In industries where continuous production is critical, unplanned downtime can result in massive financial losses, safety risks, and operational setbacks. A Pipeline Leak carrying caustic chemicals under high pressure is a nightmare situation for chemical firms such as Aarti Industries Ltd.
Ignoring the leak could have disastrous results, yet shutting down the system for repairs is frequently impractical. This case study examines how Shree Ram Sealing Engineers (SRSE) used cutting-edge methods including hot tapping and their exclusive SR Steel Bond Heavy Duty Epoxy to successfully fix a high-pressure pipeline leak at Aarti Industries without halting production.
Aarti Industries is a leading global manufacturer of specialty chemicals, pharmaceuticals, and agrochemicals. To move high-purity and corrosive chemicals between industrial facilities, their operations depend on a system of pipelines. Any interruption to this flow could put a stop to production, cause orders to be delayed, and jeopardize safety procedures.
The Crisis: A High-Risk Pipeline Leak
During a routine inspection, Aarti’s maintenance team detected a leak in a pipeline transporting concentrated hydrochloric acid (HCl). The pipeline operated at 220 PSI, and the leak was located near a welded joint, making it difficult to access. Key challenges included:
- Zero Tolerance for Downtime: The pipeline fed raw materials to a 24/7 production line. Shutting it down would disrupt orders worth crores of rupees.
- Safety Concerns: HCl is highly corrosive and hazardous. Prolonged leakage risked employee exposure, environmental contamination, and equipment damage.
- Complex Repair Requirements: Traditional welding was unsafe due to the flammable nature of residual chemicals. The leak’s proximity to a weld joint also limited repair options.
Aarti Industries needed a solution that addressed these challenges without compromising safety or productivity.
The Solution: Shree Ram Sealing Engineers’ Two-Phase Strategy
Shree Ram Sealing Engineers, well-known for their proficiency in non-invasive pipeline repairs, suggested SR Steel Bond Heavy Duty Epoxy in conjunction with hot tapping, a technique intended to permanently Fixed Pipeline Leak while maintaining pipeline functionality.
Phase 1: Hot Tapping – Gaining Safe Access to the Leak
Hot tapping, a technique used to drill into live pipelines without stopping flow, was the first step. Here’s how SRSE executed it:
- Risk Assessment & Planning
- SRSE’s engineers conducted a 3D ultrasonic scan to map the leak’s exact location, size, and depth.
- They analyzed the pipeline’s material, pressure, and chemical compatibility to design a custom repair plan.
- Installing the Hot Tap Machine
- A bi-directional hot tapping machine was mounted onto the pipeline. This device is engineered to drill into pressurized lines safely.
- A temporary containment chamber was created around the leak site to prevent chemical exposure during drilling.
- Drilling & Isolation
- A pilot hole was drilled into the pipeline to create a “saddle” access point.
- An isolation valve was installed, allowing technicians to compartmentalize the leak zone while the rest of the pipeline remained operational.
This phase required precision, as even a minor error could escalate into a chemical spill or equipment failure.
Phase 2: SR Steel Bond Epoxy – A Permanent, Corrosion-Resistant Fix
With the Fixed Pipeline Leak isolated, SRSE deployed their flagship product, SR Steel Bond Heavy Duty Epoxy Weld, to seal the damaged section. This epoxy is specifically engineered for high-stress, corrosive environments. The repair process included:
- Surface Preparation
- The pipeline’s surface was cleaned using abrasive blasting to remove rust, scale, and chemical residues.
- A primer was applied to enhance the epoxy’s adhesion to the metal.
- Epoxy Application
- The epoxy was mixed and applied as a structural reinforcement sleeve around the leak. Its thick, paste-like consistency allowed it to conform to the pipeline’s curvature.
- Multiple layers were added to ensure complete encapsulation of the damaged area.
- Curing & Reinforcement
- The epoxy cured in 90 minutes, forming a rigid, chemically inert bond.
- Post-repair, a hydrostatic pressure test at 1.5x the operating pressure confirmed the pipeline’s integrity.
- Technical Expertise
- SRSE’s team holds certifications in ASME B31.3 (Fixed Pipeline Leak) and API 1104 (Welding Standards), ensuring compliance with global safety norms.
- Their technicians underwent specialized training in hot tapping and epoxy-based repairs for hazardous environments.
- SR Steel Bond Epoxy: A Game-Changer
- Pressure Resistance: Withstands up to 2500 PSI, making it ideal for high-pressure pipelines.
- Chemical Resistance: Impervious to acids, alkalis, and solvents, ensuring longevity in corrosive environments.
- Rapid Cure Time: Minimized repair duration, reducing the window of operational risk.
- Cost and Time Efficiency
- The entire repair was completed in 8 hours, avoiding a 3–4-day shutdown.
- Aarti Industries saved in potential downtime losses.
- Uninterrupted Production: The pipeline resumed full functionality without disrupting Aarti’s manufacturing schedule.
- Enhanced Safety: No chemical spills, worker injuries, or environmental incidents occurred during the repair.
- Durability: The epoxy-reinforced section outperformed the original pipeline material, extending its lifespan by 8–10 years.
Client Feedback
“Shree Ram’s team turned a crisis into a non-event. Their hot tapping technique and SR Steel Bond Epoxy worked flawlessly. We’ve since partnered with them for preventive maintenance across our facilities.”
– Mr. Sanket Yadav, Plant Manager, Aarti Industries
- Risk Mitigation: Reduces exposure to chemical hazards and operational disruptions.
- Cost Savings: Eliminates downtime-related revenue losses.
- Sustainability: Extends asset lifecycles, reducing waste and replacement costs.
The collaboration between Aarti Industries and Shree Ram Sealing Engineers underscores the importance of proactive maintenance strategies and cutting-edge repair technologies. By combining technical expertise with innovative products like SR Steel Bond Epoxy, SRSE has set a new benchmark for solving complex industrial challenges without compromising productivity. For chemical plants, refineries, and manufacturing units, SRSE’s solutions provide a reliable pathway to operational resilience. Their approach not only fixes leaks but also fortifies infrastructure against future failures, ensuring businesses stay competitive in high-stakes environments.
