Pressure Systems
Integrity Management
1
Furmanite Confidential - 1/9/04
Pressure Systems Integrity
Management
 Objective
- To provide a
total flange service
 Result
2
- Zero Leaks
Furmanite Confidential - 1/9/04
PSI Management
Fugitive Emissions
Environmental
 Legislation
3
Furmanite Confidential - 1/9/04
PSI Management
Fugitive Emissions
Environmental
 Legislation
Safety
 Occupational Health &
Safety
4
Furmanite Confidential - 1/9/04
PSI Management
Fugitive Emissions
Environmental
 Legislation
Safety
 Occupational Health &
Safety
Commercial
 Efficiency
5
Furmanite Confidential - 1/9/04
PSI Management
Fugitive Emissions
Causes
 Damaged sealing faces
 Warped sealing faces
 Gasket selection
 Poor assembly procedures
 Incorrect bolt load
 Uneven bolt load
 Flange rotation
6
Furmanite Confidential - 1/9/04
PSI Management
Fugitive Emissions
Costs
 Loss of product
 Process inefficiency
 Cost of leak repair
 Environmental fines
 Image
7
Furmanite Confidential - 1/9/04
PSI Management
PSI Management Sequence
Planning
 Consultation
 Analysis
 Site inspection
 Specifications
 Resources
 Documentation
8
Furmanite Confidential - 1/9/04
PSI Management
PSI Management Sequence
Planning
Site
 Inspection
 Supervision
 Manpower
 Equipment
 Documentation
9
Furmanite Confidential - 1/9/04
PSI Management
PSI Management Sequence
Planning
Site
Post Job
 MDR
 Documentation
10
Furmanite Confidential - 1/9/04
PSI Management
Planning
Consultation
Identification of ‘critical’ plant:
 History
 Product contained
 Temperature / pressure
 Strategic (risk assessment)
 Physical size/access
11
Furmanite Confidential - 1/9/04
PSI Management
Planning
Analysis – Overview
 When a bolted gasketed flange joint is
assembled the gasket seal is subjected to a
compressive force – “W”
 When a system is pressurized the initial
compressive force is relieved by ‘H’
 To maintain seal integrity there must be a
residual compressive force on the gasket when
the system is in service
12
Furmanite Confidential - 1/9/04
PSI Management
Planning
Analysis
13

Maintenance involves opening/closing bolted gasketed joints. Appreciation of the
‘system’ is necessary.

The system fails, not the gasket when there is a leak.
Flanges
Gasket
Bolts
Type
Chemical Compatibility
Strength
Material
Creep Resistance
Temp Relaxation
Strength
Elasticity
Compatibility to Flange
Corrosion Resistance
Cost
Cost
Surface Finish
Handling
Corrosion Resistance
Surface Condition
Strength
Surface Flatness
Temperature Resistance
Furmanite Confidential - 1/9/04
PSI Management
Planning
Site Inspection – Accuracy of Bolting
Systems
14
 Flogging Spanner
?
 Impact Wrench
±50%
 Controlled Torque Wrench
±30%
 Hydraulic Bolt Tensioner
±15%
 Micrometer
±10%
 Ultrasonic Monitoring
±2%
 Strain Gauging
±1%
Furmanite Confidential - 1/9/04
PSI Management
Planning
Site Inspection – Torque to Tension
Time
15
Furmanite Confidential - 1/9/04
PSI Management
Planning
Specification
 Flange Surface Finish
 Flange Flatness
 Gasket Selection
 Bolt Material
16
Furmanite Confidential - 1/9/04
PSI Management
Planning
Resources
 Right skills for the job
 Right equipment for the job
 Work scheduled
17
Furmanite Confidential - 1/9/04
PSI Management
Planning
Documentation
 Generic Engineering Procedures
 Specific Engineering Procedures
 DS-155
 DS-156
 DS-158
 Colour Coded Tagging
18
Furmanite Confidential - 1/9/04
PSI Management
Site
Typical Site Workscope
 Tagging
 Unbolting / removing flanges
 Inspection
 Clocking
 On-site machining
 Gasket installation & flange assembly
 Controlled bolting
 Documentation
19
Furmanite Confidential - 1/9/04
PSI Management
Post Job
MDR & Documentation
20
Furmanite Confidential - 1/9/04
PSI Management
Training

Flange inspection

Flange assembly

Bolting procedures
For non-critical plant
21
Furmanite Confidential - 1/9/04
PSI Management
PSI Management
Only when all the components of the bolted gasketed
flanged joint are working together will an effective
long term seal be achieved:
 Selection of correct components for the application
 Careful inspection, preparation, installation and assembly
 Correct bolt tightening
KEEP RECORDS
22
Furmanite Confidential - 1/9/04
PSI Management
PSI Management
PSI Management Past Performance
23

Santos

WMC

Mobil

Caltex

TXU

ABF

BP

WMC
Furmanite Confidential - 1/9/04
PSI Management
Past Performance
Santos Moomba Gas Plant
 LRP Shutdown - 1996
 Furmanite
- Turn-Key Contract
 30 Furmanite Technicians
 40 Sub-Contractor
 Full scope of JIMS + rigging, scaffolding, welding, cleaning, insulation,
blasting & painting
 150 Critical Flanges serviced
 Workscope completed 11 hours ahead of schedule
 Subsequently Furmanite involved on every major shutdown
24
Furmanite Confidential - 1/9/04
PSI Management
Past Performance
BP QLD Clean Fuel Project 2000
 Construction - HGU & HCU Plant
 Furmanite
-
 Bolt Load / Flange Stress Calc’s
 Equipment
 Supervision (Hands on)
 Documentation
 97 Critical Flanges
 2 crews - 12 Large Flanges in 1 x Day
 Full Pressure Test - Zero Leaks
25
Furmanite Confidential - 1/9/04
PSI Management
Past Performance
WMC Phosphate Hill
 First Major Shut Down - 2001
 Furmanite - Control of 80 Critical Flanges on Ammonia Plant
 Engineer, Supervisor and 5 Technicians Zero Leaks at Start-Up ( Client signed off Furmanite 4 weeks after start up)
 Ammonia Plant Shut Down finished on schedule
26
Furmanite Confidential - 1/9/04
PSI Management
Past Performance
ABF 9th Critical Joint Shut Down
 Approx 4600 man hours
 20 Furmanite Personnel (1 Project Mngr, 3 Sup’s & 16 Tech’s )
 17 Day shutdown
 58 Critical Joints – assembled and bolted (18 not part of the original
scope)
 Bolting from 7/8” to 5-1/4” dia.
 10 RTJ Flange faces machined or lapped and polished
 31 Lens Rings Machined
 20 x 2-1/4” seized studs - drilled, threads picked then re-tapped
 3 x 4-3/4” seized studs - drilled, threads picked then re-tapped
 All work handed back on or ahead of schedule.
27
Furmanite Confidential - 1/9/04
PSI Management
Past Performance
ABF 9th
Critical Joint
Shut Down
28
Furmanite Confidential - 1/9/04
PSI Management
Past Performance
WMC Phosphate Hill
 Major Shut Down – 2003
 Furmanite assisted UKG & WMC with development of shutdown work packs
from Jan – July 2003
 Furmanite - Control of 970 Plant Flanges, including 150 critical on Ammonia
Plant
 20 personnel, including Project Manager, Engineer, Safety Representative all
with the ability to be hands on
 Over 5,500 shutdown man-hours
 Zero Injuries throughout works.
 Zero Leaks at Start-Up.
 Plant Shut Down finished on schedule
29
Furmanite Confidential - 1/9/04
PSI Management
Plant Benefits
Safety & Efficiency
 Right first time
 Re-work significantly reduced
 Reduced shutdown duration
 Down time reduced
All above = Plant owner’s confidence increased
All above = Improved Safety performance
30
Furmanite Confidential - 1/9/04
PSI Management
Plant Benefits
Efficiency Example
 Critical flanges – Syngas line
 Flange failure – 7 days downtime* at $30,000/hr = $5million
 7 days = 3 days cool down + 1 day rectification + 3 days start
up
 JIMS – 100% success on syngas flanges to date.
31
Furmanite Confidential - 1/9/04
PSI Management
PSI Management
Cost of leaks & un-planned re-work is far
greater than cost of avoiding it.
32
Furmanite Confidential - 1/9/04
Worldwide
Furmanite America Inc. Corporate Headquarters
2435 North Central Expressway
Suite 700
Richardson
TEXAS
75080
USA
Tel: 001 972 699 4000
•• •
• ••
• ••
•
Furmanite International Ltd UK
Furman House
Shap Road
Kendal
Cumbria
LA9 6RU
Tel: 00 44 1539 729009
Email: infouk@furmanite.com
33
Furmanite Confidential - 1/9/04
• •
• •••••
•
•••
• •
•
•
•
•
•
•
•
•
•
•