Swift, Innovative Response to Phenol Line Leak Emergency

An industrial client faced a critical issue with a clogged 8-inch phenol line with a large hole that had formed in the vertical line to vessel. Traditional methods involving removal, welding, pre- and post-weld heat treatment (PWHT), and non-destructive examination (NDE) were deemed impractical due to the extensive downtime they would entail...

A major chemical producer required critical flange facing services on an inverted 16-inch Oleum Column Flange Nozzle and Thimble Assembly during a Turnaround (TAR) at their facility. This project presented an extreme set of challenges that prevented the use of standard field machining procedures. Colt's solution successfully stood out by eliminating significant client costs and downtime through a unique, safety-focused methodology.

A major industrial client faced a critical maintenance issue at their facility: stress cracking had been identified on the dome of a vital DEHY Column Tank. The client required a partner capable of delivering a fast, high-quality, and structurally sound repair with minimal disruption. Colt's solution leveraged our expertise in advanced composite materials, providing a robust, custom-engineered solution that met the stringent safety and structural requirements of the high-pressure industrial environment.

The client's need was to isolate a single 4” pipeline servicing many systems inside the refinery and unofficially labeled “Slop Header” - thus necessitating a slop header linestop. Based on the temperature, pressure, and contents of the pipeline; it was determined that a #300 class pivot head linestop would provide an effective isolation...

A 36” general service water (GSW) valve had failed in the open position. Unable to close the valve, plant maintenance could not service a failed pump. The failed valve was in a very tight valve pit with only a few feet from a 54” common header to the inboard flange of the valve. This space would not allow for use of COLT's more robust pivot head linestop head, so folding head was the only option...

The client needed a temporary linestop in order to cut in a new spool piece to provide valving on the 20” main. The client also requested a permanent 10” bypass be constructed. Due to a very limited amount of pipe in the vault, there was only room for one tapping/stopping fitting.

When a 16” #150 gate valve failed in the open position, the plant requested a re-stop of the pipeline through a 20+ year old linestop fitting from a defunct competitor. Internal corrosion of the completion plug was locked in place, making it impossible to remove.

Following an unsuccessful repair attempt by another vendor, the Inlet Separator clamp at a large Petrochemical plant in Orange, Texas required immediate attention. The faulty clamp posed a significant operational risk, necessitating a rapid and precise solution to minimize downtime.

A refinery needed a highly corroded line repaired with a full enclosure. The line’s odd geometry with multiple landing points required highly precise measurements. The solution was an interlocking enclosure design that involved combining two CNC enclosures and one welded enclosure together. 

A petrochemical facility was in the middle of start up when a leak occurred on their 1000psi steam system. Colt’s large stock inventory and strategically scheduled machinists enabled the flange clamp repair to be completed within 24 hours of calculation approval.