In the process industry, unplanned downtime is not an option. When a leak occurs in a crucial cooling water pipeline, every minute counts. But what if the location of the leak is at a point where a standard repair clamp is physically impossible to install? AVK was presented with exactly this challenge by an industrial client.
A leaking 10” steel cooling water pipe (OD 273 mm) posed an acute risk to the production process. The complexity, however, was not in the leak itself, but in the environment: an extremely limited installation space of only 500 mm between a flange and a branch connection, and the presence of an obstructing tubelure (measuring or tapping point) that made the installation of a standard clamp impossible. The situation required a solution that would immediately seal the leak and be constructed seamlessly around the obstacles.
The solution was clear: a durable seal for the OD 273 mm pipe (under 3 bar operating pressure), without removing the obstacles. Because the tubelure obstructed the shell of a regular repair clamp, the engineering expertise and flexibility of the AVK production facility in Vaassen were required for a specially modified FS20 two-piece repair clamp. The repair clamp is manufactured entirely from high-grade AISI 316L stainless steel for maximum corrosion resistance in the industrial environment.
To keep the tubelure clear while still guaranteeing a full seal, the clamp was designed with a unique double lower bracket. This construction effectively creates a bridge over the obstacle, without compromising the clamping force or the integrity of the seal. The clamp, equipped with an EPDM rubber gasket featuring the characteristic wafer structure profile, was manufactured with a tolerance range of 260-280 mm. This allowed for pipe irregularities to be easily accommodated, while the specific cutout ensured the tubelure remained untouched.
Thanks to this customer-specific approach, the repair could be performed quickly and safely, without drastic modifications to the pipe network. The clamp, which is fully passivated after welding, not only guarantees an immediate stop to the leakage but also provides a durable long-term solution. This case highlights the strength of AVK repair clamps: Where standard products fall short, AVK delivers custom solutions. By combining our expertise with in-house production, we guarantee a perfect seal even when dealing with limited space and difficult obstacles.
