Versatile Piping Isolation Test Tools and Machining Ensure Integrity in Refinery Upgrade
Customer
Location
Challenge
As part of a scheduled maintenance program, several processing units were planned to be shut down at a major refinery in North America that produces over 100,000 barrels of petroleum per day.
Pipework of various diameters (from 6" (DN150) to 16" (DN400)), materials and wall thicknesses needed to be cut, beveled, counter bored, and flange faced to meet exact specifications. Alongside machining services, safe isolations were required during hot work activities and new welds needed to be pressure tested before start-up.
The shutdown period required the project to be completed within a tight timeline of 45 days to help bring the plant back online with no delay. to help bring the plant back online with no delay. Site management knew they needed to find a safe and reliable solution.
Solution
A team of Enerpac machining experts were consulted to recommend the best approach for the project. After cutting the piping, the Enerpac Mechanical Isolation and Test Tools (MITT) were deployed to maintain a vapor barrier during welding and subsequently, to perform localized weld testing to verify system integrity. With the MITT Series tools, all applications were addressed with just a small fleet of tools to manage. The MITT Series products combine isolation and test tools that cover more schedules per tool than other alternatives. The Mechanical Isolation and Test Tools MITT Series covered 3/4" to 12" (DN20 to DN300) sizes in multiple schedules.
With the light, slim and versatile design, they were used to isolate behind elbows. Previous service partners had to source custom tools for this type of operation, but Enerpac tools work in long-radius elbows without any difficulty. MITT Series tools were also able to cover the higher-pressure tests without requiring a schedule-specific or dedicated tool. Seal-backing rings were used for a small percentage of tests and were readily available for no added cost. Enerpac portable clamshell pipe cutters were selected for their versatility and proven track record in fabrication and refurbishment across various industries. In total, 18 different clamshells were approved and deployed for use on the refinery infrastructure.
Results
The scope of work was successfully completed within the 45 day deadline. A safe workspace was created on-site with operator-friendly tooling that offered fewer tools to manage. Customer expectations were exceeded by limiting the number of technicians needed to perform the work safely. The work was ultimately completed on time, at lower risk, higher efficiency, and overall lower cost.
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