Case History. Kinetics Controls & Innovation Ltd

Transcription

1 Case History The Operations Team for Customer have a requirement to place temporary isolations on an 18 spool piece on K st stage compressor pipe work and a vertical 12 spool on 1 discharge Header to create a double barrier for construction work. The spool pieces are located on the compressor mezzanine and level 2 mezzanine decks. 1 st Stage compressor Suction Scrubber 18 Pipe work showing spool piece Short Method Overview 1. valves V31079 and V Connect the deployment manifold to ¾ drain valve VL test with product against closed valve VL Mix and deploy 330 litres of IS (Extended formula) 5. PU will be recorded when IS hits the leak paths 6. sample will be taken to gauge curing time and sealant structure 7. Once isolation in place Talisman procedure for integrity test. Page 1

2 Objectives: To safely inject IS compound into designated spool pieces to create a temporary Mechanical barrier for future maintenance projects to take place. 1 Discharge Header and Short Method Overview: 1. Connect the deployment manifold to the ¾ tap flange double block & leed valves 2. test with product against closed valves. 3. Close lower Valve V Open upper valve 10% V Mix and deploy 120litres of IS (Standard formula) 6. Close the upper valve V Leave a sample to gauge curing time and seal structure. 8. llow sealant allotted time to cure 9. Once isolation in place Talisman procedure for integrity test. Page 2

3 Scope of Operations The task for KCI will be to establish an isolation by pumping IS into the spool pieces between V31079 and V31080 through ¾ drain valve VL The 1 discharge Header V31103 and V31104 through ¾ double isolation valves VL31005 and VL The IS will be pumped into the spool piece using KCI barrel pumps. It will be pumped in dry due to the gas pipeline. balanced pressure will need to be achieved during pumping operations and during IS curing time (subject to sample taken). The IS will be prepared in 60 litre batches due to the potential wastage if operations stop due to unplanned equipment problems and to reduce the likelihood of contamination of the base product. When deployed the IS will build up and fill the cavity to eventually cure to a solid flexible isolation. Once 120 and 330 litres respectively of IS has been deployed and the IS has started to cure, a balanced pressure has to be maintained throughout the curing process. It would take approximately 3 to 4 hrs and 7 to 8 hrs to deploy the IS into the separate spool pieces. Contingency Operations In the event that the first application has not rectified the leak completely or filled the spool Piece completely an additional amount of IS can be added and pumped into the spool to boost the initial application. The additional IS Will bond with the original application to Improve and add to its sealing capabilities. reaker Contingency Operations Further breaker solution can be added at P3105 if it is deemed necessary to aid the flow from the suction scrubber. Flushing Operations The pumps and the hose lines will be flushed with potable water after each application to keep the system in good order. The flushing and discharge must be put through to closed drains or pumped into an environmental receptacle. Page 3

4 V31080 V31079 V31080 Location Reference R-S31-P-PI Rev Z6: Page 5

5 V31103 V31104 Location Reference R-S31-P-PI Rev Z6: Page 6

6 First Stage Suction Scrubber 18 Horizontal Isolation etween all Method Review- IS Deployment alanced (No Flow) V31079 V alance & ccess 330litrs alanced (No Flow) 2 The IS is formulated to a high viscosity to provide displacement towards both ball valves. ccess IS 06 Deployment Fluid Condition Note: Leave a sample at the application to confirm the IS condition prior to pressure testing. Direction to scrubber 3 Testing: Flow test against closed valves when IS has cured. IS 06 Deployed and cured Page 7 leed off upstream of V31080 To confirm isolation is holding.

7 First Stage Suction Scrubber 18 Horizontal Isolation etween all Method Review- IS Removal (reaker) alanced (No Flow) V31079 V31080 The IS will compress internally allowing the IS reaker to establish and maintain a small PU (pressure uild Up) within the spool and gel pig structure. 1 llow 6 hours for the breaker to dilute a portion of the solid IS under fluid compression. ccess 80litrs KCI IS reaker V31079 V31080 Open Valve (V31080) 10% to allow the exhausted breaker to flow through towards the scrubber. The valve will retain the remaining solid IS. 2 ccess 80litrs KCI Exhausted IS reaker Closed valve (V31080) and maintain the balanced pressure if possible. This operation will be required to be completed a number of times to reduce the solid IS with an increased volume of breaker on each application. V31079 V31080 s above. 3 ccess 200litrs KCI Exhausted IS reaker 4 V31079 V31080 Open both all Valve, i.e. -V31079 and -V and flush / drain to the suction scrubber. Total volume of IS reaker 330Litres ccess 50litrs KCI Exhausted IS reaker Page 8

8 First Stage Suction Scrubber 12 Vertical Isolation etween all Method Review- IS Deployment alance & 1 alanced 45bar (No Flow) V31104 alance & 2 alanced 45bar (No Flow) V31104 ccess The IS will be deposited on top of Valve and will fill the void between both valve. ccess IS 01 Deployment Fluid Condition V31103 V31103 alance & 3 alanced 45bar (No Flow) V31104 alance & 4 V31104 Leave a sample at the application to confirm the IS condition prior to pressure testing. ccess test both ways if required or inflow test. ccess IS 01 Deployment Cured Condition V31103 Page 9 V31103

9 K I C alance & 1 V31104 The IS will compress internally allowing the IS reaker to establish and maintain a small PU (pressure uild Up) within the balanced structure. llow 6 hour for the breaker to dilute a portion of the solid IS. IS 01 Deployment Cured Condition First Stage Suction Scrubber 12 Vertical Isolation etween all Method Review- IS Deployment IS reaker Deployment alance & 2 V31104 ccess ccess V31103 V V31104 Open Valve (V31103) 10% to allow the exhausted breaker to drain through to words the Header. The valve will retain the remaining solid IS. V31104 Closed valve (V31103) and maintain the balanced pressure if possible. This operation will be required to be completed a number of times to reduce the solid IS with an increased volume of breaker on each application. ccess Talisman Operations to start compressor. On successful start of compressor open V31103 and then slowly open V31104 to flow towards the header. ccess oth valves open V31104 & V To flush & drain. V31103 Total volume of IS reaker 120Litres Page 10 V31103