Stories to Tell

Stories to Tell

Case Studies

1. Colt was called into a gulf coast facility to engineer a repair on a 150psig main water system that was vital to plant continuing production. The 6” carbon Steel line was leaking in multiple places and it was also determined the existing piping material was thinning due to internal corrosion. Using the latest CAD software the Colt engineering department developed a solution to keep the plant up and running. The enclosure was also designed with a strongback assembly due to the corrosion that was identified.

Case Study 1
Case Study 1.2

2. Colt was contacted by a West Coast refining customer to assist in a 6”, 200 psig, 650 degrees F Coker blow down vapor line recovery repair. The active leak was inspected, measured, and successfully installed within 24 hours.

The leak was stopped by combining eight of Colt’s 6”straight connectable enclosures and one 6”connectable 90 degree enclosure. During the customers’ routine turnaround, the enclosures were removed. Upon inspection, approximately 36” of the line was missing, which was kept running by Colt’s quick and effective repair.

Case Study 2.1
Case Study 2.3
Case Study 2.4

3. One of the largest Power Plants in the Southeastern part of the country developed a boiler feedwater leak on a 2500psig, 600°F bonnet. Colt engineers designed a flange clamp accompanied with a strong-backing system to ensure the bonnet could not separate if the host studs were to fail. The Colt flange clamp and strong-backs were installed within 24 hours to keep the unit up and running with a 100% seal.

Case Study 3.2
Case Study 3.1

4. A Colt 4 inch 90° custom pressure seal enclosure (39 inches long) was required to seal a leak at a major refinery in the gulf coast region. Colt engineered a custom enclosure and it was fabricated in Colt’s in-house CNC machining center in Beaumont, TX using the latest CNC technology. Each half of this enclosure was made using a solid piece of steel eliminating any need for dye penetrant testing, welding and post weld heat treating.

Case Study 4

5. Colt was called by a West Coast refining customer regarding a 2 inch 725 psig 200 degrees F process light cycle oil leak. There was a leak on the system that was unable to be contained or isolated. Colt offered the customer a safe solution when no one else could. Colt engineered and fabricated a custom line crimping enclosure. Colt’s crimping system was a double crimping and bleed procedure. Colt was able to successfully contain the crimp area while double blocking, bleeding, and terminating the flow. By using Colt’s crimping system, the refinery was able to avoid a very costly shutdown and possible environmental spill. This is one of Colt’s many one-off specialized solutions that can be offered to our customers.

Case Study 5.1
Case Study 5.2
Case Study 5.3

6. The Colt group received an emergency call from a large refinery located in Eastern Texas. The refinery needed an engineered solution to repair a crude leak on a 16” sweeping elbow line. The line was operating at 350°F at 200psig. The Colt engineering department designed a solution and then the 16” sweeping elbow enclosure was fabricated in the Colt fabrication facility. The enclosure was measured, engineered, fabricated, and installed within and incredibly short time frame allowing the plant to continue normal operations.

Case Study 6.1
Case Study 6.2
Case Study 6.3
Case Study 6.4

7. 30.00” x 24.00” Tee with Defective Weld on Cooling Water Line

Colt received a call from a gulf coast polymer plant regarding a cooling water leak that was considered critical to the continual operations of the facility. The cooling water line operated at 100psig and had ambient temperature.

The Colt engineering department had additional factors that played into this design that were more than just a typical 30.00” x 24.00” Tee design. They were:

  1. WEIGHT – 2400lbs to be exact. Due to the fact that the weight was going to be an issue for the existing pipework to hold, the design included supports on the bottom on the enclosure so jacks could be installed to disperse the overall additional weight.
  2. 1” VALVE on LEFT SIDE – The main 30” line also had a 1” valve that was 180° away from the 24” valve. This is a significant obstruction that takes incredibly precise measurements for the installation process to occur.
  3. STRONGBACK – Strongback devices are required to maintain the integrity of the existing device and to ensure that no future separation of the lines can occur with the newly installed apparatus.

As with most all Colt repairs, this was all completed while the polymer facility continued normal daily operations. This repair was completed with 48 hours and saved the facility from a costly shutdown.

If you would like to learn more about this project in detail or more about our under-pressure leak repair services please contact us anytime.