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Unique online leak repair techniques

05.01.2004 | Akhtar, O., Fauji Fertilizer Co., Pakistan; Fateh, P., Fauji Fertilizer Co., Pakistan

Consider these options when typical methods aren't feasible

Keywords:

Among the many problems that threaten daily operation of a chemical process plant, fluid leakage is
perhaps the most common. A high-velocity jet emerging from a flange due to a failed gasket, a pinhole in
an elbow, corroded threads of a level transmitter, etc., are familiar scenes that the maintenance crew
encounters and must rectify. Conventionally, a bolted/ welded clamp with sealant injected under pressure
would seal the leak, but once in a while a leak occurs that ? due to its difficult location or space
constraints ? would initially appear ?impossible? to control. Such leaks must be stopped by using custom-
developed solutions to avoid the unwelcome verdict of ?shutting down? the plant and to save precious
production loss.

This article describes some examples of highly innovative methods for online leak repair. Practiced at the
twin parallel train ammonia-urea plants owned by Fauji Fertilizer Company (FFC), Pakistan, these
methods have resulted in savings in plant production worth millions of dollars as well as enhancing
confidence and skill of the maintenance personnel.

FFC is the country's largest fertilizer producer, enjoying 64% market share. The company has received
domestic and international recognition for its excellent safety record and outstanding operational and
maintenance achievements.

Case 1. Superheated steam leak repair of a synthesis machine.

Problem details. The synthesis gas compressor driver is a steam turbine. It generates 14 MW of power,
rotating both the HP and LP centrifugal compressors in the speed range of 9,800 ? 10,000 rpm. It utilizes
170 ? 200 tph of superheated KS steam at a temperature and pressure of 5,100C and 105 kg/cm2 . A
governor connected with the help of two mechanical linkages or actuator stems to the turbine internals
controls the quantity of steam fed to the turbine.

One morning, KS steam was observed leaking from one of the actuator stem flanges. Extent of leakage
was felt by hand at a distance of approx. 3 ft (Fig. 1). Sealing of this flange with the turbine casing is by
direct metal-to-metal contact.

Fig. 1 Steam was leaking from one of the


actuator stem flanges.
Problem handling. Leak repair was attempted by flange tightening. However, leak intensity was only
partially reduced. Extensive tightening was avoided for fear of disturbing the turbine alignment, centering
and its consequent tripping. Acute space limitations ruled out installing a regular sealant injection clamp.
Therefore, a special ?ring-clamp? was conceived, designed and machined.

This custom-designed clamp fundamentally comprised one ring cut into two semicircles (Fig. 2). The ring
was provided with a groove (Fig. 3) on its outer periphery to accommodate a wire rope. The ring clamp
was slid inside the gap between the flange and the turbine casing,

Fig. 2 The custom-designed clamp comprised


one ring cut into two semicircles.

Fig. 3 The ring was provided with a groove


on its outer periphery.

Wire rope was then wrapped around the ring and tightened with the help of a come-along. This brought
together the two pieces of the clamp, wedging its sealing faces against the flange and turbine casing. For
improved sealing, a coating of thin grafoil tape was also provided on the sealing faces of the clamp.

The two pieces were then welded together. Care was taken to preserve the turbine casing itself from any
welding. Injection was done through the threaded holes already provided in the flange by the OEM for
jacking purposes. The main leak was successfully arrested after a couple of hours of sealant injection.

The minor leakage coming from one of the flange bolts was rectified by machining and installing a bolt
cap, along with an annealed copper washer, injection being done from the top of this cap. The three
nipples used for sealant injection and the clamp itself are illustrated in Figs. 4 and 5.

The clamp ring was placed in the annular


Fig. 4
space between the flange and the turbine
casing.
Fig. 5 Three nipples were installed for sealant
injection.

Case 2: Online repair of leaking head flange of ammonia synthesis reactor.

Problem background. The ammonia synthesis reactor is a 27.8-m high-pressure vessel with its top
head cover diameter 3.3 m and weighing 28 tons. The reactor operates at a pressure and temperature of
144 kg/cm2 and 250°C. The head cover sealing was provided by a double-cone ring-joint gasket (Fig. 6).
During plant startup after a 1998 turnaround, localized process gas leakage was observed from the head
flange gasket's lower face. Intensity and nature of leakage had the potential of forcing a plant shutdown.

Fig. 6 A clamp was installed on the head flange.

Problem handling. Due to space constraints (a gap of 163 mm between the cover bolts and the gasket
face), use of a standard bolted or welded clamp was not possible. Therefore, a wedge-type clamp was
designed and fabricated. It consisted of two wedges with identical degrees of taper so that they could be
placed over one another (Fig. 7). The lower wedge with greater thickness was provided with a sealant
injection port to the leaking point. A backup plate for both wedges was provided with four bolts, two each
for pressing the upper and lower wedges.
Fig. 7 A wedge-type clamp was designed and
fabricated.

The clamp was assembled behind the flange bolts and injected with sealant. Packing inserts were
provided on both sides to resist the leakage circumferentially. Leakage was successfully eliminated, thus
saving us a shutdown of at least 5 ? 6 days. The clamp was installed in 1998 and is still functioning
without any trouble.

Case 3: Onstream repair of a failed lip seal gasket installed on a waste heat boiler.

Problem background. A vertical waste heat boiler is installed downstream of an ammonia synthesis
reactor. It contains a welded lip seal gasket on its lower body flange. This gasket is actually a bellows
that, besides providing sealing, is also capable of accommodating expansion of 70 tons of shell and trim
resting on top of it. Gasket diameter is 1.7 meters. Gasket orientation with respect to the boiler is detailed
in Fig. 8.

Fig. 8 The waste heat boiler had a leaking lip


seal.

High-pressure steam leakage was reported from the interface between the lip seal gasket and its lower
flange (Fig. 8). The leakage, left unchecked, may have caused a plant shutdown of several days.
Therefore, it was decided to arrest leakage on the running plant by using a custom-designed wedge-type
clamp similar to the one used on the synthesis reactor.

Work done. The clamp functioned successfully until a plant shutdown. During startup, leakage from
the gasket reappeared but at a different location. Most probably, the leak found a new path though the
sealant after its dislodging due to thermal expansion of the gasket during plant shutdown and startup. In
this case, unlike the synthesis reactor where the sealant clamp has been functioning for many years, to
rectify the renewed problem, a new concept of box-up had to be conceived and implemented.
Back to the drawing board. This setback led to a series of brainstorming sessions between the field
engineers and area technicians, resulting in a breakthrough idea for repairing the leak.

Breakthrough idea for box-up. This essentially consisted of braided packing and a wire rope as shown
in Fig. 9. The cord of packing was inserted around the full periphery of the gasket covering the entire
lower flange-gasket interface. The packing was then pressed with a wire rope and pulled around tightly
with the help of chain blocks. The box-up remained functional for 16 months. Thereafter, it was removed
during plant turnaround, and the welded gasket was replaced.

Fig. 9 A rope clamp was installed on the lip seal


gasket.

Case 4. Online repair of hydrogen-enriched process gas leakage.

Problem description. The operating conditions of a pressure transmitter installed on a process gas
header are process gas (59% hydrogen) at 23 kg/cm2 and 215°C. The assembly of this PT is shown in Fig.
10.

Fig. Leakage was observed from the upstream


10 threads of the transmitter isolation valve.

Leakage was observed from the upstream threads of the transmitter isolation valve. Practically, it was not
possible to weld the sealing point in the presence of explosive gas. Therefore, to avert a shutdown, a
three-plate design of the clamp was conceived, fabricated and installed.

The clamp. The clamp consisted of three plates, A, B, and C, shown in Fig. 11. The central hole in
plates 2 and 3 dimensionally matched the taper of the interconnecting swage nipple. Plate 3 was also
provided with a groove on the diameter of its hole. The groove accommodated a ring cut out of graphite
gland packing, i.e., the sealing element. All three plates were provided with four smaller holes, one at
each corner, for holding the stud rods to bring the clamp together.
Fig. The clamp consisted of three plates.
11

The plates A and B were cut in two halves. Orientation of these cuts was kept perpendicular to each other,
also shown in Fig. 11. Plate A took up the function of a backup plate for plate B ? i.e., the sealing plate ?
and helped in providing a uniform pressure on the sealing element when the clamp was tightened as a
whole.

Clamp installation. The clamp was assembled onto the swage nipple with the sealing element placed
properly in its groove. All three plates were then tightened together with the help of stud rods,
sandwiching the isolation valves between themselves (Fig. 12). As the clamp was tightened, the packing
ring or the sealing element got pressed against the valve body at the leakage point, thereby completely
eliminating the leak.

Fig. The plates were tightened with the help of


12 stud rods.

Case 5. Online repair of carbamate leakage.

Problem description. Urea plants are typically provided with a high-pressure water circuit for flushing
carbamate and urea solution lines. Carbamate leakage was observed through the telltale hole of an inline
block valve installed on the flushing water circuit. This 1/2-in. PN 325 stainless steel (urea grade) globe
valve was installed for high-pressure water flushing of the carbamate recycle control valve with an
operating pressure and temperature of 148 kg/cm2 and 155°C. Valve construction and leakage path are
shown in Fig. 13.
Fig. Carbonate leakage was observed through
13 the telltale hole.

The situation called for replacing valves. This meant 48 hr of plant shutdown, with approximately 4,400
mt of production loss. Once again, the ingenuity of FFC's maintenance team came to the rescue, and, after
some effort, the leak was boxed up.

The carbamate clamp. This nontraditional box-up arrangement, specifically designed to arrest leaks
from the telltale hole of this type of valve, fundamentally comprises two halves. Each half consists of a
25-mm thick stainless steel (SS-316L) rectangular plate (Fig. 14).

Fig. Each half consisted of a stainless steel


14 rectangular plate.

Clamp installation. After installing the O-ring, the valve was sandwiched between the two plates. Both
plates were then tightened together with the help of four stud bolts (Fig. 15). Compatible sealant was then
injected through the injection port, which consequently repaired the leak. HP
Both plates were tightened
Fig.
together with the help of stud
15
bolts.

ACKNOWLEDGMENTS

We wish to express our gratitude for the support and guidance of our managers: A. Wahid Sheikh, Zafar
Hadi, Tahir Javed, S. Iqtidar Syed, Farhan Ul Karim and Pervaiz Iqbal. We are also indebted to our
colleagues for sharing their experiences and contributing valuable ideas for this article.

Pervez Fateh holds the position of unit manager ? stationary equipment with Fauji
Fertilizer Company, Pakistan. He has over 18 years of experience in maintaining stationary
equipment and his areas of specialization include inspection/ repair of high-pressure vessels,
WHBs, furnaces and special urea-grade corrosion-resistant materials. Receiving a BE
degree from the NED University of Engineering and Technology, Mr. Fateh has remained
actively involved in planning and managing FFC-II ammonia-urea plant maintenance. He is
also a member of the American Society of Mechanical Engineers.

Omer Akhtar is a senior mechanical engineer at Fauji Fertilizer Company. He has a BSc
degree in mechanical engineering from the University of Engineering and Technology,
Pakistan. During his eight-year career with FFC, Mr. Akhtar has worked both in rotary and
stationary equipment sections, and his major assignments comprised troubleshooting/
maintenance of high-speed centrifugal/ reciprocating machinery and high-pressure
equipment. Presently, he is responsible for stationary equipment maintenance at the urea
plant.

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