The In-Situ group has a team of design engineers supporting highly skilled and talented technicians to meet the particular requirements of leak sealing. Due to our long years of experience in leak sealing, we have written procedures on leak sealing that are proven and we use sealants for our leak sealing process that are similar to manufacturers’ leak sealing standards that are proven not to affect the integrity of the valves.

While most leak sealing repair methods will not be able to withstand high pressures and temperatures and so may require a shutdown in a system, In-Situ leak sealing method has the technological capability to perform leak sealing services ranging from sub-freezing temperatures to 1800 degrees Fahrenheit at 7500 psi on line.

The leak sealing process is environment friendly reducing pollutant emissions and safety issues. In leak sealing, the sealant that is injected into a joint or a leak area is non toxic that reduces health concerns. We recognize the fact that leaks does not only have to be treated immediately but effectively as it could be very expensive.

The following is a list of leak types commonly needing leak sealing solutions that could be sealed on line:

Flange Leak Sealing

Almost all flanges, being made to standard sizes can be treated by using a clamp which could be installed under pressure. The method only varies depending on the size of the gaps and the pressures and temperatures involved. The procedure however remains basically the inserting of a two piece clamp and sealing the gaps.

Depending also on the leak size and provided that pressures involved are not high, a wire wrap could be done as a temporary stop gap to the leak.

Valve Gland Packing

Leaking valve gland packing is the most common of leaks and it could be repacked without isolating the valve packing. It could be done economically and could be repaired online. Most common leak sealing repairs are done for most processes including air, chemical, water, condensates, vacuum, steam (superheated and saturated) and hydrocarbons.

Leak Sealing for Line Kills and Valve Bypass

These are the usual solutions applied to immediately stop leaking valve seats. As this kind of leak is usually caused by a valve seat that does not seat properly, the seat of the valve is injected with the leak sealing agent. Line bypass is simply isolating that part of the system if that is required.

Elbow and Tee Joints Leak Sealing

Elbow joints whether it is in the 45 degree or a 90 degree angle, short radius or long radius could unexpectedly require leak sealing when subjected for a protracted period from the points where it had been joined due to failing welded parts and couplings.

Weld Seam Leaks and Casting Pinhole Leak Sealing

Weld seam casting pinhole leaks are common types of leaks that starts rather very small but could rapidly need leak sealing before the problem grow worse. Typical remedy is to use a streamlined enclosure for leak sealing. The enclosures are pre manufactured according to typical pipe sizes. The enclosures could easily be inserted into the leaking portion and injected with leak sealing agent. By simply changing the inserts, the enclosures also be used in T shapes for Tee Joints, 90 degrees and the single bore application.

Leak Sealing for Exchanger Leakage

Sometimes it could happen that heat exchangers develop leaks even during installation. One of the more common causes of early leakage is when bolts are prematurely tightened when a gasket is not yet positioned properly. The composition gaskets also have the tendency to become brittle and dry. If for any reason the heat exchanger is to be dismantled it will be wise to check all gaskets thoroughly for leak sealing. Another cause for leak is that gaskets in the heat exchanger are usually made of metal or at least jacketed in metal. During early contact as the heat exchanger is sealed, the gasket and the metal are compressed where the initial sizes are matched. With use though, the gaskets hardens and creates imperfect matches resulting in breaks that require leak sealing. For whatever reason, It is always our practice to use a new gasket so that effective leak sealing is on when the heat exchanger is reused.

At the end of a leak sealing process, we could also provide forms for preventive maintenance that are available on request.

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The most common method for joining assemblies in mechanics is by means of bolts and the most common problems of the industry when it comes to machines are serviceable by bolt tensioning solutions.

Joint failures account for 30% caused mainly by under tightening and over tightening. Combine that with irregular tightening and the result would be an uneven tension load that result in the rigidity of the assembly being compromised. This is due to shear stresses, bending moments and fatigue. We offer bolt tensioning services to give solutions to your bolt-related problems.

Several methods in bolt tensioning have already been applied. Here at the In-Situ group we aim to reduce, if not eliminate the problems often caused by improper bolt tensioning with the aim of saving costs for the customers that is always relative to downtime caused by breakdown, shutdowns and even accidents.

Bolt tensioning equipments

Bolt Tensioning Hydraulic Torque Wrench

up to 135mm nut AF (bolt size 3-1/2”), 30,000 ft.lbs torque capacity.

This hydraulic torque wrench is applied directly to a nut which is applied thru an impact socket to provide bolt tensioning solutions. Unlike the usual torque wrenches, this bolt tensioning tool could be calibrated to apply a controlled torque during bolt tightening to ensure that the problems that are usually encountered with improper torque loads are reduced. Due to the uniformity of torque applied during fastening, the hydraulic torque wrench also eliminates the problems that are usually encountered with conventional wrenches during bolt removals.

Bolt Tensioner

1” to 3-1/2” bolt size

In bolt tensioning, it is imperative to have a control in bolt tightening loads without which, errors could develop proving very costly when the expected performance of the joined assemblies fails to function as expected.

Bolt Tensioning Torque Multiplier

up to 2,000 ft.lbs capacity

Controlled torques translates to controlled power and are very handy when it comes to bolt tensioning operations. Mechanical applications in heavy machine parts could be used successfully and could provide longevity to machine parts where joints bolted and sealed with the correct power.

Bolt Tensioning Manual Torque Wrench

up to 600 ft.lbs capacity

This high-quality, accurate and reliable manual torque wrenches for commercial and industrial bolt tensioning applications.

Contact us today for your specification and inquiries regarding our bolt tensioning services.

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On-Site Machining Benefits

The potential revenue cost caused by the downtime and possible damage to equipment due to transporting could often multiply production concerns. In-Situ on-site machining eliminates logistical and the cost related issues that go with repairs and replacements by conducting on-site machining within the company premises. With on-site machining, we have a wide inventory of machines and equipments that we transport to your premises thereby insuring that your machines requirements are done with dispatch and are operational the soonest possible time.

In-Situ machining team is composed of highly trained and innovative technical staffs and machinist and welders supported by engineers experienced mainly in on-site machining operations capable of within-your-premises planning, providing a very high quality of work in terms of finishes, accuracies and tolerances.

Our services also cover varied requirements and components for on-site machining of valves, rotors, of turbines, of generator fields, including on-site machining of shells and couplings, on-site machining of flanges and diaphragms, optical inspections, on-site machining of stacker reclaimer, on-site machining of large mechanical equipments, on-site machining of pumps and compressors, alignment of rod and ball, on-site machining and repair alignment and on-site machining to machineries as varied as coal pulverizers and rock crushers.

Types of On-Site Machining Services

• Flange Facing – ID & OD Mounted
  Up to 120inch flange diameter
• Cold Cutting & Beveling – Split Frame
  Up to 30inch nominal pipe size
• Precision Boring
  Up to 24inch ID
• XY Milling
  Precision leveling
  Milling on pump, compressor & motor base
• Milling (heat exchanger partition groove & plate)
• Drilling
• Tapping

Because of our experience in on-site machining, our group is also the ready to conduct engineering reviews after successful completion of the on-site machining jobs required.

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