WCM_PRESENTATION_Flange_Management_Rev4
-
Upload
afiman-abdul-rahman -
Category
Documents
-
view
34 -
download
0
Transcript of WCM_PRESENTATION_Flange_Management_Rev4
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 CHART
DIRECTOROMAR
SAFETY OFFICERSAMSIR
JI ENGINEERAMINUL HAKIMI
HAMZAH
JI ENGINEEREHSAN SUFIAN
JI SUPERVISORMOHD AZHAR
JI SUPERVISORMOHD FAIZUL
JI InspectorILIAS
JI INSPECTORBAHARUDIN
JI INSPECTORMOHD HANIF
JI Snr. ENGINEERAFIMAN ABDUL
RAHMAN
JI ENGINEERMOHD AZIZI
JI ENGINEERNUSRATUDDIN
NAZMI
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.
SAFETY MOMENT
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
critical joint)
- Pipeline related works
INTRODUCTION TO 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.
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
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
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
Best Industry Practices & Procedures
Asset Site
Implementation
Industry Standards and
Best Practice
Technical Centre
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
Specific Training 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.
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
FlangePRO Comprehensive Data Tracking
• Records
• Audit
• Identification
• Interfacing
• MRO
• Metrics
• Automation
• Anomaly
• Enforcement
• QA/QC
• Compliance
• Certainty
• Simplicity
• Image plant
• Improvement
• Accuracy
• Analysis
• Prevention
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.
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
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 8000
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
PROJECT TRACK RECORD
Major Operators Global Projects Total No of Joints Monitor
Exxon Mobile Tapis R/MMHE 4, 030
BP BP Tangghu LNG 9, 530
Woodside & Conoco/Phillips
Cossack/Goodwyn/Laminaria 15,300
Qatar Gas South Hook Terminal 7,340
Basrah Gas Plant Shutdown 9, 880
JOINT DATA MANAGEMENT SOFTWARE
THE KEY ELEMENT OF FLANGE MANAGEMENT SOFTWARE & BENEFIT DATABASE SEPARATE INTO 3 CATEGORIES:
JOINT DATA MANAGEMENT EQUIPMENT CONTROL PERSONNEL COMPETENCY
CONTROLS ALL ELEMENTS ASSOCIATED WITH BOLTED JOINTS SEAMLESSLY LINKED TO BOLT LOAD CALCULATION ENGINE USER FRIENDLY INTERFACE VISUAL DISPLAY OF PROJECT / JOINT STATUS SINGLE SOURCE DOCUMENT MANAGEMENT GENERATE JOB AND JOINT SPECIFIC EQUIPMENT LISTS MAINTAIN JOINT HISTORICAL DATA ACTS AS AN ELECTRONIC DATA BANK ENHANCE REPORTINGSKILLS
AN ADDITIONAL VALUE ADDED DESIGNED FEATURES IS THE ABILITY OF ITS PROGRAM TO TRANSFER DATABASE FROMFMS TO THE FOLLOWING SERVICES:
NITROGEN / HELIUM LEAK TESTING SERVICES PIPELINE COMMISSIONING SERVICES HOOK-UP AND PRE-COMMISSIONING AND COMMISSIONING SERVICES
WCM BRUNEI SDN BHDBlock C, Unit 3 , 1st (First) Floor,Lot 8981-8982, Kg.Pandan,Jalan Kerma Negara,Kuala BelaitKA1931, P.O Box 715, Seria KB1190,Negara Brunei Darussalam.
Website: www.wcmbrunei.com CONTACT US:Tel: +67(3) 334 2536Fax: +67(3) 334 2536Email: [email protected]
CONTACT US