Localised Weld Testing Streamlines Critical Valve Replacement in Australia

Welded repairs and modifications must undergo leak or strength testing to confirm their integrity. Conventionally, this can require an entire piping spool or process system to be flooded and pressurised. On large-diameter, mature pipework, a full-system hydrotest can extend the shutdown, increase test-water volumes and expose equipment outside the immediate worksite to unnecessary pressure and potential leakage. The project therefore required a controlled method that would test only the newly completed welds.

During a planned shutdown, the 36” pipeline was vented and purged before the defective welded valve was cut out and removed. New flanges were then welded to the pipe ends, and an Inline Weld Test Tool was positioned across each new flange weld. The tool’s seals were hydraulically set, creating a compact test cavity that was filled with water and pressurised to 213 bar. This allowed each weld to be verified without subjecting the wider system to a full hydrotest. The robust seal arrangement also supports reliable performance where pipework is pitted or slightly oval.

The tools were supplied with fully certified ancillary equipment and a workscope-specific technical procedure, supporting safe and efficient execution while minimising maintenance downtime.