leak coming from corroded valve

Leak Sealing

Avoid Costly Shutdowns with Engineered Leak Sealing Solutions

At KAYO Engineering Inc., we specialize in the design and engineering of Engineered Pressure Enclosures (EPEs) — safe, compliant, and effective leak sealing solutions that keep your pressurized systems online. Protect your uptime, safety, and system integrity with our custom-engineered products.

Our Leak Sealing Background

KAYO Engineering Inc. is a dedicated mechanical engineering firm with deep expertise in leak sealing. Our team of professional engineers and designers craft tailored solutions to eliminate leaks without requiring operational shutdowns.

We collaborate closely with industrial maintenance providers, operators, and plant managers to design leak sealing solution precisely tailored to your equipment, operating conditions, and regulatory requirements.

Whether you’re facing leaking gaskets, thinning pipe walls, or compromised joints, we deliver fit-for-purpose solutions engineered to meet code and perform reliably under demanding, real-world conditions.

  • To efficiently engineer innovative, fit-for-purpose leak sealing solutions that:

    • Prevent unscheduled shutdowns

    • Protect personnel and equipment

    • Maintain plant efficiency

    • Support environmental safety

  • • No Shutdown Required

    Avoid costly downtime—our leak sealing solutions are engineered to be installed while systems remain pressurized and operational.

    • Engineered Solutions, Stamped and Certified

    Each EPE is reviewed and approved by a licensed professional engineer, accompanied by a complete P.Eng.-stamped design package to ensure safety, performance, and compliance with all applicable regulations.

    • Expert Knowledge of Pressure Equipment Codes

    With years of experience, we design in full compliance with industry standards, including CSA B51, ASME BPVC Section VIII Div. 1, ASME B31.1, ASME B31.3, and ASME PCC-2.

    • CRN Registration Support Across Canada

    We specialize in CRN (Canadian Registration Number) applications and work directly with pressure authorities like ABSA, TSSA, TSBC, and others—managing the process from submission to approval.

    • Safety First

    Our designs prioritize mechanical integrity and operator safety, minimizing risks during and after installation.

    • Responsive and Reliable Service

    We deliver prompt turnaround for urgent repairs or planned maintenance, minimizing risks and maximizing uptime.

    • Trusted by Critical Industries

    Serving oil & gas, power generation, nuclear, petrochemical, manufacturing, and other sectors where failure isn’t an option.

Our Leak Sealing Process

  • 1 ➞ Leak Assessment & Consultation

    Our process begins with a detailed assessment of your system, including:

    • Leak location and severity

    • Operating conditions (pressure, temperature, and media)

    • Design requirements for safety, compliance, and performance

    • Applicable regulatory codes and jurisdictional standards

  • 2 ➞ 3D Modeling of Your Equipment

    Using data from your field personnel or third-party providers, we develop accurate 3D models of your equipment to replicate real-world conditions. These models form the foundation for designing custom-fit Engineered Pressure Enclosures (EPEs) that ensure precise fit and reliable performance.

    Sources of Measurement Data:

    • Hand Measurements: We recreate equipment geometry from field sketches and measurements, capturing all critical dimensions and nearby obstructions.

    • 3D Scanning: When laser scan data is collected using a 3D scanner such as the Artec Leo or similar systems, we convert the point cloud data into precise 3D models, capturing complex geometries and surface details.

  • 3 ➞ Custom EPE Design & Analysis

    Every Engineered Pressure Enclosure (EPE) is custom-designed to your system’s exact requirements. We ensure full compliance with all applicable codes and standards, including:

    • CSA B51

    • ASME BPVC Section VIII Division 1

    • ASME B31.1 and B31.3

    • ASME PCC-2

    • ABSA AB-521

  • 4 ➞ Engineering Design Package

    You will receive a complete, P.Eng.-stamped Engineering Design Package containing all documentation required for fabrication, verification, and regulatory submission. Each package includes:

    • General Assembly and Fabrication Drawings – Clearly detailed to support accurate manufacturing and installation.

    • Engineering Analysis and Calculations – Complete design validation in accordance with applicable codes and standards.

    • 3D Model Files – Fully detailed digital models of the Engineered Pressure Enclosure (EPE) to streamline manufacturing and quality assurance.

  • 5 ➞ CRN Application & Pressure Authority Submissions

    We handle the entire CRN (Canadian Registration Number) process on your behalf. From start to finish, we ensure smooth, efficient submissions to the appropriate regulatory body in your jurisdiction, including:

    • ABSA – Alberta Boilers Safety Association

    • TSSA – Technical Standards and Safety Authority (Ontario)

    • TSBC – Technical Safety BC

    • ACIC – ACI Central (for select provinces/territories)

    • TSASK – Technical Safety Authority of Saskatchewan

Common Leak Sealing Solutions

  • Leaking Sealing Tongue Clamp

    Tongue & Channel Clamps

    These clamps seal leaks at flanged joints caused by damaged or compromised gaskets and seals. Tongue clamps use a machined tongue to fit into the flange gap, allowing sealant to be injected directly into the joint. They are effective for most flanged joints and especially useful for misaligned flanges. Channel clamps seal around the outer edge of the flange, making them ideal for narrow gaps where a tongue clamp cannot be used.

  • Leak Sealing Plate box Images

    Plate Box Enclosures

    Machined from solid plate, this two-piece bolted enclosure is a robust and time-efficient solution. The internal cavity, sealing surfaces, and bolt holes are machined, making this option cost-effective due to its straightforward fabrication process for many applications.

  • Two industrial steel and copper cylindrical components with mounting brackets, viewed from different angles.

    Welded Enclosures

    Constructed by welding together shells, nozzles, lugs, and end plates before machining, welded enclosures are ideal for larger components where plate box enclosures are no longer practical, or where a lighter enclosure is needed compared to plate box designs.

  • A metallic roller with brown ends shown in three-quarter and front views.

    Weld-On Enclosures

    These permanent, field-welded enclosures are ideal for high-vibration environments, significant thermal cycling, or when long-term durability is essential. Typically built in two halves, they are machined and weld-prepped for on-site and live welding installation.

  • Two mechanical components with metallic and orange parts, featuring bolts and circular elements, viewed from different angles.

    Strongbacks

    Strongbacks reinforce compromised systems by countering separation forces and preventing equipment failure. They’re especially valuable when dealing with degraded bolting, damaged threads, weakened or corroded components, or welds at risk of failure. This adds a vital layer of protection for mechanical integrity, safety, and leak containment.

Industries Served

Our leak sealing solutions support safety and uptime in:

  • Oil & Gas

  • Petrochemical & Refining

  • Nuclear & Power Generation

  • Chemical Manufacturing

  • Pulp & Paper

leak coming out of corroded valve

Leak Sealing FAQs

  • It’s a process that seals leaks in pressurized systems without stopping operation—no shutdown required.

    • Leaking gaskets or gasket failures

    • Leaking flanges

    • Elbow leaks

    • Leaking valves

    • Threaded joint leaks

    • Thinning or corroded pipes

    • Weld porosity or pinhole leaks

  • There’s no single global standard, but work is usually carried out under:

    • API standards

    • ASME codes

    • Local/regional pressure vessel regulations

    • Internal company standards

    All our designs follow applicable codes (ASME, CSA B51, etc.) and are stamped by a licensed professional engineer.

  • Yes. Avoiding shutdowns can save millions in production losses, especially in continuous process industries.

  • Often it is temporary or semi-permanent, buying time until a planned shutdown. However, some EPEs can last for years.

  • You can reach us easily, and once all the necessary information is collected, designs are typically completed within 1 to 4 business days, depending on the complexity. We understand the urgency our clients face and are committed to providing accurate and reliable design timelines to support effective planning.

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