Drill

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Drill Taps, Its not heroic anymore?Jerry
DukeENCOMPAS, Inc.
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Presentation Highlights

• Introduction
• History of On-Line Leak Repair
• On-Line Leak Repair at 30,000 ft
• Common On-Line Repairs
• Equipment is it OK or is it destroyed
• Statistics From a Chemical Facility
• How to avoid drilling into equipment

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History of On-Line Leak Repair

• Safety
• Economics
• Environmental
• Agencies
• HRVOCs
• Consent Decrees

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On-Line Repair. Who? What? When? Are you crazy?

• Refining
• Chemical Facilities
• Power Industry
• Storage Transfer Facilities

• Process is running
• Equipment is live

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Services Successfully Repaired

• Vacuum to 5000 PSI
• Cryogenic to 1800 degrees Fahrenheit
• VOCs
• Steam
• Hydrogen
• Watch out for Oxygen

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Where it is today - Forcefully
c) Use "drill and tap" method (or an equivalent),
other than on a control or pressure relief valve,
if it is leaking at a rate of 10,000 ppm or
greater, unless ABC Facility can demonstrate that
there is a safety, mechanical, or major
environmental concern posed by repairing the leak
in this manner. ABC Facility shall, if
necessary, perform two "drill and taps" (or
equivelants) within 30 days of detecting a leak.
For purposes of the paragraph, the second attempt
may be made through the same hole created during
the 1st attempt.
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Where it is today Forcefully cont..
i. The owner or operator has undertaken
extraordinary efforts to repair the leaking
valve. For purposes of this subparagraph,
extraordinary efforts is defined as nonroutine
repair methods (e.g., sealant injection) or
utilization of a closed vent system..
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Common Valve Leaks
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Valve Flange Leaks

• Flange Leaks. Why?
• Stretched Bolts
• Heat/Weight Stress
• Deteriorated Gaskets
• Process Pressure Changes
• Poor Workmanship

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Valve Flange Repair

• Flange Leak Repaired. How?
• Torque Bolts or Replace
• Install Wire Wrap Brass
• Drill Flange or Install Injection Collar
• Inject Compound

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Valve Bonnet Leaks

• Bonnet Leaks. Why?
• Stretched Bolts
• Deteriorated Gaskets
• Process Pressure Changes
• Poor Workmanship

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Valve Bonnet Repair

• Flange Leak Repaired. How?
• Torque Bolts or Replace
• Install Wire Wrap Brass
• Drill Flange or Install Injection Collar
• Inject Compound

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Valve Packing Leaks

• Packing Leak. Why?
• Old Packing
• Pressure Change
• Poor Workmanship

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Valve Packing Repairs

• Packing Repair. How?
• Replace Follower Bolts
• Use Correct Tools
• Drill Tap Neck
• Inject Compound

New Compound
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Valve Seat Leak
Need to shut down a piece of equipment but the
valves are not holding?
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Killing a Valve
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On-Line Leak Repair? My equipment is ruined!!

• Sealant sets up like concrete
• Ruins the integrity of the equipment
• Flanges will never be the same
• Compound will get into my process

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On line Leak Repair?Is my equipment O.K.?

• Compounds are made of materials that are
  generally better than the packing in the valve.
• The integrity of the equipment is technically
  sustained.
• Flanges can be cleaned once the process line is
  made safe.
• Procedures designed to keep compounds out of
  process.

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On-Line Maintenance Statistics
Texas based chemical facility - 1 quarter
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How do I avoid drilling into my equipment?

• Bolt Torque Flanges Bonnets
• Replace Bolts (Packing, Bonnets Flanges)
• Clean Stems with a Non-VOC cleaner
• Proper Tools
• Live Load Valves

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What is important? Where do I go from here?

• Techniques have changedIts not 1989
• Sealants Out Compounds In
• Restrictors/Injection Fittings, leakless??
• Packings, Flanges, Seats, and Connectors can be
  injected successfully
• Know who and what is going on

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You Make The Call
Is it feasible, heroic, extraordinary, or would
it cause a safety, mechanical, or major
environmental concern?It is YOUR Facility and
YOUR Decision.
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Contact Information
ENCOMPAS, Inc. www.encompliance.com800-519-2786
Download this presentation at www.encompliance.co
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