BSR mastered the technology of installing the mechanical shackles and pumping glue to seal pipes (Part 2)

In the past time, the fabrication, installation of shackles and glue pumps to seal some locations to handle the leak points or reduce the wall thickness due to corrosion under the insulation (CUI) and the corrosion under the pipe support (CUPS) on the pipe have brought very encouraging success.

According to the working coordination process, when BSR detects incidents of fluid leakage or thickness reduction on pipe walls and equipment beyond the permitted level, BSR will conduct surveys and measure actual dimensions, summing up the necessary specifications (including: design piping sizes, materials, remaining pipe wall thickness, internal fluids, operating temperatures and pressures; temperatures and design pressures, etc) and photos to send this information to Petroseal.

Based on that data, Petroseal will calculate and design mechanical shackles in accordance with ASME PCC-2 standards and return this design drawing to BSR for manufacturing. At BSR’s Mechanical Workshop, the shackling process is carried out urgently and professionally, from the quality control of raw materials, welding rods, to the strict quality control process during welding, machining until the final product is completed. Later on the field, BSR’s maintenance staff will install mechanical shackles and glue pump to seal or reinforce pipes / equipment.

Engineer Nguyen Chi Chinh – one of 8 personnel attending the technology transfer training course of mechanical shackles and glue filling pumps online said: This job is dangerous, potentially risky, mechanical shackling and glue pump on active equipment, pipes, risk of leakage, fire, etc. However, with the experience and 10 years of plant maintenance, the team members always complete the work safely, on schedule, contributing to ensure a safe and stable operation of the Plant.

Among the dozens of works already implemented, engineer Nguyen Chi Chinh remembered that in April 2019, the BDSC team of workers and engineers had to handle a leak of the hydrogen pipeline at the CCR workshop. After receiving the report from the Equipment Testing Board, the engineers said that this is a “difficult case” with the flow of hydrogen gas generated in the technological line, the pipe has two curved corners of 900, the location is shackles are entangled in horizontal and vertical concrete beams, etc. However, with a pre-programmed process, BSR has measured the dimensions and images sent to Petroseal to receive shackles design drawings. From this drawing, BSR Mechanical workshop has fabricated the shackles system in just 8 days and carries out the installation and pumping of glue for 3 more days. The work seemed to be simple, but when installing, there was a phenomenon of slippery shackles, causing shackles to move along the pipe. Engineers have fabricated additional frames to reinforce and help fix the shackles to the pipe.

From August 2018 to January 2020, the Repair and Maintenance Department successfully dealt with 29 points of reduced pipe wall thickness, or leaked pipes up to 24 inches in size, operating pressure up to 50 bar and operating temperatures to 3800C. Including 17 treatment points for pipelines of high-risk fluids such as: Hydrocarbon, Propylene, LPG, Naptha, etc.

Measuring and making available 08 sets of closed shackles to prevent installation for the points with the phenomenon of wall thickness reduction to take initiative in handling in the fastest time when detecting the thickness continues to decline excessively of design allowed during periodic inspection / supervision.

According to engineer Nguyen Chi Chinh, the self-installation of shackles, glue pumps, sealing online online saves BSR Company about 50% of the cost if outsourced. Shackles installed have a lifespan between the limits each time the overall maintenance plant. When the Plant undergoes general maintenance, the Plant stops operating for more than a month is the golden time for the installed pipes to be replaced with new, stronger, safer pipes.

With the above-mentioned specialized solutions, the regular maintenance and repair work of Dung Quat Oil Refinery step by step improves and takes the initiative in all bad situations in order to maintain safe and stable operation for the Plant. At the same time, improving the professional qualifications for BDSC personnel, significantly reducing the cost of outsourcing services to the Company.

Productivity and Quality Office