ThinJack Service

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Separating Seized Well Flanges

Page last modified

April 11 2024

"Tree wellhead repairs" is an upstream operating companies' "key theme". So, do you need to remove bolted flanges, valve covers (bonnets), hub clamps and bolt less hub flanges on wellheads, which present real challenges in separating?
ThinJack is a unique service to separate seized well flanges where conventional techniques either do not work or are unsuitable. As well as separating the flange, the ThinJack's hydraulic power draws seized and rusty studs through the bolt holes and overcomes seal friction. It delivers hundreds of tons of controlled force, exactly where it is needed, which is significantly higher than from conventional hydraulic spreaders or the pulling-power of drill strings. ThinJack's hydraulic power can separate in any direction whilst protecting sealing faces and hanger necks. It is possible to jack within gaps an order of magnitude thinner than needed for any other system. With controlled and even flange separation, the likelihood that flange studs become tilted and jammed inside the bolt holes is minimised. ThinJack's hydraulic power is an intrinsically safe alternative to cutting and grinding tools. Human "power", improvised tools and methods "forced beyond their safe limits" are eliminated. ThinJack provides a rigless and crane less service, though some of our work is enhancing the pulling limitations of draw works, drill strings and their connections.

Pros & Limitations

Reduces the risk of damage to flange faces during the separation process

Reduces the chance of injury to people or damage to well equipment

The service usually eliminates the need to cut bolts or studs: helpful if you need to suddenly or unexpectedly re-connect them.

Separates the flange by overcoming rust in the bolt hole annuli and between the ring gasket and the inside of the bolt holes

Service includes use of higher stroke lifting equipment after the binding force is reduced by ThinJacks

International experience on four continents

Highly rated service, experienced with the usual and rare issues and can advise and deliver accordingly

Inventory of stock for commonly encountered separations. ThinJacks may be purpose made for most flat and thin shapes, maximising force

Delivered as a service only by ThinJack Ltd ensuring optimal efficiency and proper system performance.

Low stroke but high force capability from the ThinJack itself. Service uses other, higher stroke, sub systems to complete the flange separation.

Specification

Specification Title	Specification Description
Areas of Application	Wellhead flange separation where ThinJack specialists can create a gap for insertion of "ThinJacks".
ATEX certified	94/9/EC. The ATEX Directve on equipment and protection systems intended for use in potentially explosive atmospheres. ThinJackGAP: Atex Zone 0 for sensors near well. Interactive display: ATEX Zone 2.
Implementation time	Typical time for separation: 2 to 24 hours, depending on binding forces of flange.
Certifications	Documented in accordance with 98/37/EC. The Machinery Directive.
Applicability	As with any jacking system or service the following may significantly reduce the effectiveness of the service: 1. "Crumbly" services to jack against. 2. Separation of flanges where bolts or studs are bent during flange make up or subsequently.
Capabilities	Initial gap needed: 2.5 mm though thicknesses down to 1mm can be made to order. Force available: Up to 2.5 tonnes for each square cm of ThinJack area. (May not be achievable depending on shape and construction.)
Services	The system is operated as a service by ThinJack Ltd only.
Sizes	Usually, to fit between the bolt holes and the flange circumference.