PROCESS INTEGRITY

Engineering Solutions and On-Site Services

Specialised Engineering Services

Hydratight is an innovative provider of engineering solutions and on-site services
designed to maintain the integrity of production and process plant and pipework.
On-Site Bolting
In-house designed and manufactured bolt tightening tools
Competent supervisors and technicians
Leak-free start-up and production

Pipe cutting and Bevelling

Flexible internal or external mount cutting and bevelling equipment
High quality pipe cutting, bore matching for connection of pipes
Suitable for Onshore, Offshore or Subsea projects

On-Line Industrial Leak-Sealing

Avoid production losses and unscheduled plant shutdowns
by using our on-line Leak Sealing service
Cost effective and safe sealing of flanges, bonnet, valves and
fittings with around the clock availability

On-Site Machining
Hydratights On-Site, In-Situ Machining capability provides the services
of a fully equipped machine shop direct to your site, including;
Turning, Drilling, Milling and Grinding
Dismantling and transport of vessels/equipment is unnecessary, reducing plant
downtime to a minimum

Hot Tapping and Line Plugging

Tapping integrating tie-ins without production loss
Plugging isolating product flow during normal production
Tapping and plugging bypassing and replacing of damaged lines,
defective valves etc

On-Line Thermowell Installation

Installation of Thermowells under operating conditions to provide
temperature data collection without production loss
Ideal where temperature measurement of high temperature, abrasive
or corrosive media may result in premature failure of an unprotected sensor

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PROCESS INTEGRITY

On-Line Freeze Plugging

Fast, safe plugging of process lines without draining or interruption is possible
with our on-line Freeze Plugging service
Liquid nitrogen or carbon dioxide are expertly applied, freezing the process
media to create a pressure tight plug, allowing efficient modification to plant with
minimal disruption

On-Site Condenser and Heat-Exchanger

Repair and Restoration
Hydratight offer Turnkey refurbishment and maintenance packages for
Heat Exchangers and Condensers
Experienced personnel efficiently restore components to original specification
and performance, on-site and on time

On-Line Safety Valve Testing

Cutting the cost associated with Safety Valve Testing, verifying operation
at production pressures
Avoids the cost of unnecessary valve removal and replacement and
provides reassurance that safety systems are in good working order

Induction Heat Treatment

Through the DL Ricci operation, Hydratight offer on-site Resistance and
Induction Heat Treatment services
Modern portable equipment and experienced field technicians combine to
deliver accurate and affordable in-situ heat treatment

Sales and Rental Services

Bolting and Process Integrity
Hydratight offers a tailored solution to meet customers needs, with a range of
in-house manufactured products
All products and services are carried out to the highest quality standards and
best practices worldwide

Largest Portable Tool Rental Fleet

With the largest inventories of market leading products, Hydratight
brings a truly flexible approach and outstanding value in both bolting
and machining, underpinned with local technical support

enquiry@hydratight.com

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On-Site Bolting
Hydratight pioneers global standards, making leak-free bolted connections
safely and competently with full regard to the environment.
Hydratights highly trained and competent service
teams inspire confidence that all bolting operations,
whether torque or tension, will be carried out efficiently
and safely, ensuring the correct bolt loads are
achieved and not just applied.
Hydratight utilises innovative, purpose designed and
manufactured products and well trained crews to
provide an unrivalled quality of service and value for
money.

Whether the requirement is for torque or tension

equipment, Hydratight has extensive stocks of in-house
designed and manufactured product available,
ensuring leak-free bolted connections.
Selection of the required tooling may be influenced by:
Access to the joints and bolt length
Accuracy needed
Site preference and experience of personnel

Technical Support
Hydratight can quickly assess the suitability of equipment to fit particular joints
through its bolting calculation software Informate and Boltup, or in more complex
cases via the Technical Support teams
based in the companys regional facilities.
Consideration is given to;
Height restrictions
Bolt pitch issues
Proximity of bolt circle diameter to the
base of the hub or weld neck

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PROCESS INTEGRITY

Pipe Cutting & Weld Preparation

DL Ricci portable Pipe Cutting and Weld Preparation machines have led the market
for many years becoming an industry standard.
The companys extensive range of machines offers the
perfect match for any application from the small to the
heavy duty.
The patented bearing technology built into the DL Ricci
clamshells, provide easy set-up and robust operation
in any environment.

The Company
DL Ricci is one of the more
recent additions to the
Hydratight business, adding
new capability in respect of
manufacture and supply of
specialist machines, in
addition to a global on-site
service operation.

Examples of
applications
Machining of weld excavations to
remove defective material in
preparation for re-welding
Internal or external match boring to
allow pipes with a different wall
thickness to be paired together
Single V, double angle or J prep
can all be produced

enquiry@hydratight.com

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On-Line Industrial Leak-Sealing

Hydratights history of developing
innovative technologies continues with the
addition of On-Line Leak Sealing.
With continuous on-call availability, Hydratights specialist
on-line leak sealing of flanges, bonnets, valves and fittings
offer a fast, efficient and cost effective solution for leaks.
With a right first time philosophy, safety is ensured and
environmental performance optimised whilst plant
down-time and costs are reduced to a minimum.

(1) Broken down flange sealing

(2) Compound (substitute sealant)
(3) Injection adapter (closed)
(4) Injection adapter (valve to inject compund)
(5) Sealing clamp
(6) Copper seal pipe
(7) Bolted flange connection

Using expert knowledge, the selection of the right

process and materials ensures leaks are efficiently
and permanently fixed.

Benefits
Minimum disruption to
production or process
Safe, efficient, non-destructive and
cost-efficient sealing of flanges, bonnets,
fittings, elbows etc.
Rapid response with large stocks and
dedicated in-house mechanical workshops
High quality standards
Around the clock advice and service

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PROCESS INTEGRITY

On-Site Machining
Modifications and repairs
with portable machinery
Hydratight executes on-site repairs, improvements
and modifications to all kinds of equipment, plant and
construction parts with a wide range of mobile
machinery. Highly qualified engineers and technicians
ensure quality without compromise, comparable to
stationary machining.
Portable machining is recommended for turning,
drilling, milling and grinding of plant components,
which either cannot or can only be disassembled
and/or transported with great difficulty. Reducing costs
for dismantling, assembling, and transport of vessels
and equipment, on-site machining significantly
reduces downtime and increases plant safety.

Turning
Capacity up to 5.500 mm
Facing and grooving of flanges
and heat-exchangers
Pipe cutting and weld preparation of pipe ends
Machining of shafts

Milling
Pump, motor and machine bedplates
Resurfacing, milling of profiles
Keyways in bores and shafts
CNC-milling of threading up
to 200 mm, depth 300 mm

Drilling and Line Boring

Machining of bushes, bearings
and multiple in-line borings
Drilling up to 150 mm in solid material
Machining up to 800 mm of nozzles in vessels

Grinding
Large diameter rotating equipment
eg: dryers and turn furnaces

Benefits
Hydratight offers all the facilities of a
fully equipped machine shop right
where it is needed on-site.
Significantly reducing;
Plant down-time
Cost of dismantling/re-assembly
Transport costs

enquiry@hydratight.com

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Hot Tapping of Pipelines

Tapping of pipelines at full operating pressure
Meet deadlines safely and with minimum disruption to
production; Hydratights Hot and Cold Tapping service
provides the solution to plant and pipeline
modifications without the need to decommission, thus
maximising plant up-time. It is a precise process of
drilling a hole in a piping system under pressure,
without draining or spilling the products inside.

A valve (3) is mounted on the fitting (4) welded to the

line. The tapping machine (1) installed on top of the
valve drills through (2) the opened valve into the pipe
(5) and retains the coupon. Once retracted the valve
is closed and the machine removed.

Safe, fast tie-ins, repairs, modifications and bypass

of faulty or damaged systems all under full operating
conditions provides exceptional value and efficiency.

Benefits
On-line integration of tie-ins or
bypass lines without
production loss
Installation of thermowells with
minimum disruption

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PROCESS INTEGRITY

On-Line Thermowell Installation

Installation of thermowells
at full operating pressure
Hydratights technique of On-Line Thermowell
installation is approved by the TUV, offering assurance
of safe and efficient performance.

The connection of resistance thermometers or

thermocouples to existing pipelines under pressure
requires qualified engineers and special tapping
equipment.

Thermowell installation offers precise, robust and

permanent temperature measurement of process
media where the media may be corrosive, abrasive
or at high pressures.

Procedures
Welding of tapping nozzle to pipe
Assembly of gate valve and adapters
Assembly of tapping machine
Hot-Tapping of product pipeline
Disassembly of tapping machine
Positioning of thermowell on the machine
Assembly of tapping machine
Installing thermowell
Disassembly of tapping machine
Assembly of cap with thermosensor
Assembly of thermosensor

Limitations
Operating temperature up to 315 C
Operating pressure up to 48 bar
Thermocouples up to 50 mm

Benefits
Installation of Thermowell at
operating pressure
Minimum disruption to
process/production
Ideal for temperature
measurement of media where
the abrasive or corrosive nature
of the media can limit sensor life

enquiry@hydratight.com

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On-Line Mechanical Plugging

Emergency and scheduled stopping
of a liquid or gas flow in a pipeline
at full operating pressure
Purpose designed equipment in the hands of highly
skilled technicians enables fast and safe Mechanical
Line Plugging at full operating pressure.
Hydratights Line Plugging service is ideal for temporary
or permanent isolation of pipe work, allowing repair or
modification without the need for plant shut-down or the
loss of production or process media.

Benefits
Isolate, repair or modify pipework without production loss
Plug and bypass without
interruption to process flow

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PROCESS INTEGRITY

On-Line Freeze Plugging

Cryogenic freezing of process or production media at
full operating pressure to provide temporary isolation of pipe work
A non-invasive alternative to Mechanical Plugging
suitable for pipelines up to 48 diameter.

This process requires the operator to stop the flow

of media through the pipeline to allow freezing to
take place.

Freezing the media down to form a plug allows

modifications or repairs downstream without the need
to drain the pipeline.

Isolation of the downstream pipe is achieved by fitting

a purpose made enclosure through which cryogenic
Liquid Nitrogen or Carbon Dioxide are piped.
Rapid cooling of the process media inside the pipe
quickly follows forming a pressure tight frozen plug.
With no pipe modifications necessary, this temporary
plugging method offers a solution to maintenance or
repair needs.

Benefits
Continued production during pipe
work modification or repair
Integrity of pipe work maintained
no need to re-test plug location
Drainage of media avoided,
production performance
maintained

enquiry@hydratight.com

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On-Site Condenser and Heat-Exchanger Restoration

Repair and restoration of
condensors and heat-exchangers
Extend life of Heat Exchanger and Condensers by cost
effectively returning their tubes to optimum
performance using the CTI Shield/Seal Service.
The CTI Shield/Seal is a high grade alloy thin-walled
tube insert which prevents erosion and repairs
damage at the inlet and outlet of the tubes. This
process can in many cases return leaking tubes to full
service at a fraction of the cost of a full tube
replacement.
Close tolerance machining and the thin-wall design of
the insert prevent turbulence normally associated with
this type of repair.

Applications
Erosion at the tube end, pitting corrosion
Big corrosion cracks
Gaps due to corrosion
Improper tube widening
Weak tube to tube connections

CTI Full Length Tube LinerTM

as tube insert
If damage to the tubes is more extensive, the patented
CTI Full Length Tube Liner offers an effective solution
to erosion, corrosion wall thinning and plugged
leaking tubes.

Benefits
On-site cost and disruption of
plant transportation avoided
Fast, economic re-instatement to
original specification
The real alternative to full tube
replacement

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On-Line Safety-Valve Testing

Safety-valve tests under
normal operating conditions
Hydratight is able to test the response pressure of
safety relief valves under normal operating conditions.
This TV-approved computerised test system does
not require any increase of operating pressure.
Hydratights state of the art technology provides the
assurance and meets the obligation to regularly test
the operation of safety valves.
This market leading process enables testing without
the need to increase line pressure and eliminates the
need for unnecessary valve replacement.

Test procedure
The difference between operating and nominal
response pressure is simulated by a pulling force in a
special procedure. Applying this test procedure, no
increase of the operating pressure is required. This
method is applicable to all manufacturers and nominal
diameters of spring-loaded full-stroke or proportional
safety relief valves.

Benefits
Test procedure applicable for all sizes
TV approved certification for all tested valves
Enables testing of response pressures without increasing the operational
pressure
Avoids down time and labour costs associated with valve removal/
replacement
Eliminating costs for transport of the valves, avoids transport damage
Efficient management of test data including settings and results
Reducing costs
Suitable for gas, steam, condensate and water

enquiry@hydratight.com

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Qualification Management
An overview of Hydratights Approvals and Certificates.
Hydratight utilise quality standards and best practises worldwide.

German Certificate of
Approval DIN EN ISO 9001

German Certificate of
Approval SCC**

Netherlands Certificate of
Approval VCA

British Certificate of Approval

BS EN ISO 9001:2000

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German Certificate for

on-line leak-sealing

British Certificate of
Approval ISO 14001:2004

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PROCESS INTEGRITY

German Certificate for

safety-valve-testing

German Certificate for

installing thermowells

German Certificate of
Approval SCC**

British Certificate of Approval

BS EN ISO 18001:1999

Norweigan Certificate of
Approval DNV

US Certificate of
Approval ABS

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Global Standards Local Delivery

Our global network means you can rely on

the right people, products and services wherever you are in the world.

Email us at: solutions@hydratight.com

Or find your local representative at:

hydratight.com/contact

Material sourced from fully sustainable, managed forests

using Elemental Chlorine Free fibre.

HT/PI/E/12-09