WCM BRUNEI SDN BHD provides joint integrity solutions (JIS) such as controlled bolting, on-site machining, flange resurfacing and repair, inspection, and leak testing. JIS aims to ensure leak-free integrity of bolted flange joints through an integrated approach including understanding the operating environment, design, component selection, assembly specifications, procedures, personnel, documentation, and meeting leak prevention goals. A key element is a flange management software database that tracks all elements associated with bolted joints to enhance safety, reliability, and compliance.
Piping Training course-How to be an Expert in Pipe & Fittings for Oil & Gas c...Varun Patel
Course Description
Piping a must know skill to work in Oil & Gas and similar Process Industries.
Oil and Gas industry is become a very competitive in the current time. Getting right mentor and right exposer within industry is difficult. With limited training budget spent by company on employee training, it is difficult to acquire the knowledge to success.
Knowing cross-functional skill give you an edge over others in your career success.
This course design based on years of field experience to ensure student will comprehend technical details easily and enjoy overall journey.
Learn in detail every aspect of Pipe & Pipe Fittings used in process industry
•Different types of Pipe, Pipe fittings (Elbow, Tee, reducers, Caps etc.), Flanges, Gaskets, Branch Connection, Bolting materials
•Materials (Metal-Carbon Steel, Stainless Steel, Alloy Steel etc. Non-Metal- PVC/VCM, HDPE, GRE-GRP etc.)
•Manufacturing methods
•Heat treatment requirements
•Inspection and Testing requirements (Non Destructive Testing, Mechanical & Chemical testing)
•Dimensions & Markings requirements
•Code & Standard used in piping
Content and Overview
With 2 hours of content including 30 lectures & 8 Quizzes, this course cover every aspect of Pipe, Pipe fittings, flanges, gaskets, branch connections and bolting material used in Process Piping.
This Course is divided in three parts.
1st part of the course covers fundamental of process industries. In this Part, you will learn about fundamental process piping. You will also learn about Code, Standard & Specification used in process industries.
2nd part cover various types of material used in process industries. In this part, you will learn about Metallic and Non-Metallic material used to manufacture pipe and other piping components.
3rd parts covers in detail about pipe and piping components used in Process piping. In this part we will learn about Industry terminology of Piping components, types of industrial material grade used in manufacturing and entire manufacturing process of these components. You will learn about different manufacturing methods, Heat treatment requirements, Destructive and Non-destructive testing, Visual & Dimensional inspection and Product marking requirements.
Upon completion, you will be able to use this knowledge direct on your Job and you can easily answer any interview question on pipe & fittings.
Fundamental of Pipe / Pipeline used in Process Piping.Varun Patel
Learn about every aspect of pipe that used in process piping in Oil & Gas Industries. This small pipe handbook cum guide includes Fundamental of pipe, types of pipe, manufacturing, dimension, testing, hydro testing, inspection, and marking.
Here's a presentation on piping engineering in PDF format, now available for all. This presentation covers the basics points of piping for our EPC industry. This presentation covers various aspects of piping engineering
How to write a Welding Procedure Specification (ISO 15614-1Tiago Pereira
Some key aspects of writing welding procedure specifications. A good learning point for people who have no experience in the field, and a good reference for seasoned engineers
Piping Training course-How to be an Expert in Pipe & Fittings for Oil & Gas c...Varun Patel
Course Description
Piping a must know skill to work in Oil & Gas and similar Process Industries.
Oil and Gas industry is become a very competitive in the current time. Getting right mentor and right exposer within industry is difficult. With limited training budget spent by company on employee training, it is difficult to acquire the knowledge to success.
Knowing cross-functional skill give you an edge over others in your career success.
This course design based on years of field experience to ensure student will comprehend technical details easily and enjoy overall journey.
Learn in detail every aspect of Pipe & Pipe Fittings used in process industry
•Different types of Pipe, Pipe fittings (Elbow, Tee, reducers, Caps etc.), Flanges, Gaskets, Branch Connection, Bolting materials
•Materials (Metal-Carbon Steel, Stainless Steel, Alloy Steel etc. Non-Metal- PVC/VCM, HDPE, GRE-GRP etc.)
•Manufacturing methods
•Heat treatment requirements
•Inspection and Testing requirements (Non Destructive Testing, Mechanical & Chemical testing)
•Dimensions & Markings requirements
•Code & Standard used in piping
Content and Overview
With 2 hours of content including 30 lectures & 8 Quizzes, this course cover every aspect of Pipe, Pipe fittings, flanges, gaskets, branch connections and bolting material used in Process Piping.
This Course is divided in three parts.
1st part of the course covers fundamental of process industries. In this Part, you will learn about fundamental process piping. You will also learn about Code, Standard & Specification used in process industries.
2nd part cover various types of material used in process industries. In this part, you will learn about Metallic and Non-Metallic material used to manufacture pipe and other piping components.
3rd parts covers in detail about pipe and piping components used in Process piping. In this part we will learn about Industry terminology of Piping components, types of industrial material grade used in manufacturing and entire manufacturing process of these components. You will learn about different manufacturing methods, Heat treatment requirements, Destructive and Non-destructive testing, Visual & Dimensional inspection and Product marking requirements.
Upon completion, you will be able to use this knowledge direct on your Job and you can easily answer any interview question on pipe & fittings.
Fundamental of Pipe / Pipeline used in Process Piping.Varun Patel
Learn about every aspect of pipe that used in process piping in Oil & Gas Industries. This small pipe handbook cum guide includes Fundamental of pipe, types of pipe, manufacturing, dimension, testing, hydro testing, inspection, and marking.
Here's a presentation on piping engineering in PDF format, now available for all. This presentation covers the basics points of piping for our EPC industry. This presentation covers various aspects of piping engineering
How to write a Welding Procedure Specification (ISO 15614-1Tiago Pereira
Some key aspects of writing welding procedure specifications. A good learning point for people who have no experience in the field, and a good reference for seasoned engineers
In this ppt, you will learn about the different types of Flanges used in a piping system to connect the pipe ends. This ppt explains the classification of flanges based on its use.
This Presentation is about the basic fundamentals one needs to know to begin Piping Engineering. All the basic formulas and questions that are usually asked in interviews are answered in this presentation. Feel free to ask any doubts in the comments and iI may try my best to answer them for you.
In this ppt, you will learn about the different types of Flanges used in a piping system to connect the pipe ends. This ppt explains the classification of flanges based on its use.
This Presentation is about the basic fundamentals one needs to know to begin Piping Engineering. All the basic formulas and questions that are usually asked in interviews are answered in this presentation. Feel free to ask any doubts in the comments and iI may try my best to answer them for you.
This course is geared to provide enough knowledge on the fundamentals of implementing,
monitoring, and maintaining an internal corrosion control program as part of an overall
Integrity Management Program.
The challenges facing in pharmaceutical maintenanceMANUEL PACINI
Maintenance strategies for the pharmaceutical industry.
Maintenance and service-related items are often the second-largest budget element in a laboratory after salaries and benefits
API 570 Piping and Pipeline Inspectors Preparatory CoursepetroEDGE
This program is designed for in depth understanding of Inspection of piping and pipelines under operation and in-service as per API 570. This preparatory course will prepare inspectors to ensure piping and pipeline integrity in service. Practical aspect of design considerations, sizing, rating, piping and pipeline integrity, internal inspections, analysis, repair, pressure testing, and pipeline protection shall be discussed. The program shall also provide more information about types of piping system defects which may crop in during operation, repairs, maintenance and alteration. This will lead the participants to prepare them for ensuring good quality and safety of operating piping and pipelines so that they are safe in operations and ensure preventing any incident.
Precast Plant Quality System Documentation Setsjlines
This document is a basic quality manual specifically designed for precast concrete plants. This can be used as a blueprint for plants to design their quality system.
Safe Hose Assemble: From Factory to FieldDesign World
Jim Reilly of The United Distribution Group, GHX Industrial, LLC, and Rick Pitman of PSC will discuss the proper use of hydraulic hose, from fabrication and assembly to industry drivers and field usage. They will also explain NAHAD’s role in improving hose standards and what engineering personnel need to know.
Calibration of rotary shouldered connections is a critical aspect of maintaining operational efficiency and safety. By calibrating these connections, operators can ensure that they are operating within the specified tolerances, minimizing the risk of failure or leakage. Regular calibration also helps to identify potential issues early on, allowing for timely corrective actions and preventing costl
Pre Commissioning Testing Training and Maintenance of Instrumentation Analyzer, Metering Skid, Crude Oil Samplers, Corrosion, CP Radio Monitoring system, Laser HF and H2S Hydrogen, Oxygen Emerson oxymitter, Emerson Bentely Navada Vibration Analyzers, Thermography, Gas cement Petroleum Analyzers, Gas Chromatograph in Refinery Oil Gas Plants Petrochemical Aramco Sabic.
Extensive coordination between client and supplier in make sure all resolution successfully covered to achieve end client satisfaction.
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. 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. 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. SAFETY MOMENT
Explosion At Chevron Refinery, Mississippi
The Root Cause was Identified as Loose Bolts at Inlet Flange on PSV
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. 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. 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. 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. 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. 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. 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. 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. Best Industry Practices & Procedures
Asset Site
Implementation
Industry Standards and
Best Practice
Technical Centre
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. 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. 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
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. 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. 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. 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. 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