Halliburton. All rights reserved. Flange Integrity Management

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Betty Watson
5 years ago
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1 Flange Integrity Management

facility in North America experienced 180 leaks per year, six of which

failures (leaks) approximately 98% were on flanged connections

1% were on welded connections the balance were due to damage or

2 Flange Integrity Management Why? North America Pressure Vessel Research Council found that each process facility in North America experienced 180 leaks per year, six of which caused a total plant shutdown An API study concluded that of all pipe failures (leaks) approximately 98% were on flanged connections approximately 0.1% were on welded connections the balance were due to damage or corrosion The UK Operators Association (now known as Oil and Gas UK) completed their own study resulting in the creation of the Guidelines for the Management of Integrity of Bolted Pipe Joints.

Flange Integrity Management A methodology to ensure the integrity of flanged connections, minimizing, and usually eliminating, integrity-related issues (such as leaks) at start-up or re-start A

3 Flange Integrity Management A methodology to ensure the integrity of flanged connections, minimizing, and usually eliminating, integrity-related issues (such as leaks) at start-up or re-start A database with complete history of every flange on a process plant Registers, work packs, test packs, certificates and drawing mark-up all created and modified in one system, giving increased efficiency and accuracy A system that assures HSE performance and helps manage risks HSE risk eliminate leaks Commercial risk eliminate plant shutdown due to leaks

Flange Integrity Management Key Elements Engineering International Standards Industry Best Practices Detailed Design Work Packs Clear and Concise Auditable Fabrication Assembly Trained Competent

4 Flange Integrity Management Key Elements Engineering International Standards Industry Best Practices Detailed Design Work Packs Clear and Concise Auditable Fabrication Assembly Trained Competent Personnel Certified Equipment Tightening API and ANSI Standards Industry Best Practice Commissioning Testing Industry Leading Equipment Certified Equipment As Built Records Industry Leading Database Auditable

Flange Integrity Management Controlled Bolt Fastening Services The accurate application of torque or tension to flange stud-bolts and nuts is critical Certified and calibrated equipment is a

5 Flange Integrity Management Controlled Bolt Fastening Services The accurate application of torque or tension to flange stud-bolts and nuts is critical Certified and calibrated equipment is a requirement All calibration must have tractability to national standards Trained and competent personnel are used to operate the equipment Bolt torqueing Precise control of applied torque Compact equipment design Bolt tensioning Accurate application of tension State-of-the-art equipment

6 Four Part Flange Tag for Maintenance Projects Uniquely identify joints that are to be: Opened Assembled Tightened Tested Each flange within the project work scope is tagged The tags have multiple sections The colored sections are perforated to allow tear off

7 1. Blue Tag = Connection Opened or Broken Once the flange connection has been opened, section 1 of the tag system is removed and logged. The responsible person enters information on the tag and returns the tag to the joint integrity engineer The joint integrity engineer / supervisor logs the information into the database L J Abney DD/MM/YYYY

8 2. Red Tag = Inspected and Assembled Once the flange has been inspected and assembled, section 2 is completed and the person responsible enters the information on the tag and returns the tag to the joint integrity engineer The joint integrity engineer / supervisor logs the information into the database L J Abney DD/MM/YYYY

3. Yellow Tag = Tightened Once the flange has been tightened, section 3 is completed and the person responsible enters the information on the tag and

9 3. Yellow Tag = Tightened Once the flange has been tightened, section 3 is completed and the person responsible enters the information on the tag and returns the tag to the joint integrity engineer The joint integrity engineer / supervisor logs the information into the database L J Abney DD/MM/YYYY

4. Green Tag = Flange Tested Once the flange has been tested, section 4 is completed and the person responsible enters the information on the tag and

10 4. Green Tag = Flange Tested Once the flange has been tested, section 4 is completed and the person responsible enters the information on the tag and returns the tag to the joint integrity engineer The joint integrity engineer / supervisor and logs the information into the database L J Abney DD/MM/YYYY

including when, what and by who. The flange tag number enable cross reference with the information in the database.

11 White Tag Check Prior to Restart Section 5 of the tag will remain on the flange to show visually that all work stages and operations have been completed L J Abney DD/MM/YY Visual confirmation on the flange that all work on the item has been completed including when, what and by who. The flange tag number enable cross reference with the information in the database. When all flanges have been tightened and tested the flange management register / system is updated with all of the information from prior maintenance activities

Flange Integrity Management Our Goal Leak free bolted connections Trained competent personnel Calibrated and certified equipment Compliance with industry standards and best practice Benefits Flawless

12 Flange Integrity Management Our Goal Leak free bolted connections Trained competent personnel Calibrated and certified equipment Compliance with industry standards and best practice Benefits Flawless start-up on time and within budget of process facilities Minimized HSE and commerical risk associated with flanged connections World class performance and efficiencies on both maintenance and construction projects

JOINT INTEGRITY MANAGEMENT SOLUTIONS

JOINT INTEGRITY MANAGEMENT SOLUTIONS Joint Integrity Management Solutions Some 30 years after developing the technology behind hydraulic bolt tensioning, Hydratight continues to push the boundaries with