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Emergency Pipe Repair Systems (EPRS)

🔩| Subsea Innovation can provide several Emergency Pipe Repair System (EPRS) solutions, both turnkey and bespoke.

Our systems are versatile and modular to suit a range of repair and maintenance scenarios. They can perform repairs at depths of up to 3000 meters and be remotely controlled, making them ideal for hazardous deep water environments.

Subsea Innovation’s EPRS is suitable for many applications, from pinhole leaks to structural repair on a cracked pipeline or section replacement where the damage is too severe for a local repair and well intervention. They are also highly customisable and can be adapted to suit specific project requirements.

Emergency Pipeline Repair System

Key features:

  • Pipeline range 2″ NS to 48″ NS
  • Pressure range 0 to 600 bar. g
  • Temperatures 0° C to +150° C
  • Diver installed (in shallower waters) or ROV installed
  • Unique designs are undertaken for specific temperatures and pressures, and geometry, i.e. sealing over a flange joint.
  • Inter-changeable structural collet packs
  • 25 – 40 year design life
  • Additional interchangeable internal components can be supplied to increase diameter tolerances or cater for multiple pipe wall thicknesses.
  • Designed to accept API 5L or DNV diameter tolerances.

SI-Clamps

Subsea Innovation’s SI-Clamps follow a modular design allowing the clamp to be utilised as a structural or non-structural system and can be installed by diver or ROV.

A non-structural, SI-Seal system is used to repair minor damage to a pipeline, such as a pinhole leak for pressure containment. The clamp consists of 2 split seal housings machined from forged blanks. The material grade of the forging is supplied to the client’s specifications. In sour service applications, the parent material will be NACE compliant, and an Inconel cladding can be added to the wetted surfaces at the client’s request.

The seal housings house a sealed pack consisting of a dual seal arrangement (triple seals available if requested) of radial and longitudinal polymer sealing elements and metallic anti-extrusion components, allowing for redundancy and a verification pressure test to be performed. The seals are activated by a tensioned bolted connection which brings the split housings together around the pipe and activates the seals and anti-extrusion by compression against the pipe.

A structural system is used to repair a medium-damaged event. The structural system utilised the same SI-Seal system but had a mechanical, SI-Grip, collet system added to both ends of the seal housing. The mechanical collet system consists of a split housing and segmented collets, which are activated by tensioned bolts that draw the split housings together, squeezing the collets onto the pipe. Once the initial grip is achieved, the collets self-activate against additional axial loads.

The collect pack and seal pack is sized to account for API 5L or DNV pipeline diameter tolerances, where larger tolerances are required interchangeable collet segments, seals and anti-extrusion plates can be supplied with varying internal diameters.

SI – Hot Tap Clamp

Subsea Innovation’s Hot Tap Tees can be used for pipeline intervention and line stopping and can be installed by diver or ROV.

The main body of the system is the same as the SI-Clamp system. However, there is an additional flange added to the seal housing. This flange is supplied to our client’s required specifications.

SI-Connectors:

Subsea Innovation’s SI-Connectors consist of a flange, an SI-Seal, a seal pack, and an SI-Grip, collet arrangement and can be installed by diver or ROV.

The flange, seal housing, collet housing and collet pack are machined from forged blanks. The material grade of the forging is supplied to the client’s specifications. In sour service applications, the parent material will be NACE compliant, and an Inconel cladding can be added to the wetted surfaces at the clients request.

The flange mates to the client-supplied spool piece and houses an RTJ gasket. The flange on the connector can be supplied as either a fixed flange or a more complex swivel flange and is connected by a tensioned bolted connection.

The seal pack consists of a dual seal arrangement (triple seals available if requested) with polymer sealing elements and metallic anti-extrusion components, allowing for redundancy and a verification pressure test. The seals are activated axially by a tensioned bolted connection.

The mechanical collet system consists of a split housing and segmented collets, which are activated by tensioned bolts that draw the split housings together, squeezing the collets onto the pipe. Once the initial grip is achieved, the collets self-activate against additional axial loads.

The collect pack and seal pack are sized to account for API 5L or DNV pipeline diameter tolerances, where larger tolerances are required interchangeable collet segments, seals, and anti-extrusion plates can be supplied with varying internal diameters.

SI – Flange

As part of a connector installation the client required a spool piece to be made up with a flange on each end. Subsea Innovation can supply a matching flange with the SI-Connector system which weld-prepared for welding to the spool pipeline. These flanges can be a fixed item or more usually supplied as a swivel flange which aids installation to the connector by improving alignment of the bolt holes.

A misalignment flange can be supplied which allows for a further degree of freedom in alignment over the swivel flange.

SI-Sleeve Connectors

Subsea Innovations SI-Sleeve connectors are normally supplied in pairs to repair severely damaged pipelines in deep water and normally installed via ROV. Each sleeve connector consists of 2 SI-Seal dual seal system and 2 SI-Grip collect mechanisms.

The damaged section is removed, and a spool piece is lowered into position with a sleeve connector on each end. Once in position the sleeve connector is slid along the spool section over and over the gap on the existing pipeline positioning the gap between the 2 SI-Seal packs. The systems is then activated by ROV bolt tensioners compressing the seals against the pipe and activating the collet grip mechanism on both the existing and new spool sections.

Subsea Innovation Sleeve Connector

SI-Seal

This SI-Seal arrangement is used within the SI-Clamp, SI-Connector and SI-Sleeve Connector systems. consists of a dual seal system (triple seals available if requested) with metallic anti-extrusion components allowing for both redundancy and a verification pressure test to be performed.

The system is designed to accommodate full API or DNV pipe tolerances and the HNBR material is tested to NORSOK M710 and qualified for full sour service. Other elastomers such as Viton or Silicon can be supplied at client request.

There seals have been tested to seal against defects such as longitudinal weld seam misalignment, and uncoated pipes so no requirement to fully machine the pipeline.

In the SI-Clamp, the SI-Seal is made up of radial seals and longitudinal seals that are activated by a tensioned bolted connection which brings the split seal housings together around the pipe and activates the seals and anti-extrusion by compression against the pipe.

In the SI-Connector and SI-Sleeve systems, the SI-Seal is made up of 2 complete seal rings seals which are activated axially by a tensioned bolted connection pulling the activation spool against the seal which expands against the pipe.

SI-Grip

The SI-Grip system is used with the structural SI-Clamp, SI-Connector and SI-Sleeve Connector systems.

It consists of a consists of a split housing and segmented collets which are activated by tensioned bolts that draw the split housings together squeezing the collets onto the pipe, once the initial grip is achieved, the collets become self-activating against additional axial loads.

 The segmented collets allow flexibility with pipeline geometry & multiple collet inserts can be provided to adapt to suit more than one pipeline wall thickness and grips to uncoated pipe across full API or DNV tolerances without damage to the pipeline.

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