Flange Leak Containment Using Cable-Tensioned Compression Seals
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Solution Overview
Problem
Existing methods for containing leaks in flanged joints of refinery equipment are ineffective, costly, and require unit shutdown, posing safety risks and operational inefficiencies due to the flammable and explosive nature of the contained products.
Innovation Solution
A device comprising compression plates, fixing clamps, tightening elements, hollow tubular elements, and a tensioning cable is used to compress filling elements, allowing leak containment without interrupting equipment operation by distributing tensioning forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealants are injected to contain the leak, then leak containment is achieved, but the interference in the union region prevents effective placement of support to contain sealants
Solution Approach 1:
The device divides the sealing function into multiple segments: compression plates for anchoring, hollow tubular elements for positioning, filling elements for sealing, and tensioning cables for applying force. This segmentation allows the device to overcome the interference in the union region by distributing the sealing function across multiple accessible points rather than requiring access to the difficult-to-reach leak region itself
Solution Approach 2:
The hollow tubular elements act as intermediaries that bridge the gap between the easily accessible tensioning cable and the difficult-to-access leak region. These tubular elements transmit the tensile force from the cable to the filling elements at the leak site, enabling effective sealant containment without requiring direct access to the interference-prone union region
2Reliability
If the cover or flanged joint element is exchanged, then leak containment is achieved, but the equipment must be deactivated causing production losses
Solution Approach 1:
The device is installed on the existing flanged joint without requiring disassembly or deactivation of the equipment. The compression plates are anchored to the flange bolts, and the tensioning cable is installed in advance, allowing the filling elements to be positioned and activated while the equipment remains in operation, thus maintaining production continuity
Solution Approach 2:
The device enables continuous operation of the equipment by providing a leak containment solution that does not require shutdown. The tensioning cable can be adjusted and the filling elements activated while the flanged joint remains in service, ensuring uninterrupted production and avoiding the productivity losses associated with equipment deactivation
3Ease of manufacture
If a routine maintenance team carries out containment, then cost is reduced, but the complexity of the device increases
Solution Approach 1:
The device uses standard, widely-available components such as compression plates that anchor to existing flange bolts, hollow tubular elements for structural support, filling elements for sealing, and tensioning cables with turnbuckles for force application. This universality allows routine maintenance teams with basic skills to install and operate the device without requiring specialized training or custom-made parts, thereby reducing maintenance costs despite the multi-component structure
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables quick and effective leak containment in flanged joints, ensuring safety and continuous operation by distributing tensioning forces to seal leaks in both straight and corner regions of the joint.
Implementation Method 1
a tensioning of the tensioning cable, in conjunction with a tightening of the plurality of tightening elements, presses the set of hollow tubular elements and compresses at least one filling element
Data Source
AI summary
The present disclosure describes a device for leak containment, including a set of compression plates, which respectively contain fixed thereto a plurality of fixing clamps for anchoring the device, and a plurality of tightening elements including screws and nuts, at least one filling element, a set of hollow tubular elements, and a tensioning cable passing inside the set of hollow tubular elements. A tensioning of the tensioning cable, together with a tightening of the plurality of tightening elements, presses the set of hollow tubular elements and compresses at least one filling element.