The main trunk line of 30″ NB diameter belonging to a leading Oil & Gas producing company ruptured. The pipe split was over 1.2 meter long.
VKVC provided a Sub-Sea Encapsulation clamp, designed, fabricated, tested and dispatched within 7 days from date of rupture.
Our inventory of Clamp components helps to supply tailor made clamps with the shortest deliver schedule.
This 30″ Clamp was 2500mm long and weighed 4 tons.
2024
Pipeline Repair
SUB-SEA Top side
The main Tie-In flange connecting a Sub- Sea Pipeline from SBM to the Marine terminal developed a leak.
The VLCC (Very Large Crude Carrier) had to stop the Crude Oil transfer due to the leak.
VKVC had a clamp available in inventory to encapsulate the flange joint. However the Encapsulation length was to be modified.
VKVC In-House CNC unit re-machined the clamp to suit the flange joint clamp. The clamp was Hydrotested and delivered to site.
The VLCC discharged the cargo with minimum shutdown time.
VKVC machining units can machine clamps of dia 72″ and length upto 6 meters.
2023
Pipeline Rupture Repair
A highly reactive toxic inflammable fluid carrying Jetty pipeline was damaged near the main port road. This lead to the port area being cordoned for transportation.
VKVC designed, fabricated, installed and welded the clamp at site.
Timely delivery and installation of clamp saved very critical operational man hours for the pipeline operator and the port owner.
Filter Quick Opening Closure Replacement
A 24″ NB was Installed from the coastal jetty to a Power Generation Terminal
The line was dedicated pipeline for transfering naptha.
The Line was non-piggable over the years the power generation unit converted its fuel from Naptha to Natural Gas.
The Pipeline was full of Naptha. There was a security safety risk involved keeping a line full of Naptha. Further it meant a held up financial inventory.
VKVC was called in to remove the Naptha from the pipeline and make it dry.
VKVC Installed Temporary Pig Launcher and pigged the pipeline with specially designed Foam Pigs.
The Pigs were designed to crossover partial bore Gate Valves and short radius bends.
As the product was to be transformed to a tank directly from the Pipeline Receiver could not be installed.
A specially designed Nitrogen Actuated Pig stop was Installed near the tank. This stopper was Actuated to stop the pig.
The Pig was recovered from pipeline using Chain Pulley and Lever Blocks.
2025
SUB-SEA Emergency Pipeline Repairs Units
VKVC has provided several Sub- Sea Emergency Pipeline Repair units.
The units are designed to have Male / Female Misalignment Flanges, (MAF) suitable for each Unique individual repair application.
VKVC Bolt tensioners are provided with each unit.
2024
Dome Leak Repair Clamp
VKVC developed Dome Clamps to Encapsulate Variety of mounted fitting on Pipelines.
Leaking Intrusive Pig Signals, Valves and fittings mounted with an objective of Pilferage, Pressure Gauges and other fittings have been Encapsulated successfully using Dome Clamps.
VKVC also provides Epoxy Grouting and welding services for Pipeline Repair Clamps.
2023
Mechanical Pipeline End Connector
A leading Petroleum Refinery needed to replace several In-Plant Pipeline sections.
The replacement was required during ongoing operation without shutdown of any refining units with minimum down time.
VKVC provided Pipeline Repair Coupling with Dual Seals, Test Ports & Installation crews.
The new pipeline sections were fabricated and kept ready for installation
The line product was displaced with VKVC Foam Disc Pigs. The pipeline section to be replaced was cut and removed.
New pipe sections were installed with Pipeline Couplings. The seal integrity was checked thru test ports. Operations were started immediately thereafter.
As soon as the flow was resumed and stabilized welding permits were issued to VKVC.
The welding was completed with all NDT.
The pipeline had a down time of 3 hours for replacement.
The Unique VKVC Dual Seal, Test Port Couplings have been developed from Sub-Sea Repair Units for Top Side application.
This feature allows even fresh crews with no prior experience in coupling installations to install couplings safely. The test ports allow the crew to check seal Integrity prior to starting flow in pipeline.
2020
Leak Repair Clamp
VKVC Repaired a branch connection on 18″ NB ‘T’ of a cross country pipeline.
The crown radius of Branch was carefully measured and Clamp profile prepared to match the ‘T’.
2024
Bend Reinforcement Clamp
A terminal of a Gas company had the In – Plant piping inspected.
The inner radius of a Long radius bend 30″ NB diameter showed severe metal loss. The Chances of failure were high due to the metal loss.
VKVC engineer was mobilized to site to take bend dimensions and site space conditions for transportation. He wired the dimensions to the design and manufacturing team at VKVC manufacturing facility.
The Bend Clamp was fabricated and delivered to reinforce the Bend saving down time of the entire gas terminal.
2024
PIG Barrel Modifications
Quick Opening Closures for Lethal service.
VKVC provides services for conversion of Quick Opening Closures to be suitable for Lethal service or High H2S Service.
The pressure warring locks and seals are modified and installed on existing QOC.
VKVC has complete In-House facilities for molding Seals and in- site machining at site.
2023
Quick Opening Closure Replacement on PIG Launchers
QOC are provided on vessels to save operating time and enhance convenience.
The QOC often develop operational issues due to complicated design, Mantainence , Improper Installation or Operations.
VKVC designs and installs the most convenient, simple, maintenance free robust QOC.
2023
PIG Barrel Quick Opening Closures Replacement
Quick Opening Closures of Scrapper Barrels are critical during Pigging Operations.
A 48″ NB pipeline was ready for inspection. MFL tool was mobilized to site. During the pre-pigging inspection of Pig Barrels the QOC of Pig Launcher would not open using Hydraulic jacks and other equipment also proved futile.
VKVC was called to cut the old QOC and install a new QOC 54″ NB ANSI 600. The main isolation valve of pig Launcher was passing
We installed VKVC inflatable plugs thru a nozzle to isolate the cutting & welding area.
The old QOC was then cold cut and VKVC Rotary Closure welded thereafter.
The inspections of pipeline was completed successfully.
2024
70″ NB ANSI 600 Filter Quick Opening Closure Replacement
Filter Units need to be opened and closed for cleaning of filter elements.
VKVC provides Quick Opening Closures of sizes up to 96″ ANSI 900, The QOC are operated thru Hydraulic Actuators.
VKVC crews are available for Installation and testing large size QOC at site.
2019
Structural Clamp To Encapsulation Clamp
A Sub-Sea Gas Pipeline developed a leak. The Gas company located a lower rating clamp and installed it immediate. The pipeline operations continued at lower pressure. The line showed corrosion on adjoining areas.
VKVC was contacted to make an Encapsulation Clamp of the actual pipeline pressure rating and at the same time encapsulate the already installed lower rating clamp.
The Structural Sub-Sea Clamp was fabricated to Encapsulate the older clamp and reinforce the pipeline structurally. It is in operation since 2019.
Bolt Tensioning Units tailor made for the clamp installation were manufactured and supplied by VKVC
2018
Pipeline Repairs SUB-SEA
A branch outlet bend of a Sub-Sea Pipeline sheared from the weld.
The line was shutdown due to the leak developed thereafter.
VKVC provided & designed a branch outlet structural clamp, designed to withstand Axial, Torsional and Bending
stresses of the Branch Pipeline on the mainline.
The Structural Clamp was installed and is in satisfactory service since 2018.
2018
PIG Barrel Modifications
A Pig Barrel required major modifications
Replacement of QOC
Installations of New Pig signals.
Length of minor Barrel modification.
VKVC provided to replacement QOC, Pig Signal, Pressure safety valve.
The Pig Barrel was removed from installation.
All modifications were carried out and pig Barrel Shifted back and installed.
2015
Pipeline Repairs SUB-SEA
A 36 ”NB Pig Barrel Place on Sub -Sea PLEM had a leak from welding joint of the Bottom Drain 6” NB line.
The pig barrel was installed at water-depth of 35 meters. Replacement of pig barrel implied complete dismantling and removal of pig barrels for repairs.
Leak sealing onsite was possible only with a tailor-made clamp. The dimensions were taken in poor visibility conditions. Adequate margins and tolerances were provided.
VKVC designed, manufactured, tested and delivered the Clamp to seal the drain line.
The Pig Barrel on PLEM has been used for Pigging the Pipeline. The Pig Barrel is used intermittently, it was decided not to replace the Pig Barrel.
2011
Mechanical Pipeline End Connector
At a marine terminal, a 20” NB Naptha pipeline had been operational, transporting Naptha from the Jetty to a Tank Farm. The line passes under various highways, railway lines and crossings. The line is operated only during unloading of cargo at the port.
A highway located on the pipeline route was being expanded. During excavation, an excavator damaged the pipeline, creating a 3cm wide and 15cm long gouge. The Pipeline was non operational during this accident
The excavator operator backfilled the area and did not intimate the authorities. A Marine tanker arrived at the port a few days later. Naptha was pumped thru the pipeline as per normal procedures. A leakage occurred through the gouge and leak continued for a few hours before being detected, a fire erupted thereafter. On detection the pumping was shut down immediately. VKVC was contacted to provide a solution for leak sealing and repair of Pipeline.
*Solution and Implementation*
*VKVC mobilized equipment and manpower at site within 24 hours*
The Leakage location was excavated. A ‘T ’Clamp was installed with Hose. Two Non-intrusive signals were installed on either side of Clamp. The hose was connected to a road tanker. Batching Pigs were launched with Nitrogen from Jetty. Pigs pushed the product in Pipeline to the road tanker. Their passage across the leak point was detected by the non-intrusive Pig Signals.
The product was evacuated from the pipeline using the Pigs. The ‘T ’Clamp was then removed. Pipeline couplings with a new hydrotested pipe spool was kept ready. The damaged pipe section was removed and new spool piece was installed with pipe couplings. The pipeline was made operational within the next 24 hrs. subsequently the pipe couplings were permanently welded to the pipeline.
The pipeline was repaired successfully and has been since operational.
I Request public to ensure that any damage to a pipeline is reported immediately to the local authorities. Timely action in this case would have averted the accident.
2014-2025
Monolithic Isolation Joint Leak Repair
A Monolithic Isolation Joint installed at a remote desert un-manned station developed a leak.
The Operation Crew measured the pipeline diameter with coating. The Clamp was fabricated with the same dimensions. during installation the coating thickness error was revealed.
VKVC fabricated new seals to compensate the measuring error of the operating crew.
In-House polymer compounding and moulding facility, mold machining Tool room at VKVC Provides innovative designs to become a reality in the shortestm time periods.
2006
ON-Shore Gasline Flange Leak Repair Clamp
Middle East Gas Company operates a 48 ”NB ANSI 600 Gas Pipeline to transmit Gas from the fields to a central gas plant. This 48 ”NB Pipeline is the trunk line of the company.
A Sectionalizing Valve Flange Gasket developed a leak. The leakage was minute when detected. Leakage rate was lower at a pressure between 80-90 Bar but would leakage rate would increase rapidly above 90 Bar. Replacement of Gasket meant a shutdown of the 48 ” NB Pipeline. Operational and functional Constrains ruled out an immediate non planned shutdown.
VKVC was contacted on a weekend to provide an emergency leak sealing solution. A Flange Leak Repair Clamp 48 ”NB ANSI 600 was Fabricated, Pressure Tested and air freighted within 96 hours.
Leak sealing compound injection ports were installed at site. After installation of Clamp the compound was injected to seal the leakage through the studs and nuts. A pressure gauge was also installed on the Clamp to monitor the pressure built up due to leakage in the Clamp annuls.
A VKVC Technician was available at site for supervision of Clamp installation.
The Pipeline was kept safely Operational with VKVC Flange leak repair Clamp till a scheduled shutdown. 24 months later.
2023
42″ Pipeline Pigging For Product Removal
Introduction:
Torrential rains on 42″ pipeline route washed away a portion of the hill
through which the pipeline passed
A 42” NB Pipeline from Port Terminal was full of crude oil. The crude oil needed to be displaced from Pig Launcher up to 5KM i.e. the high point of the Pipeline.
VKVC used Foam Pigs to displace the crude oil from the Pipeline.
Torrential Rains washed away an entire hillside. The washed away section exposed a 42″ NB Crude Pipeline.
The Pipeline was suspended in air. The line filled with crude oil, if sheared would lead to catastrophic environment damage to the adjoining jungles.
VKVC was entrusted the job to remove crude from the pipeline up to the exposed pipeline section.
Pig were then launched with Nitrogen to remove the crude from exposed section. The line was repaired thereafter.
2022
Cleaning of Multi-Diameter water Pipeline
VKVC crews are specialists for cleaning low pressure large diameter pipelines.
VKVC inflated Pigs are best suited for converting non-piggable pipelines to piggable pipeline.
VKVC has converted several Multidia water non-piggable pipeline to piggable pipeline.
2023
20″ pigging Pipeline Decummissioning
A 20″NB 30 KM pipeline was operating between deep water wells and a crude oil processing terminal.
As the water consumption for the processing terminal increased an additional 30″ NB pipeline was installed. This made the 20″ NB pipeline redundant.
VKVC was awarded the contract for cleaning the pipeline. Then drying the pipeline upto – 15°C dewpoint. And there after purge the pipeline with 99.9% purity Nitrogen.
The Nitrogen was injected at the Launcher end tested for purity at the Receiver end. The purity of nitrogen at the Receiver end was also found to be 99.9%.
VKVC has Nitrogen Evaporators, Vaccum Pumps, Air Compressors. All available for executing critical Pipeline Repair & Service operations.
Debris from 20″ NB Pipeline
Sand and Water received during cleaning.
2021
Repair & Retrofitting of Pipeline Pigging Equipment
VKVC has repaired and recommissioned Pig Valves of various manufacturers.
These involve size 4″ NB to 16″ NB all of ANSI 600 & ANSI 900 The Pig Valve sourced from suppliers often develop technical snags that prevent then from being used for Pigging Operations.
VKVC repairs and retrofits Quick Opening Closures, Pig Valves, Pig Signals, Pig Stoppers of any make.
Our dedicated experienced pigging crew need to repair these to complete the Pigging Jobs.
A state of art CNC Machining Unit, In-house Rubber Seal Manufacturing facility and ASME U stamp certified fabrication shop ensure all equipment is repaired and retrofitted at VKVC
2017
18″ Stuck PIG Removal
Torrential Rains washed away an entire hillside. The washed away section exposed a 42″ NB Crude Pipeline.
The Pipeline was suspended in air. The line filled with crude oil, if sheared would lead to catastrophic environment damage to the adjoining jungles.
VKVC was entrusted the job to remove crude from the pipeline up to the exposed pipeline section.
Pig were then launched with Nitrogen to remove the crude from exposed section. The line was repaired thereafter.
A 115 KM 18″ NB pipeline was laid to evacuate refined product from a central state refinery.
Commissioning of refinery was delayed. Pipeline was ready 3 years ahead of schedule refinery commissioning.
Due to delaying pipeline commissioning a huge amount of rust was received during precommissioning.
Commissioning of Pipeline and Refinery was done simultaneously.
The 18″ Pig launched during commissioning did not reach the Pig Receiver.
As the refinery operations stabilized in next 5 years. The pipeline operation was critical as all refined product was evacuated through this line.
However as pigging was to be carried out VKVC was called in to remove the 18″ stuck pig. The critically of project was such that pipeline operations could not be shutdown over 24 hours.
If the refinery would need a shutdown; refined product would be in India for over 10 million people including emergency services.
VKVC had a Pig Tracking Team of 30 Trackers, Hot Tapping unit with welders and stoppling unit.
The Stuck Pig was removed without line cutting in 18 hours.
2013
Dockline Abandonment Project
Three 16″ NB pipelines were running parallel from a Port Jetty to a tank farm 16 KM away. All lines ware non-piggable, the route of pipelines was unknown.
The Pipelines had developed several leaks. The leaking media was contaminating the water supply in the pipeline route. The pipeline was to be abandoned.
Critical issue. All media needed to be removed from non-piggable pipelines prior to abondement.
VKVC was awarded the work contract to displace all product and make the pipeline touchdry.
VKVC Gel pigs with polyurethane gel follower were used. The Gel was mixed and prepared at site for product displacement. Gel mixers, coolers were all mobilized and used at site. The Polyurethane follower was molded and air lifted to site. All pipelines were made touch dry with Gel Pigs.
2013
Jetty Pipeline Product Recovery
The main trunk line of 30″ NB diameter belonging to a leading Oil & Gas producing company ruptured. The pipe split was over 1.2 meter long.
VKVC provided a Sub-Sea Encapsulation clamp, designed, fabricated, tested and dispatched within 7 days from date of rupture.
Our inventory of Clamp components helps to supply tailor made clamps with the shortest deliver schedule.
This 30” Clamp was 2500mm long and weighed 4 tons.
