24” Leaking Offshore Gas Pipeline Arrested Using Online Leak Sealing Solution

Project Summary

Wellube successfully provided a turnkey online leak sealing solution ensuring uninterrupted operations and enhanced reliability for a leading client in the oil and gas industry. The project required 41 leak repair clamps at 15 different locations of 24” (DN600) diameter. We provided an end-to-end solution including design, fabrication and installation of equipment to promptly address the leaks and prevent unplanned shutdowns in the flare system.

Client Requirement

The client encountered leaks and wall thinning issues at multiple locations in their pipeline. Due to the time-consuming nature of replacing the pipeline and the associated costs involved with production loss, shutdown was not feasible. The client required a solution without shutdown to promptly address leaks, while also strengthening the integrity of the pipeline.

Challenges faced

The primary challenge revolved around time constraints, intensified by the criticality of the piping system being the flare line. The leak not only posed environmental concerns but also resulted in significant downtime and loss of production, increasing the urgency for a swift and effective solution.

Bespoke Solution Delivered

Leveraging our advanced global engineering design – “Centre of Excellence” team and proficient project management capabilities, Wellube swiftly provided an online leak solution along with the quickest possible and mutually acceptable time frame to execute the required site work.

Following the acceptance of the proposal, Wellube conducted a detailed site survey to gather requirements at 15 different locations for the design of 41 online leak sealing clamps. Once the design was approved, we commenced with the fabrication process, which included various stages such as fabrication itself, Non-Destructive Examination (NDE), Post Weld Heat Treatment (PWHT), hardness testing, and Magnetic Particle Examination (MPE). Subsequently, a Factory Acceptance Test (FAT) was conducted for the clamp to ensure its functionality. Finally, the clamp underwent painting and packaging processes.

Upon arrival of the clamp at the site, the Wellube team was deployed to execute the installation process and perform sealant injection as required. In instances where leaks couldn’t be visually identified due to wall thinning, Wellube conducted leak tests to ensure that in the event of a pipe leak, the clamp would effectively withstand pressure and prevent gas from escaping. Following the completion of the job, a thorough walk-through was conducted with the client to verify that the project had been executed in accordance with the specified requirements.

Benefits Delivered

• The project was completed without interrupting or halting the LIVE pipeline.
• The project was executed with complete QHSE compliance and safety.
• End to end project management by Wellube team providing clients a one point of contact integrated solution
• Completed the project on-time-in-full and as per codes.