shear + plug

PLIDCO®

THE PIPE LINE DEVELOPMENT COMPANY

870 CANTERBURY ROAD WESTLAKE, OH 44145 USA

Shear + Plug

Stop Flow Without Stopping Production

www.plidco.com

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PLIDCO® Shear + Plug

Cutting edge technology that provides a safe and reliable method to isolate piping systems for maintenance, repairs or upgrades while maintaining continuous operation

Primary Industries Served

Oil & Gas Petroleum Refineries Chemical & Petrochemical Fossil & Nuclear Power Generation Primary Metals Integrated Pulp & Paper Food & Industrial Process Plants

Shear + Plug is the Best Choice for:

Isolating High Pressure / High Temperature / High Flow Rate piping systems

Systems containing questionable or inoperable valves

Header systems lacking isolation abilities without complete shutdown

Shear + Plug is the Best Choice for:

Line conditions such that standard pluggingor freezing techniques are inadequate

Lines with irregular inside diameters resulting from corrosion or internal deposits

Lines that need to remain plugged for an extended period of time

Shear + Plug Features and Benefits:

A unique, intrinsically safe design thatseals independent of the pipe

A positive metal to metal seal with a secondary sealant backup

Resistant to flow rate; providing absolutely zero leak-by isolation

Shear + Plug Features and Benefits

2” & smaller units designed for ASME Class 900 pressure / temperature ratings up to 800º F.

2.5” – 10” units designed for ASME Class 600 pressure / temperature ratings up to 800º F.

Larger sizes, higher pressure / temperature configurations available on application

Shear + Plug Features and Benefits

Provides safe, positive isolation of piping systems carrying:

Steam, boiler feed water, catalyst, slurry fuel gas, sulfur, highly viscous fluids

Other line content on application

Shear + Plug Features and Benefits:

Designed and manufactured to applicable codes and ISO accredited quality standards

D.O.T. qualified (subject matter experts), factory trained technicians with years of global field experience

A world wide customer list upon request

Installation Procedure

Work area is inspected for clearancesand obstructions

Pipe is ultrasonically tested to verifywall thickness

Installation Procedure

Pipe reinforcing rings are positioned on the pipe, straddling the location to be plugged, and welded in place

Installation Procedure

The pipe holding assembly is placed into position over the reinforcing rings; the internal seal face is aligned to within .001” and secured to the pipe by welding

The pipe holding assembly may be placedon any pipe axis

Installation Procedure

The chain notching apparatus is assembled into the pipe holding assembly and the pipeis notched

Notching can be safely accomplished because axial loads on the pipe are transferred through the pipe holding assembly

Installation Procedure

The pipe is notched to a depth equal to 1/3of its minimum U.T. thickness reading

Longitudinal stresses are carried by the pipe holding section

Hoop strength of the notched pipe is unaffected, but can be calculated and has been verified by extensive in-house burst testing

The following is an example based on 1” pipe:

inchttn 119.0179.032

32

NOTCHED PIPE CALCULATIONPIPE SIZE: 1 inch nominal, 1.315 inches outside diameter, ASTM A106 Grade BWALL THICKNESS: 0.179 inch

1.) Wall Thickness and Outside Diameter after Notching

Dn = outside diameter of pipe after notching Do = outside diameter of pipe before notching t = wall thickness before notching tn = wall thickness after notching (notch depth is 1/3 of t)

2.) Hoop Strength Based on Yield and Tensile Stresses at Temperature

Pht = pressure calculated using Barlow’s formula and tensile stress at Temperature Phy = pressure calculated using Barlow’s formula and yield stress at Temperature St = tensile stress at 265°F for ASTM A106 Grade B Sy = yield stress at 265°F for ASTM A106 Grade B

3.) Longitudinal Strength Based on Yield and Tensile Stresses at Temperature

Plt = pressure based on longitudinal strength and tensile stress at Temperature Ply = pressure based on longitudinal strength and yield stress at Temperature Ri = inside radius of pipe Rn = outside radius of pipe after notching (1/2 Dn)

inchestDD on 196.1179.0312315.13

12

psiD

tSP

n

nyhy 239,6

196.1

119.0350,3122

psiD

tSP

n

ntht 939,11

196.1

119.0000,6022

psi

R

RRSP

i

inyly 511,17

479.0

479.0598.0350,312

22

2

22

psi

R

RRSP

i

intlt 515,33

479.0

479.0598.0000,602

22

2

22

Installation Procedure

The thrust screw and seal nut assembliesare installed

Installation Procedure

Sealant injection fittings are installedand pre-charged

Installation Procedure

Assembly of the PLIDCO® Shear + Plug is completed by positioning the retraction housing and coupon receptacle housing on the pipe holding assembly

Installation Procedure

The through-bolts are hydraulically tensioned and the complete assembly is pressure tested to verify seal integrity

Installation Procedure

The hydraulic cylinder is actuated,thrusting the shear blade through the pipe and pushing the coupon into the receptacle housing; allowing retrieval of the entire coupon

Installation Procedure

The blind plate is indexed into position

Thrust screws on the downstream sideare tightened, which push the blind plate against the housing seal face forming a metal-to-metal seal

Installation Procedure

Sealant pressure is injected onto theseal face thereby verifying the seal

With flow halted, the downstream line temperature is diminished

Residual pressure and content is blown down from the unit; work to the downstream line can safely begin

Installation Procedure

The coupon receptacle housing is loweredto remove the shear blade, guidance tracks, and the sheared section of pipe

Installation Procedure

The first completion cap is welded to the bottom of the pipe holding assembly

Installation Procedure

When the downstream work is completed,the thrust screws are backed off andprocess flow is re-established

The hydraulic cylinder is reversed, retracting the blind plate into the retraction housing assembly

Installation Procedure

The retraction cock valve is rotated 90° and sealant is injected into the retraction cock annulus

Installation Procedure

Residual pressure and content is blown down from the retraction housing and the unit is disassembled

Installation Procedure

The second completion cap is welded in place on the top of the pipe holding assembly

Installation Procedure

The completed pipe holding assembly remains as a permanent part of the line

Case Histories

Case History #1Petroleum Refinery

Alberta, Canada

Inoperable valve in a 4” line carrying high octane gasoline operating at 500 psi and 465° F; threatened unit shutdown because process temperatures couldn’t be maintained

Plidco® Shear+Plug installed upstream of the faulty valve and utilized as an insertable gate valve, controlling process conditions until the next scheduled turnaround in 2009

Case History #2Large, Midwestern U.S. Steel Mill

A 6” 1400 psi boiler feed water line was in need of pump repair

Line used to send cooling water to the continuous caster process

The backup pump was questionable as to its ability to run for an extended period of time

Valving to the main pump was insufficient; not holding back enough back pressure to allow the pump to be rebuilt

Case History #2 (cont’d)Large, Midwestern U.S. Steel Mill

PLIDCO® Shear+Plug isolated the pump and the bad valve; the pump was rebuilt and the valve replaced. Upon completion:

The line was pressurized, revealing weld leaks

The Shear+Plug was used to re-plug the line and do additional repairs

With space restrictions, the PLIDCO® Shear+Plug was the only option as competitive solutions were not able to fit in the area

Case History #3Polyethylene Plant - France

A 2200 psi boiler feed line operating at 300° F. with considerable problems

The PLIDCO® Shear+Plug isolated the system so faulty areas could be replaced

With repairs complete, the Shear+Plug was used as a test valve to verify system integrity prior to the line being brought back into full operation

Case History #4Petrochemical Plant - Texas

Previous attempts to plug a superheatedsteam line using a product from a different company were unsuccessful

A PLIDCO® Shear + Plug with a positive metal-to-metal seal, isolated the line 2 feet up stream of the failed unit, enabling repairs to be safely completed

Avoided a costly system shutdown

Case History #5Petroleum Refinery – Midwest, U.S.

A16” H2S line with a broken wafer valve on the the actuator shaft

Avoiding a shutdown of the extraction unit, a PLIDCO® Shear + Plug safely isolated the system so the broken valve could be replaced

This was accomplished without H2S release or a costly system shutdown

Shear + Plug

PLIDCO®

Shear + Plug Division

Working together to make hazardous piping safer

www.plidco.com