1www. sc-intra.ru/en
ADVANCED ONLINE LEAK SEALING TECHNOLOGIES
2009
2013
INTRA Services is a hi-tech company with their primary goal to promote advanced repair & maintenance technologies for oil & gas, chemical, petrochemical, oil refining industries in Russia and in neighbour countries.
Process piping repair and maintenance standard for oil refining and petrochem-ical plants at pressures up to 10 MPa (100 kgf/cm2) authorised by Central Directorate of the Federal Service for Environemntal, Engineering and Nuclear Supervision (FSETAN) of Russia (Rostekhnadzor).
Best service company in the industry according to World Refining Association.
Endorsement by Agency for Strategic Initiatives in ‘New Business’ category.
Leak sealing technology standard for in-house up-time maintenance of pipe-lines, vessels and pressure equipment developed by Company and approved by FSETAN.
PROJECT DEVELOPMENT
ABOUT US
2007
TEAM MEMBERS 15IN CITIES
OF RUSSIA, CIS, EU COUNTRIES, THE MIDDLE EAST
REPRESENTATIVE OFFICES AND BRANCHES OPERATE
COMPANY FOUNDATION
2
2014 2015
2016 2017
Project team establishment. Testing of item models in Ansys system.
Online repair equipment manufacture launched in Miass.
Production of INTRA compounds Successful pilot testing at hazardous assets Manufacture certified as per ASME Endorsement by Industrial Development Fund (IDF) of innovative online repair and maintenance technology introduction project for oil&gas industry complex enterprises.
Pilot testing of IntraCase selfsealing clamps.
INTRA Service Company is the only company in Russia that provides the full scope of online repair & maintenance services:
• online leak sealing;
• hot tapping and line stopping;
• composite repair.
SUBSTITUTION IMPORT
100%
Design Technology Production Promotion
3www. sc-intra.ru/en
OVER
150MLN USDSAVED
INTERRUPTION COSTS
44
Any incidents at a hazardous asset result in:
• extra costs associated with maintenance and recovery of equipment;
• disruption of annual production schedule (profit loss).
Unscheduled maintenance results in disrupted profit schedule (medium efficiency plant):
Estimated loss per a single leak:
low pressure
low pressure
high pressure
high pressure
(reduc t ion of ammonia production by 2 tons per day)
MLN USDSAVED
2000 – 3000 K
600 – 1400 K
130 – 160 K
USD/DAY
USD/DAY
USD/DAY
USD/DAY
USD/DAY
USD/DAY
USD/DAY
Refinery
Petrochemical
Chemical Production
500 – 700 1500 – 2500
2000 – 5000 3000 – 10000
Steam, water
Hydrocarbons (natural gas)
1.
2.
3.
5www. sc-intra.ru/en
4 HOURSTO MOBILISEPERSONNEL ANDEQUIPMENTС МОМЕНТА ПОСТУПЛЕНИЯ ЗАПРОСАДО НАЧАЛА РАБОТ
2014 20172016
400JOBSPER YEAR
MORETHAN
18 HOURSTO COMPLETETHE TASK
2 DAYS TO REPAIR A LEAKINGDN1400 FLANGE
1+JOBS
HAZARDOUSASSETSFACILITIES
63
129 LEAKS REPAIRDIN 30 DAYSAT AN OILREFINERY
2600 LEAKS REPAIREDIN THE LAST3 YEARS
4
LOCATIONSOF RUSSIA28
PROJECTSCOMPLETED IN
NEIGHBOURCOUNTRIES
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28.02.201728.02.2017
28.02.2017
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Ñòåíä íàãðóçèòü ãèäðàâëè÷åñêèì äàâëåíèåì ñîãëàñíî ñõåìå Â. Ïîâûøåíèå äàâëåíèÿ äîëæíî ïðîèçâîäèòüñÿ ñ îñòàíîâêîé íà
Pðàá. /2 äëÿ ñâîåâðåìåííîãî âûÿâëåíèÿ âîçìîæíûõ äåôåêòîâ.Ñêîðîñòü ïîäúåìà äàâëåíèÿ íå äîëæíà ïðåâûøàòü 0,5 ÌÏà (5 êãñ/ñì 2) â ìèíóòó. Pèñï. = 15 ÌÏà (150 êãñ/ñì 2), Pðàá. = 10 ÌÏà (100 êãñ/ñì 2).5 Ïðè óñòàíîâêå çàæèìà îáåñïå÷èòü ìîìåíò ïðè çàòÿæêè ãàåê:
550...600 Í*ì ïîç. 11 130...140 Í*ì ïîç. 10
6 Ïîðÿäîê çàòÿæêè ãàåê íà çàæèìå è ôèêñèðóþùèõ çàæèìàõ ïîêàçàííà Ñõåìå Ã.7 Äëÿ óìåíüøåíèÿ òðåíèÿ ìåæäó êðåïåæíûìè èçäåëèÿìèèñïîëüçîâàòü ïàñòó Molykote ® 1000.
Ñáîðî÷íûå åäèíèöû
À2 1 ÈÒÃÅ.103012.100 Ïîëóçàæèì 1À2 2 ÈÒÃÅ.103012.100-01 Ïîëóçàæèì 1
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Ñòàíäàðòíûå èçäåëèÿ
8 Âèíò ñ ïîòàéíîé ãîëîâêîé è 8øåñòèãðàííûì óãëóáëåíèåì ïîä êëþ÷ÃÎÑÒ Ð ÈÑÎ 10642-Ì5 x 20-8.8-A3U
9 Âèíò ñ ïîòàéíîé ãîëîâêîé è 16øåñòèãðàííûì óãëóáëåíèåì ïîä êëþ÷ ÃÎÑÒ Ð ÈÑÎ 10642-Ì8 x 20-8.8-A3U
10 Ãàéêà ÀÌ16-6H.40Õ.IV.4.016 24ÃÎÑÒ 9064-75
11 Ãàéêà ÀÌ24-6H.40Õ.IV.4.016 24ÃÎÑÒ 9064-75
12 Ðûì-áîëò Ì12 ÃÎÑÒ 4751-73 413 Øàéáà 16.Ñò5ñï.I.5.016 24
ÃÎÑÒ 9065-7514 Øàéáà 24.Ñò5ñï.I.5.016 24
ÃÎÑÒ 9065-7515 Øïèëüêà À1Ì16-6gx140.40.40Õ.IV.4.016 8
ÃÎÑÒ 9066-7516 Øïèëüêà À1Ì24-6gx160.48.40Õ.IV.4.016 12
ÃÎÑÒ 9066-7517 Øòèôò 8x16.Õèì. Îêñ. ïðì. 4
ÃÎÑÒ 3128-70
Ìàòåðèàëû
18 Óïëîòíåíèå ''Viton'' 6õ9 ìì L=290 ìì 419 Óïëîòíåíèå ''Viton'' 9õ16 ìì L=203ìì 4
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1:41
ÈÒÃÅ.1011248.000 ÑÁ
Çàæèì Äó150 (Ó-881-17)Ñáîðî÷íûé ÷åðòåæ
160Îìåëå÷êîÊëàäîâ
È02.06.201702.06.2017
Ðóê.íàïð. Âåñåëîâñêèé 02.06.2017
02.06.2017
1 Îìåëå÷êî 13.06.2017-
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Êîïèðîâàë Ôîðìàò A2
1 *Ðàçìåðû èñïîëíèòåëüíûå, îñòàëüíûå äëÿ ñïðàâîê.
2 Ìàðêèðîâàòü óäàðíûì ìåòîäîì:1248-Äó150Ó-881-17 .
3 Îñòàëüíûå òåõíè÷åñêèå òðåáîâàíèÿ ïî 4834-014-82162778-2015.ÒÓ.
Ñáîðî÷íûå åäèíèöû
À2 1 ÈÒÃÅ.1011248.010 Ïîëóçàæèì 2
Äåòàëè
À3 2 ÈÒÃÅ.1011248.001 Ñòÿæêà 4
Ñòàíäàðòíûå èçäåëèÿ
3 Ãàéêà ÀÌ16-6H.40Õ.IV.4.016 ÃÎÑÒ 9064-75 484 Ãàéêà ÀÌ20-6H.40Õ.IV.4.016 ÃÎÑÒ 9064-75 85 Ðûì-áîëò Ì12.016 ÃÎÑÒ 4751-73 86 Øàéáà 16.Ñò5ñï.I.5.016 ÃÎÑÒ 9065-75 487 Øàéáà 20.Ñò5ñï.I.5.016 ÃÎÑÒ 9065-75 88 Øïèëüêà À1Ì16-6gx110.32.40Õ.IV.4.016 4
ÃÎÑÒ 9066-759 Øïèëüêà À1Ì16-6gx130.40.40Õ.IV.4.016 22
ÃÎÑÒ 9066-7510 Øïèëüêà À1Ì20-6gx160.40.40Õ.IV.4.016 4
ÃÎÑÒ 9066-75
Ìàòåðèàëû
11 Óïëîòíåíèå "Ãðàôëåêñ" 10õ10 8L=300ìì.
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DATA IN FIGURES
6
4 HOURSTO MOBILISEPERSONNEL ANDEQUIPMENTС МОМЕНТА ПОСТУПЛЕНИЯ ЗАПРОСАДО НАЧАЛА РАБОТ
2014 20172016
400JOBSPER YEAR
MORETHAN
18 HOURSTO COMPLETETHE TASK
2 DAYS TO REPAIR A LEAKINGDN1400 FLANGE
1+JOBS
HAZARDOUSASSETSFACILITIES
63
129 LEAKS REPAIRDIN 30 DAYSAT AN OILREFINERY
2600 LEAKS REPAIREDIN THE LAST3 YEARS
4
LOCATIONSOF RUSSIA28
PROJECTSCOMPLETED IN
NEIGHBOURCOUNTRIES
(1:4)
1
368
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2
369
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1:41
ÈÒÃÅ.1011248.000 ÑÁ
Çàæèì Äó150 (Ó-881-17)Ñáîðî÷íûé ÷åðòåæ
160Îìåëå÷êîÊëàäîâ
È02.06.201702.06.2017
Ðóê.íàïð. Âåñåëîâñêèé 02.06.2017
02.06.2017
1 Îìåëå÷êî 13.06.2017-
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Êîïèðîâàë Ôîðìàò A2
1 *Ðàçìåðû èñïîëíèòåëüíûå, îñòàëüíûå äëÿ ñïðàâîê.
2 Ìàðêèðîâàòü óäàðíûì ìåòîäîì:1248-Äó150Ó-881-17 .
3 Îñòàëüíûå òåõíè÷åñêèå òðåáîâàíèÿ ïî 4834-014-82162778-2015.ÒÓ.
Ñáîðî÷íûå åäèíèöû
À2 1 ÈÒÃÅ.1011248.010 Ïîëóçàæèì 2
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À3 2 ÈÒÃÅ.1011248.001 Ñòÿæêà 4
Ñòàíäàðòíûå èçäåëèÿ
3 Ãàéêà ÀÌ16-6H.40Õ.IV.4.016 ÃÎÑÒ 9064-75 484 Ãàéêà ÀÌ20-6H.40Õ.IV.4.016 ÃÎÑÒ 9064-75 85 Ðûì-áîëò Ì12.016 ÃÎÑÒ 4751-73 86 Øàéáà 16.Ñò5ñï.I.5.016 ÃÎÑÒ 9065-75 487 Øàéáà 20.Ñò5ñï.I.5.016 ÃÎÑÒ 9065-75 88 Øïèëüêà À1Ì16-6gx110.32.40Õ.IV.4.016 4
ÃÎÑÒ 9066-759 Øïèëüêà À1Ì16-6gx130.40.40Õ.IV.4.016 22
ÃÎÑÒ 9066-7510 Øïèëüêà À1Ì20-6gx160.40.40Õ.IV.4.016 4
ÃÎÑÒ 9066-75
Ìàòåðèàëû
11 Óïëîòíåíèå "Ãðàôëåêñ" 10õ10 8L=300ìì.
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Ïîç. Îáîçíà÷åíèå Íàèìåíîâàíèå Êîë. Ïðèìå-
÷àíèå
To repair a leak of flammable medium under pressure (development of documentation, fabrication of a split ring clamp, arrival of technicians to the site).
from request to start of work.
7www. sc-intra.ru/en
Preparation and reinforcement of the damaged pipeline area for further work (replacement of fasteners, installation of ring adapters, installation of a clamp to strengthen the flange joint)
Based on the medium pressure and the leak size various containment methods can be used to ensure the service is uninterrupted
Installation of impres packing and bandInstallation of sealant along the perimeter of a damaged pipeline areaInstallation of a ring clamp
Installation of a split ring clampInstallation of a peripheral clampInstallation of a sectoral clampInstallation of an enclosure clamp
LEAK SEALING IS DONE IN A FEW SIMPLE STEPS:
THE TECHNOLOGY
Online leak sealing is an advanced method of equipment maintenance without interruption of service.
PREPARATION
PRESSURE PRESSURE
LEAK AREA CONTAINMENT
8
Installation of injection adapters in the leak area for subsequent compound injection.
Compound injection (resin based filler with properties based on the media parameters) with an injection gun.
As the compound has cured a band or a clamp with injected sealant becomes a part of the pipeline, the leak has been sealed.
Application of band and unique compounds (synthetic resin fillers with varying properties based on leak temperature, medium, pressure, type and equipment design).A special clamp is installed in the leak area creating a seal. A special hydraulic tool is used to generate a higher pressure than in the system followed by
injection of a compound into the void. The higher pressure and the cured compound form a new sealing structure.Leak sealing is performed on a working pipeline or pressure vessel without interruption of service and provides a 100% seal.
THE CORE IDEA
PREPARATION FOR COMPOUND INJECTION
COMPOUND INJECTION
9www. sc-intra.ru/en
APPLICATION PARAMETERS
DEFECT TYPES: Defects in flange gaskets including pipeline fitting caps, welded joints and base metal defects in pipeline elements, equipment, vessels and tanks, gland valves, wellhead equipment elements and fittings at upstream facilities.
Oil and oil products
1200 °C 350 АТМ.
-196 °C 0.01 АТМ.
Chemically aggressive media
Associated gases
Natural gas
Ammonia, acids and alkalies
Chemicals
Steam and water
TECHNOLOGY APPLICATIONS
10
TECHNOLOGY BENEFITS
Emergency leak response ensures mitigation of incident/accident risks
Extended service life of fixed assets, material saving.
Lower emissions and oil spills (environemntal friendliness)
Lower product loss and reduced power consumption.
Lower costs associated with equipment downtime and service interruption
Safer operation in the uptime.
PRODUCTION AND TRANSPORTATIONCHEMICALPETROCHEMICALOIL REFINING
3.58%12.1%15.1%
69.22%
Projects completed
at upstream sites,oil refining, petrochemical
chemical, nucelar, food plants.
68%
22%
10%
AREA OF APPLICATION
Flange joints
Welded joints
Gland valves
1.
4.
2.
5.
3.
6.
11www. sc-intra.ru/en
Work methods and tools are defined by a combination of factors:
• working and rated parameters of conveyed medium;• design and operating indicators;• expert review reports;• defect progression modelling and current condition of the equipment
Clamps are engineered in the in-house engineering design department. The design engineers use ANSYS technolgoies to model innovative products.
Design of split clamp models as per existing standards:
• ASME PCC-2 Repair of pressure equipment.
• GOST R 52857.1-2007 Vessels and apparatus. Norms and methods of strength calculation. General requirements;
• STO 82162778-004-2013 Corporate Standard. Guidelines to application of leak sealing technology during in-house uptime maintenance of piping, vessels and equipment under pressure.
• Testing of mathematical and physical models of split clamps by finite element element method with Ansys Professional (excluding the field test phase).
• Standard design solution data base created.
• Engineering design departments classified as to their areas of expertise.
• Multi-level control system.
ENGINEERING PHASES
PHASE 1 DESIGN
PHASE 2 TESTING
ENGINEERING AND MANUFACTURE
12
Inquiry prioritisation system developed:
• the least load level;• the least dimensions;• the least material consumption;• shorter lead time and fewer phases.
• State-of-the-art clamp manufacture equipment: MAZAK, five-coordinate robotic turning circular milling
machining center.
• Production of consumables: 80+ varities of compounds.
PHASE 3 ANALYTICS
PHASE 4 MANUFACTURE
Split ring clamp of flanged joint
Reinforced ring clamp of flanged joint
Split box-shaped clamp of knuckle bend
Sector box-shaped clamp (tie-in)
Split peripheral clamp of flanged joint
Split box-shaped clampof rectilinear pipeline section
Split box-shaped clamp of T-joint (tie-in)
Sector clamp of flanged joint
Non-typical box-shaped clamps
13www. sc-intra.ru/en
• Low pressure (up to PN16);• High pressure (up to PN100).
Design and testing of split clamps with FEA Professional (ANSYS Professional):
• Testing of elements;• Testing of fasteners;• Claculation of fastener torques;• Material analysis;• Structure analysis
Testing at 1.5 x working pressure (maximum values) 10 mm through-wall defectNo visible leaking No visivle damage
Test at operation values during 12 hours. 10 mm through-wall defect No visible leakingAssessment crteria: maximum allowable pressure drop as per class “A”
CLAMP TYPES
PHASE 1 DESIGN
PHASE 2 TESTING
INTRACASE SELF-SEALING REPAIR CLAMPS
STRUCTURAL STRENGH TEST
INTEGRITY TEST
14
Test at operation values during 12 hours. Full pipe collapse simulationNo visible leaking
• Welded joints of pipe sections.
• Straight pipe sections
• Short-radius elbow, Tee, incut.
Applied on the following defects:
• Process• Mechanical• Corrosion and erosion
PHASE 3 APPLICATION
INTRACASE-M (mechanical), compression-type clamp
INTRACASE-S (subsea), underwater clamp
INTRACASE-W (welded), combined type clamp (compression, welded)
INTRACASE-C (cross-asset), can be adjusted to pipe ovality
GRIPPER STRENGTH TEST
15www. sc-intra.ru/en
64 АТМ.
420 C°
HYDROCARBON GASES
FLANGED JOINTDN1200
PRESSURE
TEMPERATURE
Operating parameters:
Transported medium:
Engineered items:
Pipeline element and valve type
AFTER
16
BEFORE
38 АТМ.
250 C°
STEAM
FLANGED JOINTDN1200
PRESSURE
TEMPERATURE
Operating parameters:
Transported medium:
Engineered items:
Pipeline element and valve type
AFTER
17www. sc-intra.ru/en
BEFORE
17 АТМ.
85 C°
NATURAL GAS
WELDED JOINT (TIE-IN)
DN50/250
PRESSURE
TEMPERATURE
Operating parameters:
Transported medium:
Engineered items:
Pipeline element and valve type
AFTER
BEFORE
18
20 АТМ.
100 C°
HYDROGEN- CONTAINING GAS
WELDED JOINT (KNUCKLE BEND) DN100
PRESSURE
TEMPERATURE
Operating parameters:
Transported medium:
Engineered items:
Pipeline element and valve type
AFTER
BEFORE
19www. sc-intra.ru/en
63 АТМ.
102 C°
FEED WATER
FLANGED JOINTDN80
PRESSURE
TEMPERATURE
Operating parameters:
Transported medium:
Engineered items:
Pipeline element and valve type
AFTER
BEFORE
20
46 АТМ.
350 C°
HYDROGEN- CONTAINING GAS, GAS-OIL
WELDED JOINT (CONCENTRIC REDUCTION) DN450
PRESSURE
TEMPERATURE
Operating parameters:
Transported medium:
Engineered items:
Pipeline element and valve type
AFTER
BEFORE
21www. sc-intra.ru/en
25.7 АТМ.
200 C°
HYDROGEN, WATER, CARBON OXIDES
WELDED JOINT(T-JOINT)
DN50
PRESSURE
TEMPERATURE
Operating parameters:
Transported medium:
Engineered items:
Pipeline element and valve type
AFTER
BEFORE
22
25.7 АТМ.
200 C°
HYDROGEN SULPHIDE GAS
FLANGED JOINTDN400
PRESSURE
TEMPERATURE
Operating parameters:
Transported medium:
Engineered items:
Pipeline element and valve type
AFTER
BEFORE
23www. sc-intra.ru/en
80 АТМ.
50 C°
SULFUR DIOXIDE
WELDED JOINT(TIE-IN) DN20/1000
PRESSURE
TEMPERATURE
Operating parameters:
Transported medium:
Engineered items:
Pipeline element and valve type
AFTER
BEFORE
24
37 АТМ.
247 C°
CONDENSATE
WELDED JOINT (KNUCKLE BEND) DN150
PRESSURE
TEMPERATURE
Operating parameters:
Transported medium:
Engineered items:
Pipeline element and valve type
AFTER
BEFORE
25www. sc-intra.ru/en
37 АТМ.
960 C°
METHANE
FLANGED JOINTDN15
PRESSURE
TEMPERATURE
Operating parameters:
Transported medium:
Engineered items:
Pipeline element and valve type
AFTER
BEFORE
26
16 АТМ.
850 C°
HYDROGEN,POTASSIUM CARBONATE
FLANGE WELDED JOINTDN25
PRESSURE
TEMPERATURE
Operating parameters:
Transported medium:
Engineered items:
Pipeline element and valve type
AFTER
BEFORE
27www. sc-intra.ru/en
42 АТМ.
-70 C°
CRACKING GAS
FLANGED JOINTDN50
PRESSURE
TEMPERATURE
Operating parameters:
Transported medium:
Engineered items:
Pipeline element and valve type
AFTER
BEFORE
28
18 АТМ.
12 C°
AMMONIA (LIQUID)
WELDED JOINTOF BENDDN300
PRESSURE
TEMPERATURE
Operating parameters:
Transported medium:
Engineered items:
Pipeline element and valve type
AFTER
BEFORE
29www. sc-intra.ru/en
120 АТМ.
110 C°
FEED WATER
FLANGED JOINTDN150
PRESSURE
TEMPERATURE
Operating parameters:
Transported medium:
Engineered items:
Pipeline element and valve type
AFTER
BEFORE
30
10.5 АТМ.
50 C°
FLUORHYDRIC ACID
FLANGED JOINTDN40
PRESSURE
TEMPERATURE
Operating parameters:
Transported medium:
Engineered items:
Pipeline element and valve type
AFTER
BEFORE
31www. sc-intra.ru/en
140 АТМ.
150 C°
FEED WATER
WELDED JOINT(T-JOINT) DN25
PRESSURE
TEMPERATURE
Operating parameters:
Transported medium:
Engineered items:
Pipeline element and valve type
AFTER
BEFORE
32
0.7 АТМ.
40 C°
FLARE GAS
WELDED JOINT(T-JOINT) DN600
PRESSURE
TEMPERATURE
Operating parameters:
Transported medium:
Engineered items:
Pipeline element and valve type
AFTER
BEFORE
33www. sc-intra.ru/en
24 АТМ.
174 C°
HYDROGEN-CONTAINING GAS, METHANE, CARBON OXIDES
PIPELINE VALVESDN400
PRESSURE
TEMPERATURE
Operating parameters:
Transported medium:
Engineered items:
Pipeline element and valve type
AFTER
BEFORE
34
ONLINE REPAIR
MANUFACTURE
INTELLIGENT SERVICES
INDUSTRIAL SERVICES
REPAIRTECHNOLOGIES
Hot tapping and line stopping Leak sealing
Composite repair
Recovery of equipment operation
Inspection control and leak detection
Testing of safety valves
Manufacture of hot tapping and line stopping equipment and fittings
Manufacture of leak sealing clamps and compounds
Miscellaneous online maintenance equipment and consumables
Intrasoft Reliability Management System
Supervising of fixed asset construction
Supervising of turnaround maintenance
Bolting
Technical University
Corrosion under insulation
Thermal spray metal coating
Chemical cleaning of pipelines and equipment
Cleaning of tanks and reservoirs
Cleaning of heat exchangers
Flange facing
Stud extraction
Cutting of pipes, end cutting
Maintenance of heat exchangers
Tube bundle extraction
Turn-key maintenance
Welding, repair of welded joints
INTRA SERVICE COMPANY: BUSINESS AREAS
10IN THE MARKET
YEARSMORE THAN
35www. sc-intra.ru/en
HEADQUARTERS:
St. Petersburg,
17, Magnitogorskaya Str.
+7 (812) 313-50-92/93
www.sc-intra.ru/en