Industry & Background

This case study features a major domestic oil refining company. Oil refinery plants use extensive piping under high-temperature, high-pressure conditions, with a constant risk of leaks due to aging and corrosion. Rapid response when leaks occur is essential for maintaining stable plant operations.

However, pipe repair in large-scale plants is not simple. Major repairs requiring equipment shutdown affect the entire production schedule, so repair methods that minimize downtime were in high demand.

Challenge

The company faced two major challenges. The first was oil leaks from corroded equipment. Piping and equipment used for many years had progressed corrosion from within, with sudden leaks occurring frequently.

The second challenge was production stoppages due to air leaks from air piping. Pressure drops in instrument air and control air are critical issues directly affecting plant-wide operations, requiring rapid restoration. However, conventional repair methods required arranging specialist contractors, with response times often ranging from hours to days.

In this situation, there was a strong need for a method that would allow on-site maintenance personnel to perform immediate repairs themselves.

Product Adopted

The UV-curing leak repair sealant "LeakAid (LL-100-LACK)" was adopted to solve these challenges. LeakAid is a groundbreaking repair sealant that cures in just 1 second when exposed to ultraviolet light — simply apply it to pipe holes or cracks and shine the light for instant sealing.

Its special resin formulation provides reliable adhesion and curing even on oil-contaminated surfaces. Unlike conventional epoxy-based repair agents that require extended curing time, equipment can be restarted immediately after repair — the biggest advantage of this product.

Test Results

Prior to adoption, two tests were conducted under conditions close to actual usage.

Test 1: Sealing Micro Holes

LeakAid was applied and cured on a 0.5 mm diameter hole under 1.5 MPa pressure, and the leak was completely sealed. Stable sealing performance was confirmed even under high-pressure conditions.

Test 2: Repairing Large Cracks

A similar test was performed on a large 5 cm x 1 cm crack. Under 0.5 MPa pressure, LeakAid was applied and cured in multiple layers, and again complete sealing was achieved. This demonstrated that even damage previously requiring welding or pipe replacement could be addressed as an emergency repair with LeakAid.

Results

The adoption of LeakAid has produced the following remarkable benefits:

  • Works on oily surfaces — Reliable repairs can be performed even in oil-contaminated environments typical of oil refineries, significantly reducing the need for pre-cleaning.
  • Instant response through instant curing — With just 1 second of UV curing time, the time from leak occurrence to restoration was dramatically reduced from hours to minutes.
  • Avoided equipment shutdowns — Eliminating the need to stop equipment for repairs has greatly contributed to reducing production losses.
  • Reduced external contractor costs — On-site maintenance personnel can perform repairs themselves, eliminating outsourcing costs to specialist contractors.

Based on these results, LeakAid has been officially adopted as a standard emergency repair supply. It is stocked in maintenance departments across all plants, enabling immediate response whenever leaks occur. On-site feedback has been highly positive, with comments noting that work that previously took half a day can now be completed in minutes.