25 Bar, 350 °C Steam Leak Successfully Sealed in UAE

Project Summary

Wellube successfully executed an online leak sealing solution for a high-temperature superheated steam pipeline, addressing the facility’s urgent operational requirements. Leveraging rapid response capabilities, we designed and manufactured customized sealing clamps and applied specially formulated compounds to ensure a secure and reliable seal. This approach minimized disruption, prevented costly downtime, and safeguarded operational continuity.

Client Requirement

The client faced a critical steam leak on a 4” (DN100) superheated steam pipeline operating at 350°C and 25 bar. Due to the essential role of this pipeline in ongoing operations, any production shutdown was not feasible and minimizing environment impact from loss of containment. To mitigate the risks, the client required a live leak sealing solution that would enable safe, continuous operation without interrupting production.

Application Challenges

The leak posed several technical and operational challenges that needed to be addressed for a successful intervention:

• Extreme Temperature Conditions – The pipeline operated at 350°C, requiring specialized sealing materials capable of withstanding high thermal stress.
• Stringent Time Constraints – A rapid response was essential to prevent operational disruptions and mitigate potential financial losses.
• Environmental & Safety Considerations – The high-pressure steam leak presented significant safety hazards, necessitating strict adherence to QHSSE protocols and precision-engineered sealing techniques.

Bespoke Solution Delivered

Wellube’s Centre of Excellence (CoE) leveraged its global engineering expertise to develop a tailored leak sealing solution under stringent time constraints. The process began with a comprehensive site survey to diagnose the root cause of the leak, assess operational parameters, and collect critical technical data. Based on these findings, Wellube engineered a custom-designed clamp specifically for the 4” elbow section of the high-temperature steam pipeline, ensuring a precise fit and effective sealing under sustained 350°C and 25-bar operating conditions.

Given the urgency of the project, the manufacturing of the custom clamp was expedited while adhering to industry standards and rigorous quality control measures. Upon delivery to the site, Wellube’ s field specialists executed the live leak sealing procedure without requiring a system shutdown. The intervention was carried out in strict compliance with QHSSE protocols, ensuring maximum safety and environmental protection. Following the successful execution, a final inspection and integrity testing were performed, validating that the solution met the client’s operational performance requirements and industry regulations.

This project highlights Wellie’s expertise in delivering rapid, high-precision leak sealing solutions for complex, high-temperature applications, ensuring uninterrupted operations while maintaining pipeline integrity.

Key Highlights

• Operational Continuity – Achieved a key turnaround, avoiding any operational downtime and minimizing environmental and personnel risk.
• Design Standards Compliance – The solution was engineered and manufactured in strict accordance with ASME standards.
• QHSSE Adherence – Full adherence to QHSSE standards and safety protocols was maintained throughout the project execution.
• In-Country Value (ICV) Framework – Materials were locally sourced, supporting the IN-COUNTRY VALUE (ICV) framework.