On-stream welding: Innovating pipe repairs for Shell
The precision of Effee’s robots is ushering in a new way of repairing assets that, in the past, would have required extensive shutdown.
Corrosion repair on a pressurized pipe
Shell faced an issue with external corrosion on a pipe operating at 14 bar back pressure. The pipe had no stop valve upstream, which meant shutting down the entire pipeline was the only conventional option to isolate the section for repair—a costly and time-intensive process.
Luckily, Effee had no plans of repairing the pipe using conventional methods.
On-stream welding with robotic precision
Effee’s robot perform an innovative on-stream welding operation on the corroded pipe. The solution featured:
Precision robotic welding: Using advanced automation, Effee welded the damaged section while carefully monitoring heat input to ensure no compromise to the pipe's structural integrity.
In-situ repair: By avoiding the need to cut off the damaged section, Effee worked within the pipe's existing parameters, restoring the corroded area to a flush surface.
Safety first approach: Detailed thermal modelling ensured the heat-affected zone remained well within safe limits, preventing any risk of leaks or weakening of the pipe walls.
Executing this repair showcased Effee’s unique capability to handle onstream welding operations – an industry-first innovation.
Cost and safety benefits for Shell
Cost savings: By eliminating the need to shut down the pipeline and replace the corroded section, Effee saved Shell substantial expenses in operational downtime and material replacement.
Enhanced HSE: The repair was completed without interrupting pipeline flow, reducing risks associated with depressurization and human intervention near hazardous areas. Personnel operated the robot remotely, maintaining a safe distance throughout the process.
This project not only solved Shell’s immediate challenge but also contributed to industry advancements, as Effee continues to write the operating manuals for onstream welding.