1.1 Introduction
Proactive maintenance in the petrochemical and oil & gas industries is essential for operational efficiency, safety, and cost control. Yet, when it comes to pipelines, especially those carrying hazardous materials, maintenance is often delayed until scheduled shutdowns or turnarounds to avoid the perceived risks of performing maintenance with the equipment in service. This approach may avoid short-term risks, but it leaves facilities vulnerable to potential incidents and lost production opportunities.
Ovolifts is an advocate for proactive maintenance, which often involves lifting lines while they remain on-stream or in service. While there is hesitancy in the industry to lift live pipelines, the costs associated with production downtime can lead some facilities to delay maintenance, accepting the potential risk of leaks or piping failures until a scheduled shutdown or turnaround.
At Ovolifts, we have developed and refined an Engineered Touchpoint Access methodology for addressing common piping failures such as Corrosion Under Pipe Supports (CUPS), also known as Touchpoint Corrosion (TPC) or Contact Point Corrosion (CPC), demonstrating that maintenance can be safely performed without interrupting operations.
1.2 The Cost Of Production Downtime
In today’s highly competitive market, the financial impact of production downtime is significant. Planned shutdowns are carefully scheduled to reduce economic losses, but they are not always sufficient to address the full spectrum of maintenance needs. Delaying pipeline repairs or inspections until these scheduled downtimes can lead to gradual wear and tear that may ultimately lead to unexpected breakdowns.
Operators should carefully assess the cost implications of deferring maintenance until a planned shutdown against the results of a comprehensive risk assessment for performing an in-service line lift. While certain piping systems, such as those involving high-pressure systems or hazardous chemicals and gases, may pose excessive risks for live lifting, our experience at Ovolifts demonstrates that the majority of pipelines can be safely lifted while in service, provided that robust risk mitigation measures are implemented.
Ovolifts’ on-stream lifting solutions allow facilities to address critical maintenance needs without halting production, providing a solution that keeps operations running smoothly and safely. By making this maintenance feasible outside of shutdown periods, facilities can avoid prolonged exposure to risks that might otherwise accumulate between scheduled downtimes.
1.3 The Challenge of On-Stream Lifting
The primary challenge with lifting pipelines on-stream is the potential risk of a leak or failure under live conditions. Many facilities hesitate to lift in-service lines using some type of pipe rack jack, largely because of the perceived risk associated with unplanned movement of pipes under pressure or the stresses applied to damaged sections of piping. However, the cost of avoiding these proactive measures can be high: as equipment and piping components degrade, the risk of unplanned outages and the costs of emergency repairs increase, potentially leading to costly and unsafe situations.
Ovolifts has addressed these concerns by engineering our lifting solutions to ensure safety and stability throughout the process. Our methods, which include rigorous pipe stress analysis, lift planning, procedures and specific features of the lifting equipment, provide unmatched security for lifting pipelines under live conditions.
1.4 Safety-First: Decades of Incident-Free Operations
With a record spanning decades, Ovolifts has built its success around on-stream lifting projects without a single incident. This track record speaks volumes about our adherence to safety protocols and our continuous refinement of lifting procedures. Central to our approach is "engineered touchpoint access" - a method we’ve developed to ensure precise lifting to provide safe access to pipe touchpoints during each lift. By adhering to an engineered process and implementing safety procedures, we mitigate risks associated with unplanned stress, movement, or loss of containment.
Our commitment to safety begins with a detailed analysis using ASME piping codes, such as B31.3 or B31.4, to ensure the integrity of each lift. Incorporating these standards into our "engineered touchpoint access" method allows us to pinpoint exact stress points and deflection limits, ensuring stability throughout the lift.
Additionally, our pipe rack jacks are hydraulically activated and mechanically lock in place to prevent accidental movement or dropping. This locking feature provides an added layer of security, minimizing the risk of sudden shifts and ensuring that each lift remains supported. Furthermore, our equipment offers real-time feedback on weights being lifted, enabling our engineers to confirm load calculations and make adjustments as needed.
1.5 The Ovolifts Advantage: More Than Just Equipment
Our approach at Ovolifts goes beyond merely providing lifting equipment. We believe in delivering a complete service package to our contracting partners that includes consultation, site planning, and hands-on training for facility staff. By ensuring that everyone involved understands the safety requirements and procedures, we enhance the overall reliability of on-stream lifting.
Moreover, our team is often requested to be on-site to supervise each lift, reinforcing our commitment to safety and quality. This hands-on approach helps us respond to any unexpected challenges that may arise and allows us to share our best practices with facility teams, empowering them to recognize and address pipeline maintenance needs proactively.
1.6 Bridging the Gap: Proactive Maintenance Outside of Shutdowns
For many companies, the idea of lifting live pipelines might initially seem risky. However, Ovolifts’ decades of safe, incident-free operations demonstrate that proactive pipeline maintenance is not only possible but beneficial. Our methods reduce the need to defer critical repairs, allowing facilities to manage wear and tear before issues escalate. By bridging the gap between scheduled turnarounds and immediate maintenance needs, we help facilities maintain productivity without compromising safety.
1.7 Conclusion
Ovolifts is committed to setting new standards for proactive maintenance on existing piping infrastructure to address problems such as Corrosion Under Pipe Supports (CUPS). By offering safe, reliable, and efficient on-stream pipeline lifting solutions, we empower facilities to take control of their maintenance schedules. Our refined methods, unparalleled expertise, and strong focus on safety allow us to minimize risk while maximizing operational uptime. As industry standards evolve, Ovolifts stands ready to lead the way in safe, effective pipeline maintenance.
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