensuring a safe working environment for his employees. Any
unsafe conditions shall be immediately brought to the attention of the Owners Engineer, and all leak
sealing work suspended while the unsafe conditions exist.

10.2.3

The LRC shall obtain the necessary permits from Owner prior to inspecting the leaking component,
and prior to the actual installation of the LRD.

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10.2.4

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The LRC shall describe to the Owner all possible modes of failure of equipment or devices during
installation or pumping of sealant, and discuss contingency plans for the safe evacuation of
personnel and the containment of unsafe conditions.

11.0 MATERIALS
11.1 Metallic Materials
11.1.1

All materials used for pressure containing parts (including bolting) shall be in accordance with the
ASME Code Section VIII, Division 1. Unless otherwise specified by the Owners Engineer, CMTR
are required for all materials except bolting.

11.1.2

(*)Unless otherwise specified by the Owners Engineer, the material of the leak-sealing device shall
be made from the same material (based on ASME Code Pnumber) as that of the leaking
component.

11.1.3

Bolting materials shall be in accordance with EP 5-2-2.

11.1.4

Copper and its alloys, (e.g., brass) and aluminum are not permitted in the pressure containing or
load bearing parts of any device. However, copper tubing may be used for leak sealing clamps up to
a temperature of 450F for services that are not categorized as an AES.

11.2 Sealants and Packing Materials


11.2.1

(*)Sealants and packing materials shall be selected by the LRC and submitted to the Owners
Engineer for approval.

11.2.2

(*)Sealants and injectable valve packing materials shall be asbestos free and Material Safety Data
Sheets must be submitted to the Owners Engineer prior to use.

11.2.3

Sealants and valve packing materials shall not contain corrosive materials that would result in
accelerated corrosion of piping and pressure vessel materials.

11.2.4

The possibility of stress corrosion occurring in piping and pressure vessel components is enhanced
by using sealants that contain high levels of chlorine, fluorine, sulfur and heavy metals (arsenic,
bismuth, lead, tin and zinc). Therefore, the LRC shall provide documentation indicating that the
sealants and valve packing materials meet the following standards (Note: Laboratory tests to
determine leachable rather than total quantities are not acceptable.). The test results should be
based on an analysis by an independent laboratory:
Total Chloride 150 ppm maximum
Total Fluoride 75 ppm maximum
Total Sulfur 150 ppm maximum
Total Arsenic 50 ppm maximum
Total Bismuth 50 ppm maximum
Total Lead 50 ppm maximum
Total Tin 50 ppm maximum
Total Zinc 50 ppm maximum

11.2.5

Below 450F, rubber based sealant materials may be used. Above this temperature, thermosetting
sealants shall be used.

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12.0 DESIGN
12.1 General Requirements
12.1.1

All LRDs and enclosures shall be designed in accordance with the ASME B&PV Code, Section VIII,
Division 1 (Code). Any configurations not specifically covered by the Code shall be designed using
good engineering practices (see paragraph U2 of the Code).

12.1.1.1 For design of clamp type LRDs, the design calculations shall include the applicable attributes of the
design procedures and details outlined in Appendix 24 of the Code.
12.1.1.2 For welded box type enclosures, the design calculations shall include the applicable attributes of the
design procedures and details outlined in paragraph UG34, Appendix 9 and Appendix 13 of the
Code.
12.1.1.3 As an alternative to design calculations, the maximum allowable working pressure of an LRD can be
established by a proof test. The proof test shall be in accordance with paragraph UG 101 of the
ASME Code, Section VIII, Division 1.
12.1.2

The calculations for all proposed designs shall be explicitly detailed and the source of formula and
procedures shall clearly be identified. All possible modes of failure of the material and welds shall be
checked and shown to be acceptable.

12.1.3

All design calculations shall be signed by the design engineer representing the LRC.

12.1.4

(*)For custom LRDs, the design calculations shall be submitted to the Owners Engineer for review
and approval prior to the initialization of fabrication. For standard LRDs or stock items, design
calculations shall be submitted when requested by the Owners Engineer.

12.1.5

(*)The design conditions and corrosion allowance for the LRD shall be specified by the Owners
Engineer on the OnStream Leak Sealing Data Sheet.

12.1.5.1 For clamps and bands around flanges, the clamp or band shall be designed for the maximum
permissible flange pressure rating or the maximum sealant injection pressure, whichever is greater.
For other LRDs, the design pressure shall be the same as the leaking component, or the maximum
sealant injection pressure, whichever is greater.
12.1.5.2 The design temperature shall be equal to the design temperature of the leaking component.
12.1.5.3 (*)A minimum corrosion allowance of 1/8 inch shall be used unless otherwise specified on the data
sheet.
12.1.6

If slotted bolts are used to facilitate injection of sealant, the slot shall not decrease the stud strength
by more than 10%, and all design calculations shall reflect this decrease. The decrease in strength
may be computed based on the reduction in bolt area, or may be established by testing.

12.1.7

(*)In an effort to prevent or minimize the introduction of sealant into the process stream (mainlining),
the amount of sealant needed shall be calculated and indicated on the drawing. When feasible the
leak in the component shall be covered or sealed before the LRD is installed to prevent seepage of
sealant into the process stream, see paragraph 15.3. The amount of sealant in excess of required
calculated volume shall not be injected without prior approval by the Owners Engineer.

12.1.8

(*)The estimated total weight of the LRD, full of sealant, shall be shown on the drawing. The
Owners Engineer shall determine that the device can be supported by the leaking component;
otherwise, suitable supports shall be designed and installed by the LRC.

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The maximum sealant injection pressures shall be determined by calculation or based on testing to
assure that damage to piping valves, fittings and bolts will not occur during the repair process. In
addition, the maximum sealant injection pressure that can be used without effecting the bolt stress
shall be calculated on shown the design drawings, see Section 9.1.

12.1.10 The injection nuts used in all onstream repairs shall be designed to have equal or greater strength
than the hex nut that they replace.
12.2 Requirements For Strongbacks
12.2.1

The design of all leak sealing or dissipating devices shall include provisions to support the axial
thrust force due to pressure if the component being repaired is (or may become) insufficient to
support this force. If the integrity of the component cannot be verified, the LRC shall include in the
design package an adequate strongback system that includes provisions to support the unbalanced
hydraulic force in the event of a component failure.

12.2.2

The strongback system (screws, crunch teeth, pipe clamp, welded enclosure, etc.) shall be shown to
be adequate for the unbalanced hydraulic load. Such devices shall be designed to minimum
stresses imposed on piping components. The effect of clamping (crushing) forces on the component
also shall be considered. A strongback design is shown in Figure 27.

12.2.3

Strongbacks shall be included on all LRD designs that are to be installed on equipment which is
categorized to be in AES, see EP 10-2-1.

12.2.4

All LRDs that traverse unequal diameters or that are applied to piping components that do not lie in
the same straight line (such as elbows) shall be designed to restrain the resulting unbalanced
hydraulic loads. Details for a strongback used on a short branch connection are shown in Figure 28.
The design of all strongbacks for LRDs closing on different diameters shall assume a sealant cavity
pressure no less than 1000 psig or actual design service pressure whichever is larger.

12.3 Requirements For Wire Wrap Designs


12.3.1

(*)Unless otherwise specified by the Owners Engineer, stainless steel wire shall be used to seal
flange leaks. If less than six turns of wire are used, a backup strap or cable is required to insure
blowout integrity.

12.3.2

The hoop stress developed in the wire shall be calculated and shown to be strong enough to hold
the required service pressure. The allowable stress for wire shall be taken as the minimum of one
quarter of the specified minimum tensile strength at ambient and design temperature.

13.0 FABRICATION
13.1 General Requirements
13.1.1

All fabrication shall be in accordance with the ASME Code Section VIII, Division 1 and the additional
requirements of this Practice.

13.1.2

LRDs shall be fabricated and welded only in Owner approved fabrication shops; subcontracting to
nonapproved shops is not permitted.

13.2 Welding
13.2.1

All welding shall be in accordance with EP 5-5-2 or EP 7-1-5, as applicable.

13.2.2

All strength welds shall, preferably, be full penetration welds. If fillet welds are used, their strength
shall be calculated for all modes of failure. If fillet welds are used, a joint efficiency no greater than
specified in Table UW12 shall be used. Seal welds may be fillet welds.

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EP 5-11-3

On-Stream Leak Repairs of Piping


Components

Page 20 of 54

August 2007

Revision 0.0

13.2.3

All flange to body welds on fabricated LRDs shall be made using a full penetration double sided
groove joint.

13.2.4

All double welded groove and corner joints shall be backgouged to a clean metal surface and
inspected before completion of the second side of the weld, see paragraph 14.2.2.

13.2.5

Additional requirements for attachment welds that are used to connect the LRD to the leaking
component while the component is onstream are covered in EP 5-7-1. In general, the same
requirements for welding to onstream equipment should be in accordance with those used for hot
taps.

13.3 Heat Treatment


13.3.1

(*)Carbon and low alloy steel LRDs shall be postweld head treated (PWHT) when required by the
ASME Code, the AES criteria in EP 10-2-1, or when specified by the Owners Engineer.

13.3.2

PWHT shall be in accordance with EP 7-1-5 or EP 5-5-2, as applicable.

13.3.3

(*)PWHT for LRDs installed by welding on lowalloy materials will be stipulated by the Owners
Engineer. Generally, a butter layer is recommended on lowalloy materials prior to installation of the
LRD. The LRD can then be welded to the butter layer without subsequent PWHT.

14.0 INSPECTION
14.1 General Requirements
14.1.1

Magnetic particle examination (MT) and acceptance criteria shall be per the ASME Code,
Section VIII, Division 1, Appendix 6.

14.1.2

Liquid penetrant examination (PT) and acceptance criteria shall be per the ASME Code, Section VIII,
Division 1, Appendix 8.

14.2 Inspection Of New Leak Repair Devices (LRDs)


14.2.1

All pressure containing welds on LRDs shall be inspected using the MT or PT examination method.

14.2.2

The backgouged clean metal surface of all double sided and corner welds shall be inspected using
the MT or PT examination method before completion of the second side of the weld.

14.2.3

Material hardness requirements for components categorized to be in AES are stipulated in EP 10-2-3

14.2.4

Positive Material Identification (PMI) shall be in accordance with EP 1541.

14.2.5

Inspection requirements for welds which are used to attach the LRD to the leaking component shall
be as follows:

14.2.5.1 For metal temperatures less than or equal 300F - Visually inspect the root pass and perform
magnetic particle (dry powder technique) or liquid penetrant examination of the final pass.
14.2.5.2 For metal temperatures greater than 300F - visually inspect each weld pass.
14.3 Inspection Prior To Installation Of A Leak Repair Device (LRD)
14.3.1

For bolted LRDs, visual inspection of the surface area that will be covered by the device is required.
The surface that will be used to create the seal with the LRD shall be free of cracks, excessive
pitting, rust, scale or insulation residue.

14.3.2

For LRDs that are attached to the leaking component by welding, all inspection requirements
stipulated for hot taps shall be utilized including the minimum thickness requirements, see EP 5-7-1.

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On-Stream Leak Repairs of Piping


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Page 21 of 54

August 2007
14.3.3

Revision 0.0

If a crimp clamp is to be used for an LRD or strongback on a piping system, the thickness in the area
where the clamp is installed shall be determined to insure structural integrity during the crimping
process. The following thickness limitations shall be followed unless calculations or experience are
submitted by the LRC to support alternative values.
For NPS 2 inches and smaller - 0.10 inches
For NPS 3 inches and larger - 0.15 inches

15.0 INSTALLATION OF ONSTREAM LEAK SEALING DEVICES


15.1 Owner responsibilities
15.1.1

(*)The Owners Engineer shall complete all necessary parts of the OnStream Leak Sealing Data
Sheet, see paragraph 16.1.

15.1.2

(*)The Owners Engineer shall provide all necessary information to the LRC to enable him to obtain
all necessary permitting, and to insure that all work is performed in accordance with the local refinery
Safety Practices and Procedures Manual, see Section 10.0.

15.1.3

(*)The Owners Engineer shall provide all necessary information to the LRC to enable him to obtain
all necessary permitting, and to insure that all work is performed in accordance with the local plant
Safety Practices and Procedures Manual, see Section 10.0.

15.1.4

(*)The Owners Engineer and the LRC shall agree upon the divisions of responsibilities for
enforcement of the safety requirements (stipulated in Section 10), and for reviewing safe work
procedures before the installation of an LRD.

15.1.5

The Inspector shall witness all onsite preinstallation inspections for LRDs.

15.2 Leak Repair Contractor Responsibilities


15.2.1

The LRC shall be responsible for the actual installation of the LRD in accordance with the
requirements of this Practice. The Leak Repair Contractor shall complete Part III of the OnStream
Leak Sealing Data Sheet.

15.2.2

(*)When requested by the Owners Engineer, the LRC shall submit for review written job procedures
detailing each sEP in the planned leak sealing process. The written procedures shall include a copy
of the LRD drawing and design calculations, a complete OnStream Leak Sealing Data Sheet per
EP 5-11-3DS, a description of all tools to be used in the installation process, and bolting tightening
procedures.

15.2.3

All technicians provided by the LRC shall be trained, competent and experienced in performing on
stream leak repairs, and must be able to perform all work in a safe manner consistent with the
Owners safe working practices. The Owner may reject any technician who fails to meet quality
standards for safety and work performance.

15.2.4

The LRC shall submit all details of his training program requirements that are used to qualify
personnel to perform onstream leak repairs. These training program requirements shall include, as
a minimum, the required OSHA training on chemical hazards consistent with the type of work and
hazardous chemical exposure that the LRC personnel may be subject to while performing work in
the Owners Facility.

15.2.5

(*)When requested by the Owners Engineer, the LRC shall submit all training conducted for each of
his technicians working at the Owners site. The training records shall show the technicians name,
date, length of training and a description of the subject matter covered during the training session.

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15.2.6

Revision 0.0

The LRC engineering facilities including design, shop manufacturing, technical and safety support
and supervision shall be available during the installation of an LRD to provide technical support in
the event of installation problems.

15.3 Stop Gap Repairs


15.3.1

Procedures involving enclosures may require that the LRC perform a stopgap repair before
measuring the leaking component. The purpose of the stopgap repair is to diffuse the leak making it
less dangerous to work on. In addition, the stopgap repair will help prevent mainlining during the
injection process.

15.3.2

Some typical stopgap repair methods are shown in Figure 29.

15.3.3

The stopgap repair is performed prior to measuring so that the dimensions of the stopgap hardware
can be included in the data sent to the LRC. This will insure that the LRD chosen will fit and enclose
the stopgap repair as well as the leaking component.

15.4 Requirements For Bolting


15.4.1

All bolt tightening procedures used to install LRD shall be in accordance with EP 5-5-4.

15.4.2

The actual bolting procedures used by the LRC shall be submitted for review and approval to the
Owners Engineer prior to the installation of an LRD that utilizes a bolted connection.

15.5 Sealant Reinjection


15.5.1

All LRDs that require periodic or frequent reinjection of sealant to reseal a recurring leak are cause
for concern and indicates that the original installation may have been performed incorrectly. Loss of
sealant it typically attributed to loosening of LRD bolting or leakage through LRD perimeter seals.

15.5.2

(*)Reinjection of a sealant into an existing LRD is strictly prohibited without prior approval from the
Owners Engineer. In general, three reinjections will be permitted on any recurring leak unless the
cause is clearly attributable to severe vibration, water hammer or cyclic operation. If the clamp
requires more than three reinjections or dynamic service conditions prevail, an engineering review of
the initial LRD installation shall be performed to determine the adequacy of the design. Based on
this review, the LRD may need to be replaced.

15.5.3

All reinjections into existing installed LRD shall be documented on the appropriate OnStream Leak
Sealing Data Sheet, see EP 5-11-3DS).

16.0 DATA SHEET INSTRUCTIONS


16.1 General
An OnStream Leak Sealing Data Sheet, see EP 5-11-3DS shall be filled out for all onstream leak repairs.
16.2 Instructions For EP 5113 DS
16.2.1

(*)Part I of the OnStream Leak Sealing Data Sheet shall be filled out by the Owners Engineer
responsible for the repair work. Upon completion of Part I, the data sheet shall be given to the LRC
who shall complete Part II.

16.2.2

After completion of Parts I and II of the OnStream Leak Sealing Data Sheet and prior to the
installation of the LRD, Part III of the Data Sheet shall be completed.

16.2.3

Part IV of the OnStream Leak Sealing Data Sheet shall be completed if the LRD is reinjected with
sealant, and when the LRD is removed.

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16.2.4

Revision 0.0

All special requirements shall be included on the OnStream Leak Sealing Data Sheet in the Special
Notes Section. In addition, a sketch of the component showing the location of the leak should be
supplied.

16.3 Part I - Owner Supplied Information:


16.3.1

Specify the name of Facility, Unit Name, and Zone Number, if applicable.

16.3.2

Specify the name of the Owners Engineer who is responsible for the onstream leak repair. This
person will also be the refinery contact for the LRC.

16.3.3

Specify the name of the leaking component including the line or equipment identification number, its
size and location in relation to major equipment.

16.3.4

Specify the type of leak.

16.3.5

Specify if the component is currently leaking.

16.3.6

Specify if the leak has caused any damage to the component.

16.3.7

Specify information regarding the leaking fluid including its constituents (give approximate
percentages if possible), whether it is categorized as AES (see EP 10-2-1), design and operating
conditions, and toxic hazard/protective equipment requirements.

16.3.8

Specify if mainlining (leakage of sealant into the process stream) is a potential problem.

16.3.9

Specify all pertinent information regarding the leaking component, including the presence of
refractory lining, if any, whether the component is to be insulated following repairs and whether a
strongback is required.

16.3.10 Specify any special material requirements due to the fluid service, see EP 10-2-3.
16.4 Part II - Leak Repair Contractor (LRC) Supplied Information
16.4.1

Specify the name of the company, the name of the sales representative, the blanket contract number
and purchase order number.

16.4.2

Specify a brief description of the type of LRD and proposed method of repair.

16.4.3

Specify the LRD assigned serial number.

16.4.4

Specify if all required documentation is provided, see paragraph 9.1.

16.4.5

Specify materials of construction of the LRD.

16.4.6

Specify if the LRD is to be void injected with sealant (or packing for valves), or if perimeter seals are
used.

16.4.7

Specify the volume of sealant required for the repair.

16.4.8

Specify the sealant type and properties.

16.4.9

Specify all steps taken to prevent mainlining.

16.4.10 Specify the calculated total weight of the repair device and sealant.
16.4.11 Specify whether the LRD is supported by the leaking component, or whether additional external
supports are required.
16.4.12 Specify if the leaking component will be drilled and tapped. If so, specify what size hole and how
many times.
16.4.13 Specify the total unbalanced hydraulic force (pressure thrust load) and its direction.

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EP 5-11-3

On-Stream Leak Repairs of Piping


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Page 24 of 54

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16.4.14 Specify whether strongbacks are required, see paragraph 12.2.


16.5 Part III - Design/Installation Review, Owners Engineer
16.5.1

Specify whether the LRD design has been reviewed and approved for installation.

16.5.2

Specify whether a structural integrity check has been performed and documented by the LRC.

16.5.3

Specify whether a site safety review has been performed (escape routes identified, fire extinguishers
are available if welding is required, etc.)

16.5.4

Specify whether all pertinent safety items have been discussed with the LRC.

16.5.5

Specify whether safety permits have been issued.

16.5.6

Specify personal protection requirements for clamp installation technicians.

16.5.7

Specify whether a weatherproof tag has been installed on the LRD for identification purposes.

16.5.8

Specify any items that occur during installation of the LRD that may result in inadequate
performance.

16.5.9

Specify thickness readings of the component in the vicinity of the leak through a sketch with
inspection points labeled and a thickness table.

16.6 Part IV - LRD Removal And Repair, Owners Engineer


16.6.1

Specify whether reinjection of the LRD has been performed.

16.6.2

Specify the date of the LRD removal.

16.6.3

Specify (briefly) the repair instituted to the pressure boundary and structural integrity to the
component.

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EP 5-11-3

On-Stream Leak Repairs of Piping


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17.0 TABLES

TABLE 1
CLAMP SELECTION TABLE
APPLICATIONS
CLAMP

TYPE
High
Temp

High
Press

Severe
Leaks

Advantages

Dis
advantages

Comments

5.2 Tongue

Insert

Yes

Yes

Yes

A, B, C, D

5.3 Packing

Peripheral

Yes

No

No

E, F, G

b,c

2,3,4

5.4 Tubing

Peripheral

Yes

Yes

Yes

b,c

2,5

5.5 Crunch
Groove

Peripheral

Yes

Yes

Yes

E,H

b,c,d

5.6 Tongue
& Packing

Peripheral

Yes

Yes

Yes

D,I

KEY TO ADVANTAGES:
A - Relatively easy to install
B - Tolerant of flange misalignment
C - Can be used on flanges with unequal diameters
D - Reduces amount of sealant required
E - Can be used for narrow gap flanges
F - Can be reused if packing material is replaced
G - This is the preferred clamp for use on large
diameter flanges (NPS 16 inch and larger)
H - Can be used on any combination of high
temperature, high pressure, and severe leaks
I - Provides both primary and secondary seals

KEY TO DISADVANTAGES:
a - Sufficient flange gap is required to

accommodate clamp tongue


b - More sensitive to flange misalignment than

insert-type clamps
c - No direct means of pressure release
d - Use is limited to flanges which have machined

surfaces on the flange OD and which are


aligned with very little mismatch. Normally used
only when there is a combination of high
temperature, very high pressure (above 2000
psig), and/or severe leakage.

KEY TO COMMENTS:
(1) Generally used when flange gap is 0.375 in. or more. Can be used on gaps less than 0.375 in. if an alternate means of sealant
injection is provided.
(2) Because there is no direct means of pressure release, it is advisable to check the ability of the joint fasteners to withstand fullline
pressure over the total flange area. See Paragraph 5.1.7.
(3) The packing clamp is limited to a service pressure of 300 psig or less. Can be used for temperatures up to 1200F, depending on
packing material.
(4) Requires less torque on the clamp bolts to achieve a seal than any other peripheraltype clamp.
(5) Copper tubing may be used for design temperatures up to 450F. Stainless steel tubing shall be used above 450F and in services
designated as AES. May be used for pressures up to 2000 psig and temperatures up to 1400F.

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On-Stream Leak Repairs of Piping


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18.0 FIGURES
Pipe
Crunch/wipeout grooves
T ongue
Injection
port

Clamp

Flange
Ear

Flange

Clamp
Gasket

Injection
Valve

Sealant

Stud

FIGURE 1
TYPICAL FLANGE CLAMP

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RF
Flange

Clamp

Gasket

Injection
Valve
Sealant

Stud

FIGURE 2
TONGUE CLAMP

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RF
Flange

Braided
Packing

Clamp

Gasket

Injection
Valve

Sealant

Stud

FIGURE 3
PACKING CLAMP

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On-Stream Leak Repairs of Piping


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RF
Flange

Tubing

Clamp

Gasket

Injection
Valve

Sealant

Stud

FIGURE 4
TUBING CLAMP

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Stud

Flange

Gasket
Injection
Valve

Clamp

Sealant

FIGURE 5
CRUNCH GROOVE CLAMP

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RF
Flange

Tounge

Clamp

Gasket
Injection
Valve
Packing

Sealant

Stud

FIGURE 6
TONGUE AND PACKING CLAMP

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FF Flange

Stud

Flange

Sealant

Full
Face
Gasket

Injection Valve

FIGURE 7
REPAIRS FOR FLAT FACE FLANGES
WITH FULL FACE GASKETS

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Capnut

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On-Stream Leak Repairs of Piping


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Cap Nut

Injection Valve

Reservoir

Slot In
Cap Nut

Gun
Hose
Slot In Stud

Gap

Stainless Steel
Wire

Sealant Flow - How It


Works
1. Sealant enters the cap nut through the gun hose and injection valve.
2. From the reservoir sealant can travel to the gap by two paths.
a: Through the slot which is milled in the stud or
b: Through the slot which is milled in the cap nut then via the anular space of the bolt hole.
3. As the gap fills sealant then travels around the gasket outside diameter and into the
companion flange to seal all leaks.

FIGURE 8
FLANGE WIRE WRAP

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On-Stream Leak Repairs of Piping


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Cap Nut
Injection Valve
Reservoir

Slot In
Cap Nut
Gun
Hose

Gap

Slot In The Stud

Mechanically Peen
Edges Of Flange

Wire Wrapping If
Needed

Sealant Flow - How It


Works
1. Sealant enters the cap nut through the gun hose and injection valve.
2. From the reservoir sealant can travel to the gap by two paths.
a: Through the slot which is milled in the stud or
b: Through the slot which is milled in the cap nut then via the anular space of the bolt hole.
3. As the gap fills sealant then travels around the gasket outside diameter and into the
companion flange to seal all leaks.

FIGURE 9
FLANGE PEENING

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On-Stream Leak Repairs of Piping


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Cap
Nut

Injection
Valve

Reservoir

Slot In
Cap Nut

Gun
Hose

Gap

Slot In Stud

Flange
Band

Sealant Flow - How It


Works
1. Sealant enters the cap nut through the gun hose and injection valve.
2. From the reservoir sealant can travel to the gap by two paths.
a: Through the slot which is milled in the stud or
b: Through the slot which is milled in the cap nut then via the anular space of the bolt hole.
3. As the gap fills sealant then travels around the gasket outside diameter and into the
companion flange to seal all leaks.

FIGURE 10
FLANGE BANDING

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Cover
Thickness

Perimeter
Seal
End Plate
Thickness

Defect

Leaking
Component

Bolts

Side bars

FIGURE 11
TYPICAL BOLTED ENCLOSURE (BOX)

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Shutoff adaptor

FIGURE 12
FLANGE ENCLOSURE

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FIGURE 13
TYPICAL BOLTON STRAIGHT LINE ENCLOSURE

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Tee Enclosure

Revision 0.0

Defect

FIGURE 14
FULL TEE ENCLOSURE

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FIGURE 15
FULL ELBOW ENCLOSURE

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On-Stream Leak Repairs of Piping


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Packing

Tubing

Crunch Teeth

FIGURE 16
ENCLOSURE PERIMETER SEAL TYPES

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On-Stream Leak Repairs of Piping


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Vent
valve

Full packing
Non-metallic pipe
such as PVC, fiberglass
or concrete

FIGURE 17
FULL PACKING ENCLOSURE FOR NONMETALLIC PIPE

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Stuffing
box

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FIGURE 18
FULL VALVE ENCLOSURE

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On-Stream Leak Repairs of Piping


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Injection Valve

Perimeter
Seal

FIGURE 19
ENCLOSURE FOR AN EXPANSION JOINT

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On-Stream Leak Repairs of Piping


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Expansion joint cover
used as a box
Field weld to
create enclosure

Expansion joint box, can be design


with ring type or angled end plates.

NOTE: To use an expansion joint cover as an enclosure to seal a leak,


the structural integrity of the cover must be evaluated !

FIGURE 20
EXPANSION JOINT ENCLOSURES ATTACHED BY WELDING

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Circumferential
attachment welds

Clamshell ring, installed


in two half sections

Clamshell bellows, installed in two half sections with


a field longitudinal weld and circumferential
attachment welds.

FIGURE 21
EXPANSION JOINT CLAM SHELL ENCLOSURE

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Shut off
Adapter

Valve
Packing

FIGURE 22
ONSTREAM VALVE REPACKING

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Sealant

Shutoff adaptor

FIGURE 23
SEALING A LEAKING GATE VALVE SEAT

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(Open position)
Stem

Valve
seat

Valve
body

Center joint

Ball

Seal

Shutoff
adaptor

Packing
material

FIGURE 24
SEALING A LEAKING BALL VALVE SEAT

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Shutoff
adaptor

GATE VALVE

Shutoff adaptor

GLOBE VALVE

FIGURE 25
KILLING A VALVE

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Typical pressure seal valve

Retaining
ring
Pressure seal ring
Valve
body
Shutoff
adaptor

Valve
bonnet
Void at tip of
seal ring

FIGURE 26
SEALING A LEAKING BONNET ON A PRESSURE SEAL VALVE

Maintained by E2G Shaker Heights, OH

Site Technical Practices

EP 5-11-3

On-Stream Leak Repairs of Piping


Components

Page 52 of 54

Toledo
Refinery

August 2007

Revision 0.0

Finger (Install between


flange bolts)

Clamp bolt (Typ.)


not shown
Flanged
sidebar
Jack bolt (Typ.)
not shown

Outer shell

Endplate
Fingers
Flanges

Jack bolt (Typ.)

Clamp

FIGURE 27
FLANGE CLAMP STRONG BACK

Maintained by E2G Shaker Heights, OH

Toledo
Refinery

Site Technical Practices

EP 5-11-3

On-Stream Leak Repairs of Piping


Components

Page 53 of 54

August 2007

Revision 0.0

FIGURE 28
SHORT BRANCH CLAMP STRONG BACK

Maintained by E2G Shaker Heights, OH

Toledo
Refinery

Site Technical Practices

EP 5-11-3

On-Stream Leak Repairs of Piping


Components

Page 54 of 54

August 2007

Revision 0.0

FIGURE 29
STOPGAP MEASURES

Maintained by E2G Shaker Heights, OH

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