A New And Safe Solution to

Separating Stuck Flanges

Alastair MacDonald
Industrial Solutions International Ltd
This paper was presented to the Oil & Gas Maintenance Technology Conference, Bahrain in
January 2009. It describes ThinJack - a patented method of separating stuck flanges which
are often the cause of costly delays in production, well workovers and pipeline maintenance
programs.

THE PROBLEM
The common denominator of the problems which ThinJack is called on to solve is rust, both
external and internal to the flanges, in the extent of corrosion itself and the resulting internal
friction.
Rust corrosion is caused by the effects in combination of age, operating atmosphere and
environment and of course the heat and corrosive nature of the product carried through the
flange unit. Rust fills up what little gap may exist between the flange surfaces. Often the gap
is minimal between the two surfaces some are less than 1mm - with just the remains of
original gaskets being removable.
Even where there is a gap which can take wedges, crowbars or hydraulic flange spreaders,
there is often not enough space surrounding the flange to insert and to safely operate these
tools. In some areas, due to the risk of use of generating sparks conventional tools can not be
permitted.
Additionally, there might be no pulling power available due to no cranes/lifting gear being
available or the cost being too great to install cranes just for flange removal. Often the
structure floor itself does not have sufficient loading capacity on which to place lifting
devices. Thus when conventional flange spreading and lifting systems can not perform,
another solution is required. ThinJack is such a solution, focussing on delivering very
powerful forces in very small gaps and exactly where the force is needed.

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WHAT IS THINJACK?
ThinJack is made of two precision-cut grade 316L steel plates sealed and bonded by TIG
welding. A pressure-insertion pipe penetrates the bonded area between the two plates.
The resulting steel envelope is hollow and typically only 2mm thick. ThinJack is made to
meet most flanges of API6A specifications and can also be engineered to custom designs.
To cope with the significant inflation pressures during energizing (q.v.), the welding quality is
a critical item of the ThinJack manufacturing process. Rigorous quality control is documented
throughout the manufacturing production flow, from the source batch of steel, through the
cutting and the welding processes.

PRINCIPLES OF OPERATION
The principle of operation of ThinJack derives from the scientific formula: F = P x A.
Force = Pressure x Area.
As seen in the typical flange separation problems encountered, the objective is to overcome
limitations of space and to maximize the forces generated through as small a delivery
mechanism as possible.
The operations involve energizing the ThinJack envelope by pressurizing it with
environmentally-safe hydraulic fluid to very high pressure levels. Depending upon the forces
of rust and friction to be overcome, these pressures can be up to 30,000 psi [>2000bar].
The pressure forces the two ThinJack plates apart but the plates remain held together by the
strength of the TIG welding. The result of the pressure is that the steel plates are actually
deformed out of shape. Once energized, the ThinJacks have successfully done their work, and
they can not be re-used.
The key issue is to ensure that the gap between the two flange surfaces is tightly packed so
that no energy forces are wasted filling any airgap. To achieve this, ThinJacks are used in
parallel, with energizing taking place consecutively or when sandwiched between one or more
sets of ThinShims. When hydraulic fluid is pumped at high pressure into the ThinJack, the
energy from the fluid is converted into forces perpendicular to the steel plates, forcing them
apart. The ThinJack expands to ~15mm delivering a separating force of > 350 tonnes or more
according to dimensions, design and opposing forces. ThinJack is designed for single
operation use, but several ThinJacks can be used in parallel to achieve larger separation
forces. The degree of force generated by ThinJack is surprisingly powerful.

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GENERATION OF POWERFUL FORCES

IMPERIAL UNITS. Pre calculated ThinJack Pressures between flanges, at different effective 60% effective area (A
areas. Tree cap removal. API6A 11" 3k psi possibility)

40% effective area

900,000 (Reasonably likely if Thin
Jacks pushing against a
T h in J a c k P re s s u re b e tw e e n

800,000
smooth and flat surface)
700,000
F la n g e s (p o u n d s )

If Drill string pulls on tree

600,000 cap (estimate)
500,000
400,000
300,000
200,000 ISI Ltd 20 Nov 07
100,000 All rights reserved.
0
14,504 21,756 29,008
Input Pressure to "ring" of 3 ThinJacks (psi)

Table A: Forces generated by ThinJack (imperial)

In this example (Table A) the graph describes the typical forces generated by ThinJacks made
to separate flanges of an API6A specification 11, 3000 psi lubricator flange, beneath a Tree
Cap offshore the North Sea. Table A presents the data in imperial units, psi and pounds force.
The X axis shows the input pressure to a ring of three ThinJacks surrounding the flange to be
separated.
The Y axis shows amounts of pounds pressure developed between the flange surfaces.
The calculations examine:
1. the combined surface area of the three ThinJacks deployed 294.9 sq cm;
2. the range of input pressures input to each ThinJack;
3. the forces generated at 40% and 60% effective area of the flange surfaces covered by
the ThinJacks. More than 60% effective area coverage may be unrealistic due the
challenge of getting the push on all the effective area, for example, the influence of the
protrusion of the wellhead/flange studs and their actual position within their holes.
Bolts or studs are not often centrally situated within the holes, but this is one of the
key factors which are determined during the initial site survey of the flanges to be
separated.
4. This particular project structure had a drill string available which in theory could have
been used as the pulling and lifting device, but in practice due to the rust and friction,

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 it was unable to separate the flanges with its own pulling power of around 300,000
pounds. And the drillstring was actually needed for an urgent drilling program.
5. The calculations show that at pressurizing ThinJacks with 29000psi [~2000 bar], the
ThinJacks generated forces of between 500,000 pounds [~226 tonnes] and nearly
800,000 pounds [~362 tonnes] depending upon the actual area covered by the
ThinJacks.
It should be noted that:
A) the pressures from TJ are very powerful though they are not infinitely powerful;
B) the pressure depends on the effective area, i.e. the smaller the air gap, the higher the force;
this is why getting the gap cleared and the correct use of ThinShims to fill the gap is crucial;
C) high pressures are important;
D) the pressures from the ThinJacks are extremely powerful but ultimately finite, and at that
point it is beneficial to work with other tools in combination, e.g. the drill string to provide
more pull. At this point the flanges will have been unstuck by the ThinJacks.
E) there needs to be a plan, agreed between ISI and Client, of what actions can be jointly
taken when all the forces of ThinJack are used and if it proves not to deliver enough pressure
to separate the flange. In this project, ThinJack reduced the forces holding the flanges together
to less than 6 tonnes, and the unit was lifted off with a gantry.
METRIC UNITS. Pre calculated Thin Jack Pressures between flanges, at different effective areas.
Tree cap removal. API6A 11" 3K psi.
400

350 60% effective area (A

ThinJack P ressure between flanges

possibility)
300

250 40% effective area

(Tonnes)

(Reasonably likely if Thin

200 Jacks pushing against a
smooth and flat surface)

150 If Drill string pulls on tree

cap (estimate)
100

50 ISI Ltd 20 Nov 07

All rights reserved.
0
1,000 1,500 2,000
Input Pressure to "ring" of 3 ThinJacks (Bar)

Table B. Forces generated by ThinJack (metric)

Table B presents the same example data in metric units, bar and tonnes.
The ThinJacks each have an outside diameter of 21.5 inches [55 cms] and a depth of 1.8cms,
thus providing 294.9 sq cms of useable surface area. At 2000 bar pressure the force generated
is equivalent to ~ 2000kgs, or 2 tonnes, per sq cm.

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THINJACK SYSTEM COMPONENTS
The main system components are:
THINJACKS. These are routinely
manufactured in radial form to address
flanges listed in the API6A specifications.
The ThinJacks are designed to meet each
project flange after an initial site survey
has confirmed dimensions and condition
of the target flanges. A typical issue of the initial survey is to determine the level, if any, of
chamfer around the flange edges, as this impacts greatly on available effective surface area.
ThinJacks are also manufactured in custom designs e.g. straight for non-standard flanges and
other purposes such as removal of protective concrete weight coating from pipelines.
THINSHIMS are individual shims precision cut to match exactly the ThinJacks, and they are
pre-prepared in a range of sizes from 0.1mm to 10mm thick to enable the filling of any size
gap-width and to ensure tight fit for the ThinJacks for the reasons explained above.
THINFLATE is the high-pressure pump system [rated to 36,250 psi] which includes sets of
similarly rated colour-coded hoses, and a steel, four- branch manifold. The manifold
incorporates individual needle valves for controlling the pressure into the individual
ThinJacks. Through this pressure balancing capability, the horizontal position of the
ThinJacks and the flanges being separated can be maintained. In the event one side of the
flange begins to tilt vertically and becomes jammed off-horizontal, the flow of pressure can
be directed to the individual ThinJack where it is most need to restore the horizontal position.
The ThinFlate pump uses environmentally-friendly hydraulic oil [e.g. Envirologic 146].

EXAMPLE PROJECT 1: North Sea Separation of Oil Bonnet

A 25-year-old christmas tree had to be brought to workshops onshore for bonnet removal. The
offshore location had neither space nor pulling or lifting facilities available to attempt the
bonnet separation offshore, and the maintenance project had tight timescales to meet.
The bonnet was 380 mm outside diameter, and the gap between the flange surfaces was only
1.7mm. This gap had been made after two hours spent removing the rust and cleaning the
surfaces as best as possible. Two ThinJacks were configured to provide 172 sq cms of surface
area coverage with the potential of generating a force of 103 tonnes.

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 The ring of two ThinJacks was inserted into the
prepared gap between the flange surfaces (Fig.1).
The ThinJacks were energized initially to 8700psi
(600bar) with a stroke of 9mm. This overcame a
force of 34 tonnes caused by rust between bolts
and the bolt holes and created some initial
movement. However the bonnet became stuck on
the rear studs.
Fig. 1: Ring of 2 ThinJacks inserted
under bonnet to be removed
This necessitated using the manifold valve
control procedure previously described to level off the bonnet back to a horizontal position.
The ThinJacks at the rear of the bonnet were then
pressurized to 19000 psi (1310bar) delivering 197
tonnes force. The horizontal state was restored and
a sufficient gap created (Fig 2) to allow removal of
the bonnet with the aid of hydraulic flange
spreaders. During this step by step process, the
energized ThinJacks can be removed by leverage
and replaced with a combination of new ThinJacks
and ThinShims and wedges. Fig. 2: Energized ThinJacks create
the initial gap under bonnet

EXAMPLE PROJECT 2: Gulf of Mexico Separation of 5000lb Master Valve Block

In the Gulf of Mexico, ThinJack was specified to
assist in removing a 20year-old 5000lb Master
Valve Block to enable bolt replacement (Fig 3).
The challenge was to overcome the severe rust
deposits on both the outside and the inside of the
unit, and to overcome the heavy friction around
the studs caused by the rust on the bolts and
wellheads.
Fig. 3: Master Valve Block to be separated.
The Master Valve Block has a studded bottom,
i.e. no bolts and nuts. The gap at the break point between the flange surfaces was less than
3mm, with no room to insert or use wedges, and there was no time to strengthen platform
beams for casing jacks.

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The ThinJacks used were made to
meet an API6A specification 7 1/16,
10,000psi flange. The high levels of
rust and friction required six separate
combined ThinJack and ThinShim
operations, each opening the gap by up
to 10mm, (Fig 4). This resulted in a
sufficient gap being created to allow
safe entry for the stepped jaws of an
hydraulic flange spreader system. Once it Fig. 4: Energized ThinJack sandwiched
was free, the Master Block was then lifted between two sets of ThinShims

by a crane mounted on an offshore barge.

Technicians often try and insert hydraulic flange spreaders when they can not be properly
placed square on, both horizontally and vertically, because of insufficient gap. This frequently
results in the jaws breaking off and damaging the flange surfaces. ThinJack helps to ensure
adequate space is available for the jaws of hydraulic or mechanical flange spreaders.

EXAMPLE PROJECT 3: Australia Removal of Hub Clamp

The task required removal of fireproof Hub Clamps holding 11inch and 13 5/8inch, 5000 psi
flanges as part of a major workover programme. Each 11 inch hub clamp has two bolts and
the 13 5/8inch has 4 bolts. All bolts were seriously stuck because heavy rust was gluing the
two halves together along the bolts. The rust was bonding most of the existing gap and was
significantly deposited around the retaining rings.
Rust removal had been done offline with
intrinsically safe grinding, scraping and air drills
to ensure as clean surfaces as possible.
As previously mentioned, in order to maximise
their forces, the ThinJacks need to push against as
clean and flat surface as possible.
This project required specially designed straight
ThinJacks. The single design, but made to fit both
hub clamp flange sizes, was straight, and measured Fig. 5: ThinJack and ThinShims
inserted in between Hub Clamp
approximately 260mm length x 30mm depth x 2mm
wide.

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The site survey indicated that the ThinJacks might be required to push with a force of up to
242 tonnes [534,000 pounds] to successfully separate the hub clamp flanges. Each ThinJack
had an area of 100.8 sq cm. A protective screen of scaffolding pipes was erected to protect the
horizontal tie pins.
The initial gap between the hub clamp surfaces was 10mm, and this was created by removal
of a significant amount of rust. Operations technicians had previously tried unsuccessfully to
use crowbars and wedges to separate the flanges. A sandwich
of ThinJack and ThinShims was inserted as shown in Fig.5.
The ThinJacks were energized to 4000 psi, which delivered
about 75,000 lbs of force and broke through the rust. The gap
was widened to 40mm (Fig.6).
The decision to use ThinJack came after many man-hours had
been expended in previous projects trying to pry the clamp
apart with crowbars, sledgehammers and wedges. A further
deciding factor was to prevent injuries and any damage to
Fig.6: ThinJack and ThinShims collateral equipment. The ThinJack operation took only two
inserted between Hub Clamp
hours.
SAFETY ISSUES
The ThinJack system is CE rated to ATEX ignition hazard assessment Group II category 3
(Gas and Dust). This means that it is suitable for use in Zones 2 & 22 (places where an
explosive atmosphere will only rarely occur and last for a short time). The US (NEC)
equivalent is Zone 2 (explosive atmosphere unlikely or infrequent).
All platforms are monitored for gas and whenever it is essential for photographs to be taken as
part of the initial site survey, these are always subject to issuing minor hot work permits.
Hazard assessments are a key part of the ThinJack initial site survey HSE procedures.
Anti-static protection is addressed particularly with the ThinFlate pumping system. This is
grounded/earthed to prevent sparking. This illustrates another frequent reason why ThinJack
is so often required i.e. where the local operating area environment is too gaseous and risky
to allow the danger of sparks being generated from hammers or wedges during flange
separation tasks.
Included in the safety assessment are key safety margins at all stages of the system and
process: The welding of the ThinJacks is such as to permit no leakage at the welds until at
least 40,000 psi is reached. The maximum ThinJack operational pressure currently in use is up
to ~30,000 psi [~ 2000 bar]. If a leak at a weld does occur, there is no explosion, only a jet of

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the hydraulic oil as pressure inside the ThinJack is quickly released. The Technicians and
immediate operating environment are protected by distance and safety procedures against
danger. The pump, manifold and connectors are function tested as a system to 36,250psi
(2500 bar) and safety rated to at least 40,000 psi. The hoses are safety rated to 100,000 psi.
Because personnel are dealing at close quarters with these significant pressures, ThinJack has
significant operational safety procedures. Starting from the risk assessment performed during
the initial site survey, through to personal protection items for the Technicians during
operations. There is a mandatory 5-meter safety and exclusion zone between the Technician
and the ThinJacks. Whenever possible, toughened polycarbonate screens are also positioned
between the Technician and the ThinJacks being energized. Behind all the focus on safety
there is a quality control system which tracks each ThinJack from its batch of steel, through
the cutting and welding processes, and to the packaging stages and right up to its use on site.
Additional safety procedures entail checking: pressure barriers are in the well, and are not
leaking, before separating; that there is no asbestos in the gaskets and that there is no
hydrogen sulphide (from organic matter) behind the flange to be separated.
TIME SAVINGS AND COST BENEFITS
The ThinJack benefits quickly become apparent in the time and cost savings. It should be
remembered that ThinJack is not the technology for routine workovers or flange splitting
which might be done by conventional systems. ThinJack is best suited for those problems
where conventional tools and systems have failed, or look like they will fail, to separate stuck
flanges.
As an example, one project in the North Sea here illustrates and quantifies the time and cost
savings delivered by ThinJack.
The project required flange separation of a number of wells on the cellar deck of an active
offshore facility. Previous attempts involved pulling with the drillstring and drawworks using
a lifting force of 45 tonnes. The trees still did not separate easily, with the operations taking
anything from between 15 to 31 hours to complete a separation. During all this time
production had to be stopped.
When the ThinJack system was used to kickstart the flange separation, it was found that the
time taken per wellhead was dramatically reduced - by more than 9 hours. Translated into
direct savings on an average wellhead, this meant reductions of 60% in both time taken and in
costs of lost production. And these savings did not include savings from the additional
benefits of operational safety or the fact that ThinJack does not damage flange surfaces and
thereby avoiding costs and delays in any re-milling of the flange surfaces.

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WELL SEPARATION No. of Service Time
METHOD hours converted to US $ of
USED lost Production
revenues*

A DRILLSTRING & 15 $90,000

DRAWWORKS

B DRILLSTRING & 31 $186,000

DRAWWORKS

C DRILLSTRING & 6 $36,000

DRAWWORKS
and ThinJack

*assuming well flow of 100bbl/hour at US $60/bbl

On wells A & B, even pulling with the drill pipe to a weight of 45 tonnes, it was not possible
to separate the trees.

By using ThinJacks on well C, and pulling with the drill string & draw works, to 34 tonnes,
the tree separated easily.

Table C: Time and Cost Savings achieved by using ThinJack in well workovers

It should be borne in mind that ThinJack is not a technology for routine maintenance
programmes; ThinJack is most suitable only when all other traditional or conventional
systems have failed. By definition therefore, ThinJack is needed whenever time is of the
essence in terms of restoring production or achieving working repairs.
Whether the oil price increases/reduces from its current market rate is not necessarily the only
issue. The real benefits are of course that ThinJack significantly reduces both direct and
indirect servicing costs.
CONCLUSIONS
ThinJack has converted a proven scientific formula into a simple and sound engineering
concept. There are no computers, electronics or software involved in the operation of
ThinJack. ThinJack has proven itself all over the world as a successful technical solution to
the industry-wide problem of separating stuck flanges where asset integrity can be maintained
with minimal, if any, collateral damage. ThinJack operations are intrinsically safe and
flexible, applying powerful force and pressure always where it is most needed. And, ThinJack
delivers significant time and cost savings. In the words of a satisfied major global operator:

ThinJack does exactly what you say it does it separates stuck flanges.

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