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
FM PROJECT ORGANIZATION
JI Snr. ENGINEER
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.
Explosion At Chevron Refinery, Mississippi
The Root Cause was Identified as Loose Bolts at Inlet Flange on PSV
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
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.
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.
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
- Pipeline related works
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
WHAT do we need to control?
The process used in the construction and operating environment, the components, the assembly and tightening
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.
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
Flange Management Overview
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
• Risk Assessments
Best Industry Practices & Procedures
Industry Standards and
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.
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
Flange Controlled Torquing Course
Involved in Controlled Tightening using
Flange Controlled Tensioning Course.
Joint Identification &Tagging
Example Line Number, FlangePRO is configured to match the format
of the project
The default joint
The pipe spec for enabling a link
direct to joint details
The service code for risk
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.
“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
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
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
0 100 200 300 400 500 600 700 800
Bolt Stress Relaxation from BS4882:1973 - Fig 9
8000 temp .B7 temp .B16 temp .B8 temp .B8M
Major Operators Global Projects Total No of Joints Monitor
Exxon Mobile Tapis R/MMHE 4, 030
BP BPTangghuLNG 9, 530
Qatar Gas South HookTerminal 7,340
Basrah Gas Plant Shutdown 9, 880
JOINT DATA MANAGEMENT
THE KEY ELEMENT OF FLANGE MANAGEMENT SOFTWARE & BENEFIT
DATABASE SEPARATE INTO 3CATEGORIES:
JOINT DATA MANAGEMENT
CONTROLS ALL ELEMENTS ASSOCIATED WITH BOLTEDJOINTS
SEAMLESSLY LINKED TO BOLT LOAD CALCULATIONENGINE
VISUAL DISPLAY OF PROJECT / JOINTSTATUS
SINGLE SOURCE DOCUMENTMANAGEMENT
GENERATE JOB AND JOINT SPECIFIC EQUIPMENTLISTS
MAINTAIN JOINT HISTORICALDATA
ACTS AS AN ELECTRONIC DATABANK
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