ENGINEERING SOLUTIONS AND TECHNOLOGY FOR MAXIMUM PRODUCTION EFFICIENCY

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Saint-Petersburg Atyrau Baku Miass, Russia Vilnius, Lithuania Iran

INTRA Services Company has grown into the INTRATOOL independent engineering and manufacturing group of companies having consolidated all THE related services While effectively developing traditional services—on-line repair, INTRASOFT® integrated reliability management system, and improving overhaul efficiency services —the company continues increasing adaptability, integrity, and diversifying.

INTRA SERVICES COMPANY

FACTS ABOUT THE COMPANY

• Established in 2007• Belongs to the INTRATOOL group• 570+ employees

• Own operational and manufacturing facilities• A wide network of representative offices• The best service provider for oil refining and petrochemical

industries of the CIS market (World Refining Association)

To this end, the structure of the Group has been augmented to include:• INTRAFIT plant for production of couplings and pipes tee

located in the city of Miass, Chelyabinsk Region

LICENSES AND CERTIFICATESINTRA Services Company operates in accordance with the following licensing documents issued by Rostekhnadzor (FSETAN) and GOST R.Certificate of admission to work.The license for the industrial safety expertise.Integrated Quality Management System of INTRA Services Company is certified by the International Organization for Standardization (ISO) and the Occupational Health and Safety Assessment Series (OHSAS).to the ISO 9001, ISO 14001, and OHSAS 18001 (TUV NORD CERT) quality management system standards.

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CUSTOMERS

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570

SERVICE EXCELLENCE

INTRA has increased its capitalization 4 times during the last five years. Also, the company invested in operational fleet expansion and staff qualification enhancement. Owned manufacture in Russia helps further reduce costs for clients.

Employees are certified and highly qualified engineers and technicians vastly experienced in field operations .

INTRA SERVICES COMPANY

WORKING WITH FOREMAN FOR AT LEAST 1 YEAR

TRAINING IN THE UK AND USA

INSIDE TRAININGS AND DEGREES

The company aims at reducing production downtime, maximizing equipment life, while minimising maintenance, repair and overhaul costs.

CAREERS

EMPLOYEES

INTRA SERVICES COMPANY

OVER THE LAST

5

4

YEARS

The company has shown

fold growth

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CAREERS

Technical University aims at both the advanced training of INTRA employees and at addressing the need for education of customer’s own specialists.

INTRA has an educational license. Multiple training & educational programs have been developed.A wide range of high-grade pilot demonstration stands have been designed for the development of practical skills in innovative technology solution application.

TECHNICAL UNIVERSITY

COMPLIANCE

TRAINING PROGRAMS

• On-line repair methods • Modern management of bolted joints• Mechanical processing with portable equipment • Installation/removal of heat exchanger tube bundles• Ssafety valves testing

• Highly qualified trainers• Educational activity permit• Development of industry standards and training manuals

• Facility for practical skills testing• Lectures and handouts• Exams

Development of industry standards and training manuals

International standards adjustment

Elaboration of field procedures and training manuals

Specialized services development

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ON-LINE SERVICES Hot tapping and line stopping services LDARLeak sealing Composite repairSafety valves testing

MANUFACTURE Manufacture of equipment and fittings for hot tapping and line stoppingManufacture of leak sealing equipment and materials

JOINT INTEGRITY SOLUTIONS INTRASOFT Integrity Reliability Management System (IMRS) Fixed asset construction / turnaround maintenance supervisingBolting

INDUSTRIAL SERVICES Corrosion under insulationThermal spray aluminumPipeline and equipment chemical cleaningTank and reservoir cleaningHeat exchanger cleaning

ON-SITE SERVICES Flange facing Stud removalPipe cutting, beveling. Heat exchanger maintenanceTube bundle extraction

RENTAL AND WARRANTY SERVICES Equipment rentalMobile warehouse with tools and equipmentWarranty service center

HYDROCARBONS REFINING

CHEMICAL AND PETROCHEMICAL

UPSTREAM AND MIDSTREAM FACILITIES

OFFSHORE FACILITIES

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ON-LINE SERVICES Hot tapping and line stopping services LDARLeak sealing Composite repairSafety valves testing

MANUFACTURE Manufacture of equipment and fittings for hot tapping and line stoppingManufacture of leak sealing equipment and materials

JOINT INTEGRITY SOLUTIONS INTRASOFT Integrity Reliability Management System (IMRS) Fixed asset construction / turnaround maintenance supervisingBolting

INDUSTRIAL SERVICES Corrosion under insulationThermal spray aluminumPipeline and equipment chemical cleaningTank and reservoir cleaningHeat exchanger cleaning

ON-SITE SERVICES Flange facing Stud removalPipe cutting, beveling. Heat exchanger maintenanceTube bundle extraction

RENTAL AND WARRANTY SERVICES Equipment rentalMobile warehouse with tools and equipmentWarranty service center

POWER GENERATION

PULP AND PAPER INDUSTRY

HEAVY INDUSTRYMINING

ENGINEERING SOLUTIONS AND TECHNOLOGY FOR MAXIMUM PRODUCTION EFFICIENCY

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ON-LINE SERVICES

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HOT TAPPING AND LINE STOPPING SERVICES

INTRA HAS THE CUSTOMS UNION DECLARATION OF CONFORMITY FOR EQUIPMENT UTILISED

Hot tapping and line stoping services do not require production interruption or product transportation stoppage.

APPLICATIONS• New line connection• Nozzle installation • Pressurised line stopping• Defect pipeline section bypassing

ON-LINE SERVICES

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OPERATIONAL PARAMETERS • Pressure up to 100 bar at 38°C• Pressure 48 bar at 370°C• Tap diameters range from 12.5 up to 1400 mm• Line stop diameters range from 100 up to 1420 mm

HORIZONTAL, VERTICAL OR INCLINED TAPPING

IN SOME CASES TAPPING CAN BE PERFORMED FROM THE BOTTOM UP

PRODUCTS Natural gas, oil, water, steam, petroleum, various chemicals and gases, compressed air and more

PIPELINE MATERIAL Steel, stainless steel, cast iron, polyethylene, asbestos cement, concrete and more

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HOT TAPPING AND LINE STOPPING SERVICES

ADVANTAGES • All operations are performed without interrupting

production, pressure is maintained at the working level

• No costs for discharging and collecting the product • Environment pollution is avoided• A reliable & cost-effective temporary shut-down of

the pipeline

CASE STUDIES • Double two-position line-stop of a DN 500 pipeline

with bypass at an upstream facility, Russia • DN 100 - DN 800 hot tappings in refineries and

chemical plants of Russia, Lithuania, Belarus, and Kazakhstan

• Two-position line stop of a DN 700 pipeline in two locations simultaneously without bypass, Kazakhstan

• Double two-position line-stop of a DN 500 pipeline with bypass, Russia

ON-LINE SERVICES

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THERMAL IMAGING AND LDAR

TECHNOLOGY SCOPEELIMINATING FUGITIVE EMISSIONS OF:

• Steam• Water• Hydrocarbons• Aggressive chemicals

PROCESSING UNITS

MACHINERY

CONTROL VALVES

PIPELINE ELEMENTS

RESERVOIRS

Accuracy: +/- 1 ° C-40°C 2000°C

ON-LINE SERVICES

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TARGETS• Flange joints• Swivel joints (pumps and compressor shafts)• Valve sealings

• Flare lines • Tank reservoir vent valves

APPLICATION • Pipeline elements and fittings integrity assessment (metal

loss, defects, corrosion, welding defects, gasket damages) • Proactive management of emergencies and product leaks • Early detection of developing leaks of hydrocarbons • Classification of versatile product leaks and leak volume

analysis

• Third-party repair jobs QC• Pre-emergency condition equipment and pipeline section

detection• Damaged insulation and assembly defects detection • Repair operations optimization. Prioritising activities

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ON-LINE LEAK SEALING

ADVANTAGES• Quick response to leaks significantly reduces accidents

occurrence• Reduction of emissions into the environment• Increases lifetime of assets, saving materials• Significant reduction of costs associated with equipment

downtime and maintenance shutdowns• Reduction of product loss and energy consumption

INTRA OBTAINED CERTIFICATES OF CONFORMITY TO TECHNICAL REGULATIONS OF THE CUSTOMS UNION, GOST R AND THE PERMISSION TO OPERATE ON HAZARDOUS INDUSTRIAL FACILITIES OF ROSTEKHNADZOR (FSETAN)

The offered method is based on the modern approach implying on-line repair and maintenance of industrial pipelines and equipment.The method involves comprehensive application of a special bandage (enclosure) and unique compounds (synthetic rubber based fillers).

Leak sealing is performed online on a pipeline or a pressurized vessel without interrupting the production process. This ensures complete sealing in flange joints, gland valves, welded joints, housings of pipeline elements and various fittings.

ON-LINE SERVICES

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CASE STUDIES • АVТ-8 process unit. Product - oil (18 atm., 300°C) • Mineral fertilizers production unit. Product - pyrolysis gas

(37 atm., 960°C)• Gasoline by acid alkylation production unit. Product -

hydrofluoric acid (17.3 atm., 38°C)• Petrochemical industry unit. Product - feed water (180 atm.,

110°C)• Process unit АVТ-4. Product - oil (10 atm., 350°C) • Styrene production unit. Product - styrene (3 atm., 90°C) • Ammonia production unit. Product - urea solution (17 atm.,

165°C) • Catalytic reforming unit. Product - hydrogen gas (27 atm.,

510°C)• Hydrogen production unit (for deep oil refining). Product -

steam (40 bar, 400°C) • Hydrocracking unit. Product - gasoil (15 atm., 370°C) • Pyrolysis separation unit. Product - pyrolysis gas (42 bar,

70°C)• High-density polyethylene production. Product - feed water

(55 atm, 210°C) • Pyrolysis separation unit. Product - natural gas (30 atm.,

-150°C)

MORE THAN 2500 LEAKS STOPPED

tem

pera

ture

-196 °C

1200 °C

pres

sure

0.01 atm.

350 atm.OIL AND PETROLEUM PRODUCTS

APG

NATURAL GAS STEAM AND

WATER

AND ALKALIS

CHEMICAL INDUSTRY PRODUCTS

AGRESSIVE CHEMICALS

AMMONIA, ACIDS,

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INTRA Services Company offers composite systems for the recovery of structural integrity of damaged pipe sections to ensure corrosion protection and reinforcement of the pipe wall.

ADVANTAGES • No pressure drop required• Fast application and curing • No hot work• Applicable for complex geometry pipe parts• Works at temperatures up to 200°С• Resistance to chemically aggressive environments • No limitation on the operating pressure

COMPOSITE REPAIR

ON-LINE SERVICES

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INTRA KRM-U® epoxy composite system is a long-term repair solution. It combines glass/carbon fibers and high temperature resin, offering outstanding durability for long-term applications.

INTRA KRM-U® APPLICATIONS• Internal corrosion — up to wall through• External corrosion — wall thinning up to 90%• Mechanical defects — dents, gauges, etc.• Girth welds defects — discontinuity, lack of penetration

INTRA COMPOSITE MATERIALS

INTRA KRM-C® instant composite wrap is a ready-made material consisting of a prime coating and MCU (moisture cured urethane)-impregnated glass/carbon fiber

INTRA KRM-C® TYPICAL APPLICATIONS • External corrosion (wall thinning up to 90%)• Mechanical defects — dents, gauges, etc.• Subsea application

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SAFETY VALVE TESTING

Valve testing is used by oil and gas companies, chemical, nuclear and other industries with high requirements for reliability of control and safety valves.

PROVIDES ADJUSTMENT OF THE SET PRESSURE WITHIN +/- 1%Detects potentially dangerous problems, such as:• Leaky valve• Malfuncitioning valve• Valve with long release and simmer

(boiling)

ADVANTAGES • Applicable for all sizes of tested valves• Cost savings by eliminating the need of dismantling and lab

testing• Testing is carried out for a variety of working medias (gas,

water, steam)

INCLUDED INTO THE STATE REGISTER OF SAFETY VALVE TESTING SYSTEMS.INTRA HAS A CERTIFICATE OF COMPLIANCE GOST R AND THE PERMISSION TO OPERATE ON HAZARDOUS INDUSTRIAL FACILITIES OF ROSTEKHNADZOR (FSETAN).

ON-LINE SERVICES

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DEVELOPMENT AND PRODUCTION

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CERTIFICATESWe have all the necessary certificates and permits. Our certification covers oil gas and power generation industries.Own laboratory for performing corrosion, hydraulic, mechanical and complex diagnostic tests. We also perform product-in-field tests at customers’ facilities.

DEVELOPMENT AND PRODUCTION

INTRAFIT PRODUCTION OF PIPE TEES AND COUPLINGS

FACTORY INFORMATION Location: the city of Miass, Chelyabinsk RegionEstablished in 2007Enterprise area — 15,000 m2

ISO 9001 Quality SystemOwn railway siding

QUALITY ASSURANCE • Radiography• Ultrasonic flaw detection• Penetrant flaw detection• Hydraulic pressure testing for pressures of up to 1000 bar• Magnetic particle test

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QUALITY CONTROL DEPARTMENT (QCD) AND RESEARCH & DEVELOPMENT (R&D)• Testing laboratory• Design and technology bureau• Advanced R&D department

PRODUCTION UNITS AND AREAS• Mechanical processing• Heat treatment• Press shop• Welding shop• Warehouse• Logistics service

MECHANICAL PROPERTIES TESTS • Brinell hardness• Tensile strength and SMYS• Impact resistance (Sharpee test) at normal and negative

temperatures (down to -80°C)

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PRODUCE • The equipment for hot tapping and line-stop services — split

tees, sandwich valves, plug-in heads, purge valves, housings, tap adapters, sealings

• Pipeline components — nozzles, connectors, valve manifolds, manways, thermocases, air escape hatches and tees, inspection hatches, control unit points, spools, elbows, metal structures

• Moving and stationary supports• High pressure parts — elbows, reducers, tees• Housings and valve closures• Repair clamps, rings, couplings• Flanges

INTRAFIT PRODUCTION OF PIPE TEES AND COUPLINGS

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The method involves comprehensive application of a special bandage (enclosure) and unique compounds (synthetic rubber based fillers). This ensures complete sealing. Sealing leaks in flange joints, gland valves, welded joints, housings of pipeline elements, and various fittings. We offers a leak sealing solution on various systems - steam, water, chemical, gases and air on such units as:• Valve bonnet joints• Valve glands• Flange joints• Pipeline cracks or pinholes• Pipe unions• Pipe elbows, etc.

LEAK SEALING IS PERFORMED ON-LINE ON A PIPELINE OR A PRESSURIZED VESSEL WITHOUT INTERRUPTING THE PRODUCTION PROCESS

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JOINT INTEGRITY SOLUTIONS

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INTRASOFT® INTEGRATY MANAGEMENT SYSTEM

ADVANTAGES• Overhaul planning automation• Idle time minimisation• Processing units and performance control• Assets management optimisation• RCM, RBI data collection• Staff qualification upgrade

INTRASOFT®- integrated reliability management system includes software, engineering related services amd online database updates

Complete INTRASOFT® software package implementation will ensure high quality repair operations

JOINT INTEGRITY SOLUTIONS

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PRE-ENGINEERINGTechnical documentation processing and database handling

SUPERVISINGIndependent technical control of repairs and capital construction

FLANGE JOINTS MANAGEMENTTorque calculations, fastener and gasket material recommendations

MAINTENANCE AND REPAIR OPERATIONSMRO process management, comprehensive analysis and further recommendation development

MONITORING AND DIAGNOSTICSNon-destructive control

LEAK DETECTION AND REPAIR (LDAR)LDAR with further product loss analysis

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SUPERVISING BENEFITS• Reduced timeframes as a result of optimization of the

interaction between contractors• Significantly reducing the number of repeated pressure tests

and equipment start-up time• Facilities are back into operation due time in working

condition• Improves the reliability of equipment • Ensures trouble-free runlife during operation • Reducing the number of injuries to zero, increasing

compliance to the world’s best manufacturing practices as a result of occupational health and safety compliance and use of personal protective equipment

THE MAIN OBJECTIVES OF SUPERVISING• Quality assurance of repairs at customer’s site• Collection, organisation and analysis of the actual state of

disassembled and reassembled equipment during overhaul/repair

JOINT INTEGRITY SOLUTIONS

ASSET/CONSTRUCTION SUPERVISING

TYPES OF INDEPENDENT TECHNICAL CONTROL PERFORMED BY INTRA SERVICES COMPANY

FLANGE CONNECTIONS

ROTATING EQUIPMENT

MONITORING OF CONSTRUCTION

WELDED JOINTS

HEAT EXCHANGE EQUIPMENT

EC&I REPAIR

INCINERATOR REPAIR

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Timely detection of deviations from the design and compliance documentation

ASSETS CONSTRUCTION SUPERVISING

COMPARISON OF DIFFERENCES BETWEEN MONITORING OF CONSTRUCTION AND SUPERVISING

Introduction of the INTRASOFT® IRMS to the project construction stage

Quality control at all stages of work

Controlling the workscope and compliance

Monitoring performance time

Quality improvment methods developing

Control over timely elimination of project deviations

Monitoring of construction by the customer Supervising — independent technical control

OBJECTIVES

FEATURES

TASKS

TOOLS

METHODS

Ensuring project completion on time with the best quality and within the planned budget

Quality control of construction and installation operations

Identifying defects in constuction and installation activities

Recording of log notes, instruction, work stoppage until defects are eliminated

Periodic monitoring with visits to the consruction site

Monitoring customers’ production control system

Ensuring high quality of construction and installation operations. Preventing defects

Training for contractors. Work control at all stages of the process

Operational reports on abuse, work stoppage once violations of construction technology and installation performance are identified

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APPLICATIONS• Applying stud tensioners, torque wrenches, hydraulic torque

wrenches and other hydraulic tools• Tightening with torque control from 48 to 181,000 Nm

(imprecision of no more than 3%)• Assembly/disassembly of fasteners with nut size from 12 up

to 165 mm

ADVANTAGES • Work in confined areas with minimal mounting space• Non-standard bolting tasks• Torque control• Safe operations• Fast tightening• Minimizing the chance of leaks in operation of equipment• Possibility of extensive use in various industries

INTRA Services Company offers a wide range of services for flange joints management on-siteThe works are performed with high-tech professional equipment made by Hi-Force, Norbar, Usag and others

JOINT INTEGRITY SOLUTIONS

FLANGE JOINT MANAGEMENT

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CASE STUDIES • Assembling and dismantling stripper in urea shop with the

help of hydraulic stud tensioners, nitrogen plant, Russia• Installation of crushing and screening equipment at an open-

cast mine utilizing hydraulic ratchet head wrenches, MMC, Russia

• Installation of heating equipment with hydraulic wrenches for drive sockets, cement plants, Russia

• Installation of a tower crane using hydraulic wrench, NPP, Russia

• Installation of an activation unit of a diagnostic gas cleaning

unit (DCU) at a compressor station of the Nord Stream gas pipeline using hydraulic tools, Russia

• Installation of equipment in units: LCh-35-11/600, LCh-35-11/300 of an oil refinery, Russia

• Installation of equipment on a drilling platform, Russia• Maintenance of bolted joints of heat exchangers’ flanges in

an oil refinery, Kazakhstan• Maintenance of bolted joints and flange facing on an offshore

platform, oil and gas offshore field, Kazakhstan

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INDUSTRIAL SERVICES

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PREVENTION OF CORROSION UNDER INSULATION

Replacement of thermal insulation for prevention of corrosion is being delivered on live equipment without interruption of service

PROJECT PHASES:• Dismantling of cladding and thermal insulation• Assessment of heat tracing cable and coating condition • Visual inspection, corrosion detection, non-destructive

examination• Dismantling of heat tracing cable• Soft abrasive blasting of paint • Surface roughness and salt tests (Bresle method)• Application of new coating• Installation of thermal insulation and heat tracing cable• Installation of cladding

INDUSTRIAL SERVICES

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THERMAL SPRAY ALUMINIUM (TSA)

• INTRA has completed a series of localized TSA jobs on pipes and equipment to extend service life of critical elements of hazardous industrial facilities substantially

• TSA method ensures overs 30 years of corrosion protected surface

Work can be delivered on live equipment without interruption of service provided that necessary HSE and QA/QC plans are in place.

PROJECT PHASES:• Dismantling of cladding and thermal insulation• Assessment of heat tracing cable and coating condition • Visual inspection, corrosion detection, non-destructive

examination• Dismantling of heat tracing cable• Soft abrasive blasting of paint • Surface roughness and salt tests (Bresle method)• Application of TSA• Installation of thermal insulation and heat tracing cable• Installation of cladding

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CHEMICAL CLEANING

Chemical cleaning is an effective way to remove dirt and solid residues that appear on the process piping inner surfaces of any length and configuration. Chemical cleaning is a forced circulation of technical detergent (TD) inside the circuit under cleaning.

Durability and efficiency of all pipe elements directly relies on regular maintenance.

There are a few prerequisites that have to be met in order to provide high quality of scale cleaning:• Scrutinous selection of most effective solvent based on

aboratory studies and solvent ingredient combination analysis

• Obtaining specifications from the customer where pipeline details are provided

• Development of a cleaning technology

CLEANING STAGES • Cleaning the site from oil residues • Collapsible pipeline installation • Filling the process pipeline with TD • Static phase • Dynamic phase • Selection of samples to determine the degree of activity of

the TD • Neutralization, passivation • Dumping, disposal

BENEFITS• Chemical cleaning excludes or at least minimises any

installation activities• High quality of hardly accessible areas, discharge piping,

bends, turns• High level (up to 95%) of metal protection during washing• Safe non-toxic agents• Extended failure free operation• Biodegradability of ingredients• Permit to discharge used solvents in industrial sewage

INDUSTRIAL SERVICES

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COLUMNS HYDROCHEMICAL PURIFYINGChemical technological solutions which esnure high quality cleaning are preferable when it comes to determining the optimal treatment technology of contaminated surfaces. This increases the time and efficiency of equipment operation.

CLEANING STAGES • Control of product residues release from the column• Filling the column with TD • TD circulating within the column with filtration • Selection of samples all along the cleaning process• Adjustment of TD reactivity• Neutralization and passivation of the TD• Dumping and disposal of the TD

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TANK AND RESERVOIR CLEANING

TANK AND RESERVOIR CLEANING Tanks maintenance and recommended treatment periods:• Jet fuel, oil, unleaded petroleum products – 2 times a year• Oil with/wo additives – once a year• Motor oil without additives, industrial oil and other automobile gasoline, fuel, and other petroleum products similar in physical

and chemical properties – once in 2 years

INDUSTRIAL SERVICES

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CASE STUDIES• Cleaning a 5000 m3 vertical reservoir carrying vacuum gasoil

with the residual sludge 225 m3. All activities have been completed within 11 days. Customer’s deadline was 21 days

• Cleaning 6 5000 m3 vertical tanks and the total volume of sludge residue of more than 900 m3 within 30 working days. Customer’s deadline was 60 days

• Cleaned 62 vertical storage tanks with the volume from 2000 m3 to 20,000 m3, and removed more than 20,000 m3 of oil sludge at a single oil refinery plant from 2012 to 2014

EFFICIENCY • The degree of surface cleaning complies with the regulation

requirements• The oil product can be changed or repairs can be performed • Significant slowdown of corrosion processes• Increased operational capacity of the reservoir• Increased service life of the reservoir

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HEAT EXCHANGER CLEANING

Scale, rust and other deposits significantly reduce the performance of heat exchange processes, increase costs and harmful emissions into the environment.One of the most efficient and environmentally friendly methods of removing sediment is hydrodynamic cleaning.

IN MANY CASES HYDRODYNAMIC CLEANING IS AN ALTERNATIVE TO OVERHAUL REPAIR OF EQUIPMENT AND COMMUNICATIONS, APPEARING MULTIPLE TIMES MORE ECONOMICAL

INDUSTRIAL SERVICES

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EFFICIENCY • Reducing energy expenses• The heat transfer coefficient of untreated or poorly treated

heat exchangers is 10-35 W/m2K • The heat transfer coefficient of heat exchangers with high

quality purified pipe and shell side is 266 W/m2К — whereas the efficient operation requires 120–270 W/m2K

* These coefficients are applied for shell and tube heat exchangers for oil products with liquid-to-liquid heat exchange type

CASE STUDIES • Cleaning heat exchange equipment on the AVT-1 unit. We

have cleaned the total of 26 heat exchangers with the diameter of 800–1400 mm and the length of 6000 mm, as well as 42 sections of an air cooler unit.. Customer’s deadline for this work was 18 days. With the new high-performance equipment applied, the actual timeframe had been reduced to 12 days without compromising the quality

• INTRA has serviced 848 of heat exchangers of Ø from 400 mm to 1600 mm and 509 air cooler unit sections from 2012 to 2014 during the complex repair

• In 2012, we have cleaned up 42 heat exchangers with a total length of 75,138 linear meters. The cleaning was performed in winter at negative temperatures up to 25°C below zero. On call mobilization was 24 hours

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ON-SITE SERVICES

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INTRA Services Company provides reconditioning of flange faces machining

APPLICATION PARAMETERS:• Portable equipment• Flanged joints for machining Ø from 0 up to 3048 mm (up to

12,000 mm - upon request)• Surface machining quality up to 1.6 μm Ra• Applicable for flange surface machining of different profiles:

tongue/groove, male/female, ring type. Machine installation available both at ID and OD

• If installed on a tube plate, two-sided machining in one unit is available

• Solutions for non-standard technical requirements• Solutions for square and rectangular flanges

FLANGE JOINTS MACHINING EQUIPMENT IS AVAILABLE FOR RENT

ADVANTAGES • All activities are performed without dismantling flanges or

any equipment (on-site services)• Equipment service life is extended by restoring the sealing

surface of flanges• Labour force is reduced and the need in NDT of welded joints

in case of dismantling and removal of a flange for facing is eliminated

• Minimal work space required around the machining area• The total repair time reduced• Product leakage through a flange joint can be avoided

MACHINING FLANGED JOINTS FACES

CASE STUDIES

• Repair of 80 heat exchangers in an oil refinery, Kazakhstan• 53 flanges and tubeboards faced at a gas processing plant,

Russia• Ø 3048 mm flange facing for construction of a modern

polypropylene production complex, Russia• 4 Ø 4045 mm flanges facing at Liebherr floating cranes

bases, Russia• Ø 925 mm bottom flange facing at a vertical reactor and

flanges for lens seal of a petrochemical plant, Russia• 63 flanges and tube sheets facing within one year at an oil

refinery, Russia• 4 flanges facing of the foundation for azimuth thrusters of Ø

3000 mm for a shipbuilding company, Russia• Removing 23 different diameter studs as part of the repair

project of high-pressure devices at a chemical plant, Russia

ON-SITE SERVICES

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MECHANICAL STUD REMOVAL

When it is impossible to unscrew the stud in the traditional way, the experts of INTRA apply an integrated approach to solve the problem: • Drilling the remaining part of the studs from the device,

retaining threads in the machine• Calibrating the retained threads with a tap• Assembling flange joints

ADVANTAGES• The studs are removed while the threads are retained in the

device body• The equipment service lifelife is extended• Quicker repairs

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Cold cutting pipes and cylindrical parts

APPLICATION PARAMETERS:• Cold cutting of pipes• Beveling• Internal boring• Axially orientated machining• Machining range from 20 up to 1448 mm• Electric, hydraulic, or pneumatic drives

ADVANTAGES • Operation in hard-to-access places• Mounting equipment on pipeline fittings — outlet, pipe tee,

etc.• Cold work• Welded joint repair method• Working in harsh climate conditions

PORTABLE TOOLS FOR MACHINING ARE AVAILABLE FOR RENT

PIPE CUTTING, BEVELING

ON-SITE SERVICES

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CASE STUDIES • Repairing defective welded joints on a gas compressor station of an UGS

(underground gas storage facility). 217 welded joints of pipeline fittings with wall thickness of up to 20 mm Repaired. 09G2S steel, Russia

• Repairing defective welded joints in gas compressor stations of the main gas pipeline system. 111 welded joints of pipeline components (fittings) with wall thickness of up to 20 mm repaired. 09G2S steel, Russia

• Repairing welded joints of two natural gas transporting pipeline sections. 80 pipeline fittings welded joints with wall thickness exceeding 20 mm repaired. 09G2S steel, Russia

• Two 1000 OD welded joints of the MV series crane repaired. Wall thickness of 16 mm. The machine has been mounted on the crane, Russia

• Cutting out defect sections with wall thickness of 14 mm at the natural gas pipeline. Performed in the caisson of an underwater line crossing the Sura River, Russia

• Repairing welded joints of gas compressor stations of the main gas pipeline. 48 welded joints of pipeline fittings Repaired. 09G2S steel, Russia

• Repairing welded joints of three joint parts of LOS MGP 276 welded joints of pipeline fittings Repaired. 09G2S steel, Russia

• Repairing welded joints of a natural gas pipeline section. 6 welded joints of pipeline fittings Repaired. 09G2S steel, Russia

• Cutting pipes with beveling on an OPS of the main oil pipeline, Kazakhstan

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INTRA offers the following maintenance services for heat exchangers:

• Disassembly/assembly of heat exchanger flanged joints using hydraulic tools with the ability to control the tightening torque of threaded connections

• In-situ removing of membrane plates of heat exchanger distribution chambers

• Inspection, cleaning, lubrication of heat exchanger fasteners, detection of defects, and advice concerning replacement of fasteners

• Extracting tube bundles by means of hydraulic extractors

• Assessment of the tube bundle and sealing condition surfaces of flange joints — detection of defects and advice on facing flanges

• Cleaning tube bundles — mobile manual and stationary units for tube cleaning provide high-performance, safe, and fast tube bundles cleaning in heat exchangers

• Membrane plates bevelings of distribution chambers using portable machines

• Flange facing

EXPERIENCE• Complex repair of 6 heat exchangers, including tube bundles

extraction, petrochemical plant, Russia• Extracting 58 tube bundles, oil refinery plant, Russia• A range of activities for overhaul repair of the U-shaped heat

exchangers with a membrane in the distribution chamber—bolting, membranes cutting, extraction, facing)—oil refinery plant, Russia

EQUIPMENT FOR HORIZONTAL AND VERTICAL HEAT EXCHANGERS CAN BE USED BOTH AT A SPECIALISED REPAIR SITE OR THE UNIT INSTALLATION SITE

Accumulated experience allows INTRA to perform maintenance of heat exchangers of various design in order to keep them in operating condition, prevent emergency situations, and minimize customers’ expenses.

HEAT EXCHANGER MAINTENANCE

ON-SITE SERVICES

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EXTRACTION OF TUBE BUNDLESINTRA offers installation and removal services for tube bundles of various types heat exchangers with the length of up to 12 meters, diameter of up o 2 meters, and weight of up to 45 tones by means of tube bundle hydraulic extractors.

ALL ACTIVITIES ARE PERFORMED BY QUALIFIED PERSONELL WITH ADEQUATE TRAINING AND REQUIRED CERTIFICATES

ADVANTAGES• Significant repair time reduction• Heat exchanger damage prevention

• Minimal work space required• Immediate equipment pressure test success • Increased safety

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RENTAL AND SERVICING

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RENTAL AND WARRANTY SERVICES

CURRENTLY, THE COMPANY HAS A DIVERSE EQUIPMENT & PARTS STOCK AVAILABLE FOR RENT ACROSS BALTIC & CIS STATESThe equipment stock includes a wide range of tools, devices and machines designed to perform specialised repair and maintenance services for industrial enterprises.

INTRA offers the following high-tech professional equipment for rent for companies that face a wide range of problems when installing/removing/operating equipment, commissioning/dismantling and other activities:

• Portable tools for on-site machining of pipes and tanks • Aluminum and steel jacks, hydraulic cylinders, power packs• Hydraulic wrenches• Stud tensioners

• Torque multipliers from 0 to 47,500 Nm• Electrical and pneumatic torque multipliers with electronic

control devices providing torques of up to 100,000 Nm• Pneumatic impact wrenches

RENTAL AND SERVICE

57 www.sc-intra.com

INTRA offers mobile warehouses that are widely rented worldwide to industrial enterprises.

HIGH-PERFORMANCE EQUIPMENT FOR FLANGE JOINTS MAINTENANCE• Torque wrenches and hydraulic wrenches with associated

stations• Pneumatic impact wrenches

• Nut splitters• Labor saving tools — wire cutters, chain cutters, flange

spreaders, jacks and more

TOOLS AND EQUIPMENT MOBILE WAREHOUSE

EQUIPMENT REPAIR SERVICE CENTERINTRA provides service warranty and post-warranty repair of tools and equipment.

THE SERVICE REPAIR CAN BE PERFORMED AT THE SERVICE CENTER, AS WELL AS ON-SITE

ADVANTAGES

• Located directly on the job site or the repair shop• Hourly rental fee can significantly reduce costs• Equipment does not require repair, it is not a corporate asset

that can be found on the enterprise balance sheet, there is no need to purchase it

• Consultation on working with the tool is provided by qualified experts and technical support specialists

• Does not require maintenance, repair, replacement, rigging• Savings and rational use of financial resources

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59 www.sc-intra.com

WWW.SC-INTRA.RU/EN

HEADQUARTERS:

17 Magnitogorskaya St., 195027, St. Petersburg. tel./fax: +7 (812) 313-50-92/93 e-mail: intra@intratool.ru

REPRESENTATIVE OFFICES:MOSCOW Office 712, 108 Profsoiuznaya St., 117437, Moscowtel./fax: +7 (495) 781-38-07 e-mail: info@intratool-m.ruTYUMEN Office 301, 1 Permjakova St., 625013, Tyumen,Khokhlov Konstantin Mikhailovichtal./fax: +7 (345) 259-38-77e-mail: intra@intratool.ruVOLGOGRAD400078, Volgograd Office 310, 67 Lenina Ave.Grebeniuk Vladimir Vasilievichtel. +7 (8442) 26-99-61mobile: +7 (919) 791-55-15е-mail: volga@intratool.ruе-mail: grebenuk@intratool.ruYUZHNO-SAKHALINSKOffice 1, 27/2 Kholmsk Highway, 693000, Yuzhno-SakhalinskVdovukhin Mikhail Aleksandrovichtel./fax: +7 (4242) 77-14-39, 77-40-17mobile: +7 (914) 759-09-20e-mail: MVdovukhin@intratool.ruUFANigmatullin Iskander Mudarisovichmobile: +7 (919) 145-91-49e-mail: intra@intratool.ru

PERMOffice 8, 73 Promyshlennaya St., 614065, PermPaltsev Denis Olegovichtel./fax: +7 (342) 205-50-18/19mobile +7 (919) 498-10-51e-mail: intra@intratool.ruIRKUTSKGorelov Denis Sergeevichtel.: +7 (902) 578-81-44e-mail: intra@intratool.ruRYAZAN Romenets Igor Vyacheslavovichtel.: +7 (4912) 31-27-88fax: +7 (4912) 32-12-06e-mail: intra@intratool.ruSAMARA Office 602, 60/126 Solnechnaya St., 443031, SamaraPonomarev Mikhail Borisovichtel./fax: +7 (846) 200-09-93/94mobile: +7 (927) 205-93-67e-mail: intra@intratool.ruOMSKTel.: +7 (914) 054-86-50 E-mail: intra@intratool.ru MIASSbuilding 1, Severnaya Base, bypass of Turgoyakskoe highway, Miass, 456390Chelyabinsk Region,mobile: +7 (911) 998-78-63e-mail: EChekalev@intraservices.ruBALTIC STATES AND BELARUS UAB SK INTRA BALTIC77B Laisves Ave., Vilnius, Lithuania tel./fax: +370 5,203-04-51/53e-mail: info@intrabaltic.lt

AZERBAIJAN 95, Mezhdunarodniy Trade Center Heydar Aliyev Ave., AZ1029, BakuRakhimov Giundouztel./fax: +9 (9412) 567-38-85mobile: +9 (9450) 271-53-90e-mail: grakhimov@intraservices.ru

TURKMENISTANAshgabatTuraev Kamiltel.: +7 (981) 727-02-82е-mail: KTuraev@intra-line.ru

UZBEKISTANTashkentAbduvailev Utkir Abduganievichmob.: + (998 90) 956-10-33е-mail: U Abduvaliev@intratool.ru

KAZAKHSTAN7A Dostyk St., Atyrau, Atyrau region, The Republic of KazakhstanVolkov Alexander Sergeevichtel./fax: +7 (7122) 30-61-26, 32-26-63 mobile: +7 (911) 127-00-11; +7 (776) 104-40-10 е-mail: ASVolkov@intraservices.ruINTRA-KZ@intraservices.ru AstanaGafarov Artyom Vyacheslavovichmobile: +7 (701) 026-23-93 PavlodarAntoniuk Vladimir Vladimirovichmobile: +7 (701) 522-42-33