Repair, Rehab, Reimagine

Technological advancements are constantly providing better, faster, and safer solutions to the industry’s most challenging obstacles. Quickflange™ is a unique technology that specializes in piping and pipeline repairs and rehabilitation and is a leading provider of high performance pipe connection systems in the oil and gas sector. Quickflange™ understands that operators are constantly tasked with maximizing production and flow assurance as well as protecting the integrity of their piping infrastructures as long-term assets. When dealing with repairs of leaking utilities or working in tight spaces, sometimes a quick fix is invaluable to maintain daily activity. This knowledge of how critical certain aspects of production are begs the question: Why not make a quick fix permanent?

NO HOT WORK
The Quickflange™ solution is a modified, standard weld neck flange with a patented internal groove machined into it. The design incorporates the ease of sliding the flange onto the pipe without heat or other potential ignition sources. An hydraulic tool is then used to activate the flange resulting in a mechanically robust flange-to-pipe connection within minutes. Since the cold-forging tool eliminates hot work, no spark or heat is generated during the activation process. This complete dispensing of the gases, ignition sources, flames and hot work associated with traditional welding ensures increased safety, flexibility and speed thusly increasing profitability. Quickflange™ offers operators an opportunity to do more work in less time with permanent flange-to-pipe connections that fix potential hazards in minutes. The simple metal-to-metal seal removes moving parts, balls, springs, seals and gaskets. Start to finish, the entire connecting process takes an average of thirty minutes for the largest size (14 inches [355.6 millimeters]) and far less for the smaller sizes, regardless of pipe wall thickness or material base.

SIMPLICITY AND SPEED
Due to the fact that Quickflange™ consists of a modified standard flange and is self-contained, this technology drastically reduces procedure time compared to welding. The cold-forging tool forces the pipe wall into the machined grooves of the flange, simultaneously affecting the seal and grip on the pipe, resulting in an assembled joint that is stronger than the flange itself. The joint is energized by the natural relaxation “springback” of the deformed pipe material forced into the groove modification in the flanges. The two processes generate huge contract pressures, forming a seal and a structural grip on the pipe. Installation can take place in contained areas with no impact on production and covers a wide variety of piping diameters (1 to 14 inches [25.4 to 355.6 millimeters]). Numerous materials are compatible with Quickflange™ including carbon steels, stainless steel F316, duplex, super duplex, CuNi (Copper-Nickle), and more are all available with rating 150-900#. Quickflange™ assures flexibility with other pressures, sizes and materials on request. Reduced personnel requirements compared to traditional welding ensures a cost effective pipe connection solution.
APPLICATIONS
To date, Quickflange™ has deployed its piping solutions as a quick and safe alternative to welding on over 2500 applications worldwide. Typical applications include replacement of sections of damaged/corroded piping or existing flanges. Insertion of valves and tee’s, Re-routing and de-bottlenecking, pipe work and new spool tie-in are also common. Fitting flanges in areas with restricted space has never been easier and the avoidance of welding in ‘difficult-to-weld’ materials such as CuNi, Monel and Duplex is an added benefit of Quickflange™. The Quickflange™ solution has been tested on larger diameter pipes and less familiar materials, such as high strength, thin-wall alloys with increased diameters. In order to prevent corrosion in the crevices between the pipe and the flange, these areas are effectively sealed off by applying an epoxy filler during the installation process. Testing has demonstrated that this is a suitable protection against crevice corrosion and the Quickflange™ solution is no more susceptible to corrosion than a weld-neck flange. DNV testing has proven that Quickflange™ is equivalent to welded weld-neck flanges in terms of pressure retention and load resistance. Resistance figures also meet the ASME 31.3 code for process piping as well as the maximum stress values allowed in pipe work with this standard.
AN EVOLVING SOLUTION
The Quickflange™ solution is constantly evolving with new combinations of pipe diameters, materials and pressure rating – all tested according to criteria set by DNV. No solution comes to market without rigorous testing of pressure containment properties and minimal load resistance values. Having made such a major impact topside, Quickflange™ has taken its technology subsea, where the need for safe, cost effective, flexible and quick connection solutions is every bit as critical. The Quickflange™ solutions can be deployed subsea with minimal modifications. With its compact size at up to 60 percent shorter than other sleeve connectors Quickflange™ Subsea requires less pipe preparation and the simple activation processes means divers can install the technology quickly and efficiently. The joint can then be pre-tested and verified without the need to hydro test the pipeline through its external pressure test facility. The Quickflange™ activation system can be used on multiple pipe ranges and is fully retrievable and re-usable, thus offering a cleaner advantage to both repair and Emergency Pipeline Repair systems (EPRS) contingency situations.

Quickflange™ offers operators an opportunity to do more work in less time with permanent flange-to-pipe connections.
INSTALLATION AND HSEQ
Each installation of the Quickflange™ solution is subject to detailed pre-planning, ensuing that the solution performs accordingly to safety, health and environment requirements and the product’s suitability prior to mobilization. The dimensions of the Quickflange™ tools are verified by the client, securing the necessary space for appropriate rigging and lifting devices. The HSE Material Data Sheets are approved, and suitable cutting and testing equipment are made available prior to operation. Installation is performed by certified personnel and while Quickflange™ technicians area available, most clients are able to train their own personnel for installation. Health and safety is promoted at all times and in order to preserve and protect the environment for future generations, Quickflange™ complies with all the relevant legislative requirements and regularly monitors its processes and solutions to pre-empt any negative environment impact. Process descriptions and procedures are regularly updated based on lessons learned and client specifications, with legal requirements and best practices always adhered to. ■
About the Author
Yvette Schmiz is the Gulf Coast Sales and Marketing Coordinator for Integra Technologies and can be reached at yschmiz@integratechnologies.com. She works closely with the senior engineer of BlackHawk Engineered Products, a division of Integra Technologies, and offers services, sales and rentals pertaining to critical connections to the U.S. and Canada. For more information, visit www.integratechnologies.com.