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WCM_PRESENTATION_Flange_Management_Rev4

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WCM_PRESENTATION_Flange_Management_Rev4

  1. 1. WCM BRUNEI SDN BHD
  2. 2. Health and Safety • Fire alarm, assembly points and fire exits • No smoking policy • First aid • PPE requirements • Hazards present on site • Designated walkways • Toilets and washroom • Manual handling
  3. 3. FM PROJECT ORGANIZATION CHART DIRECTOR OMAR SAFETY OFFICER SAMSIR JI ENGINEER AMINUL HAKIMI HAMZAH JI ENGINEER EHSAN SUFIAN JI SUPERVISOR MOHDAZHAR JI SUPERVISOR MOHD FAIZUL JI Inspector ILIAS JI INSPECTOR BAHARUDIN JI INSPECTOR MOHD HANIF JI Snr. ENGINEER AFIMANABDUL RAHMAN JI ENGINEER MOHDAZIZI JI ENGINEER NUSRATUDDIN NAZMI
  4. 4. SAFETY MOMENT This Hub Connector passed a Nitrogen Helium Leak test but leaked 3 years later causing an explosion. The cause -fitting a Carbon Steel Seal Ring instead of a Stainless one.
  5. 5. SAFETY MOMENT Explosion At Chevron Refinery, Mississippi The Root Cause was Identified as Loose Bolts at Inlet Flange on PSV
  6. 6. Joint Integrity Philosophy All leaks from bolted joints are avoidable We have a moral and legal obligation to protect safety of employees in the industry The true cost of leaks from bolted connections is far greater than the cost of avoiding them We also have to minimise the impact of our activities on the environment
  7. 7. Joint Integrity Solutions "The final, essential creator of the force is the mechanic, and the time of creation is during assembly. So it's very important for us to understand this process". -John Bickford, "Handbook of Bolts and Bolted Joints" Joint Integrity Solutions (JIS) by WCM Brunei Sdn Bhd were offered to the industry as the most comprehensive and sophisticated service to cater all service and work related to bolted joint integrity and asset reliability. JIS is in accordance and compliance with most recent requirements by ASME PCC-1 and 'Guidelines for The Management of The Integrity of Bolted Joint For Pressurised System' by Energy Institute UK.
  8. 8. Joint Integrity Solutions Joint Integrity Solutions (JIS) by WCM Brunei Sdn.Bhd is considered as the key elements to achieving prime objectives of flange joint integrity which is to assure leak-free integrity of the bolted flange joint. An integrated approach has been adopted to ensure success of the process of joint integrity. This process shall begin with; i) understanding of the operating environment ii) continues with design iii) selection of the flange components iv) setting of assembly specifications v) establishment of best procedures vi) appointment of competent personnel vii) quality assurance traceability through complete documentation (using sophisticated and systematic software for database) viii)  finishes with meeting the goal of leak prevention.
  9. 9. Joint Integrity Solutions (JIS) Joint Integrity Solutions (JIS) - Controlled bolting (MTW, HTW, HBT)-Hot bolting - On-Site Machining - Cold cutting and bavel - Flange resurface and repair - Thorough inspection and by competent personnel at 3 major stages (1-preparation-material selection & purchasing, 2- Installation- witness and inspection on site during job execution,3- Handover -Final report and database record) - Flange Management software - Leak Testing (Hydrostatic, N2, Helium) - Leak sealing. - Real time condition based monitoring (Live monitoring on critical joint) - Pipeline related works
  10. 10. INTRODUCTIONTO FLANGE MANAGEMENT SYSTEM WHY do we need a Flange Management program? The program will help improve Plant Safety and Reliability, the Cost of a Leak is enormous in terms of People, Plant and Environment. WHAT do we need to control? The process used in the construction and operating environment, the components, the assembly and tightening processes. WHO do we need to control? Anyone who may have an influence on a flanged joint, engineers, supervision, field operatives HOW do we control? Improve awareness of Best Practice, train personnel to on site based on their role on the project. Adopt best practices for assembly and tightening of flanged joints. Implement a quality assurance database and program that provides traceability and ensures compliance to all Project specifications.
  11. 11. What is Flange Management?  The easiest comparison is to look at a welded joint, if we compare what is required for a welded joint then its easy to see similar requirements for a flanged joint  Materials management and controls  Training and competency – look at what qualifications a coded welder needs  Process and procedure  Documentation and records
  12. 12. Flange Management Overview Client Ownership Best Industry Practice Procedures Criticality Assessment Rules Training & Competence Management Joint Identification, Tagging Data Tracking, Recording Inspection Compliance Leak Management KPIs, Analyze, Improve
  13. 13. Client Ownership An owner within the Client organization must be appointed. WCM works with all tiers in the supply chain implementing Flange Management. WCM can assist clients to implement Flange Management throughout the organization, through assistance with: • Gap Analysis • Procedures • Risk Assessments
  14. 14. Best Industry Practices & Procedures Asset Site Implementation Industry Standards and Best Practice Technical Centre
  15. 15. Assess Criticality, Set Rules Determine Joint Criticalities Risk Assessment process; consider process media, temp and pressure Based on Leak and Loss potential as well as local factors Joint analysis, bolt loads, rules for use of torque and tension Leads into Risk Based Inspection TIGHTENING METHOD BOLT DIAMETER 1 Torque tighten <1 ½” 2 Bolt tension >1 ½” Low-risk Within alignment tolerances, existing controls are in place, eg procedures, vendor information, competent personnel; safe to proceed Medium-risk Additional controls need to be identified, consider the use of specialist contractors, limit personnel in the area during testing and initial operation, improve access, re-check after completion. High-risk Engineering review of piping design and configuration, consider the use of a specialist contractor or vendor.
  16. 16. TRAINING & COMPETANCY SpecificTraining courses for all roles:  WCM training schemes is based on standard training program stated in Energy Institute – Guidelines for the management of the integrity of bolted joints for pressurised systems (Chapter 4). Personnel Role Includes: Training Course Direct/Indirect Effect on Flange Integrity FMP Awareness Course Direct Effect on Flange Integrity Principles of Joint Integrity Course Involved in Inspection or Assembly Flange Inspection and Assembly Course Involved in Controlled Tightening using Torque Equipment Flange Controlled Torquing Course Involved in Controlled Tightening using Tensioning Equipment Flange Controlled Tensioning Course.
  17. 17. Joint Identification &Tagging Example Line Number, FlangePRO is configured to match the format of the project 24”-FG-50394-AB1-NI-001 The default joint size The pipe spec for enabling a link direct to joint details The service code for risk assessment Bolt load calculation and tightening policy Unique joint number
  18. 18. FlangePRO Comprehensive DataTracking • Records • Audit • Identification • Interfacing • MRO • Metrics • Automation • Anomaly • Enforcement • QA/QC • Compliance • Certainty • Simplicity • Image plant • Improvement • Accuracy • Analysis • Prevention
  19. 19. Inspection Compliance In-service Inspection of bolted joints is an integral activity to ensure the continued integrity of the joints and as such should be built in to all relevant inspection programmes. This section looks at the possible damage that can occur, the inspection methods available for detection of defects and mitigation measures that can be put in place to minimise such degradation.
  20. 20. Leak Management “The objective of a correctly designed and installed bolted joint is to provide a long-term tight seal and prevent ingress or egress of fluids through the joint. However, leaks can occur and managing the investigation and repair of the leak is essential to avoid recurrence. It can also provide useful data for prevention on other projects.” A defined process is in place for Leak Management Investigation shown on the right
  21. 21. KPI’s, Analyze, Improve Analysis of leakage and inspection data coupled with formal reviews of the management system should occur at agreed intervals by the owner and users. The results obtained from commissioning, incident analysis and in-service inspections should be used to generate ideas for continuous improvement. Easily monitored but meaningful performance standards should be put in place at launch to quantify the contribution being made by the management system and evaluate user satisfaction. Feedback on good practice in integrity issues and causes and solutions to incidents should be provided both internally and to industry to contribute to continuous improvement. Collect Data Analyse Improve 0 100 200 300 400 500 600 700 800 0 0.25 0.5 0.75 1 Bolt Stress Relaxation from BS4882:1973 - Fig 9 100% 0 .res.B7 .res.B16 .res.B8 .res.B8M 8000 temp .B7 temp .B16 temp .B8 temp .B8M
  22. 22. PROJECTTRACK RECORD Major Operators Global Projects Total No of Joints Monitor Exxon Mobile Tapis R/MMHE 4, 030 BP BPTangghuLNG 9, 530 Woodside & Conoco/Phillips Cossack/Goodwyn/Laminaria 15,300 Qatar Gas South HookTerminal 7,340 Basrah Gas Plant Shutdown 9, 880
  23. 23. JOINT DATA MANAGEMENT SOFTWARE THE KEY ELEMENT OF FLANGE MANAGEMENT SOFTWARE & BENEFIT  DATABASE SEPARATE INTO 3CATEGORIES:  JOINT DATA MANAGEMENT  EQUIPMENT CONTROL  PERSONNEL COMPETENCY  CONTROLS ALL ELEMENTS ASSOCIATED WITH BOLTEDJOINTS  SEAMLESSLY LINKED TO BOLT LOAD CALCULATIONENGINE  USER FRIENDLYINTERFACE  VISUAL DISPLAY OF PROJECT / JOINTSTATUS  SINGLE SOURCE DOCUMENTMANAGEMENT  GENERATE JOB AND JOINT SPECIFIC EQUIPMENTLISTS  MAINTAIN JOINT HISTORICALDATA  ACTS AS AN ELECTRONIC DATABANK  ENHANCE REPORTINGSKILLS  AN ADDITIONAL VALUE ADDED DESIGNED FEATURES IS THE ABILITY OF ITS PROGRAM TO TRANSFER DATABASE FROM FMS TO THE FOLLOWINGSERVICES:  NITROGEN / HELIUM LEAK TESTING SERVICES  PIPELINE COMMISSIONING SERVICES  HOOK-UP AND PRE-COMMISSIONING AND COMMISSIONING SERVICES
  24. 24. JOINT DATA MANAGEMENT SOFTWARE
  25. 25. WCM BRUNEI SDN BHD Block C, Unit 3 , 1st (First) Floor, Lot 8981-8982, Kg.Pandan, Jalan Kerma Negara,Kuala Belait KA1931, P.O Box 715, Seria KB1190, Negara Brunei Darussalam. Website: www.wcmbrunei.com CONTACT US: Tel: +67(3) 334 2536 Fax: +67(3) 334 2536 Email: enquiry@wcmbrunei.com CONTACT US
  26. 26. THANKYOU

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