pressure systems integrity management

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1 Furmanite Confidential - 1/9/04 Pressure Systems Integrity Management

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Pressure Systems Integrity Management. Pressure Systems Integrity Management. Objective - To provide a total flange service Result - Zero Leaks. PSI Management. Fugitive Emissions. Environmental Legislation. PSI Management. Fugitive Emissions. Environmental Legislation Safety - PowerPoint PPT Presentation

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Page 1: Pressure Systems Integrity Management

11 Furmanite Confidential - 1/9/04

Pressure Systems Integrity Management

Page 2: Pressure Systems Integrity Management

22 Furmanite Confidential - 1/9/04

Pressure Systems Integrity Management

Objective - To provide a total flange service

Result - Zero Leaks

Page 3: Pressure Systems Integrity Management

33 Furmanite Confidential - 1/9/04

Fugitive Emissions

Environmental Legislation

PSI Management

Page 4: Pressure Systems Integrity Management

44 Furmanite Confidential - 1/9/04

Fugitive Emissions

PSI Management

Environmental Legislation

Safety Occupational Health &

Safety

Page 5: Pressure Systems Integrity Management

55 Furmanite Confidential - 1/9/04

Fugitive Emissions

PSI Management

Environmental Legislation

Safety Occupational Health &

Safety

Commercial Efficiency

Page 6: Pressure Systems Integrity Management

66 Furmanite Confidential - 1/9/04

Fugitive Emissions

Causes Damaged sealing faces

Warped sealing faces

Gasket selection

Poor assembly procedures

Incorrect bolt load

Uneven bolt load

Flange rotation

PSI Management

Page 7: Pressure Systems Integrity Management

77 Furmanite Confidential - 1/9/04

Fugitive Emissions

Costs Loss of product

Process inefficiency

Cost of leak repair

Environmental fines

Image

PSI Management

Page 8: Pressure Systems Integrity Management

88 Furmanite Confidential - 1/9/04

PSI Management Sequence

Planning Consultation

Analysis

Site inspection

Specifications

Resources

Documentation

PSI Management

Page 9: Pressure Systems Integrity Management

99 Furmanite Confidential - 1/9/04

PSI Management Sequence

Planning

Site Inspection

Supervision

Manpower

Equipment

Documentation

PSI Management

Page 10: Pressure Systems Integrity Management

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PSI Management Sequence

PSI Management

Planning

Site

Post Job MDR

Documentation

Page 11: Pressure Systems Integrity Management

1111 Furmanite Confidential - 1/9/04

Planning

PSI Management

Consultation

Identification of ‘critical’ plant: History

Product contained

Temperature / pressure

Strategic (risk assessment)

Physical size/access

Page 12: Pressure Systems Integrity Management

1212 Furmanite Confidential - 1/9/04

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

PSI Management

Page 13: Pressure Systems Integrity Management

1313 Furmanite Confidential - 1/9/04

Planning

Flanges Gasket Bolts

Type

Material

Strength

Corrosion Resistance

Surface Finish

Surface Condition

Surface Flatness

Chemical Compatibility

Creep Resistance

Elasticity

Cost

Handling

Strength

Temperature Resistance

Strength

Temp Relaxation

Compatibility to Flange

Cost

Corrosion Resistance

PSI Management

Analysis Maintenance involves opening/closing bolted gasketed joints. Appreciation of the

‘system’ is necessary. The system fails, not the gasket when there is a leak.

Page 14: Pressure Systems Integrity Management

1414 Furmanite Confidential - 1/9/04

Planning

PSI Management

Site Inspection – Accuracy of Bolting Systems

Flogging Spanner ?

Impact Wrench ±50%

Controlled Torque Wrench ±30%

Hydraulic Bolt Tensioner ±15%

Micrometer ±10%

Ultrasonic Monitoring ±2%

Strain Gauging ±1%

Page 15: Pressure Systems Integrity Management

1515 Furmanite Confidential - 1/9/04

Planning

PSI Management

Site Inspection – Torque to Tension Time

Page 16: Pressure Systems Integrity Management

1616 Furmanite Confidential - 1/9/04

Planning

PSI Management

Specification

Flange Surface Finish

Flange Flatness

Gasket Selection

Bolt Material

Page 17: Pressure Systems Integrity Management

1717 Furmanite Confidential - 1/9/04

Planning

PSI Management

Resources

Right skills for the job

Right equipment for the job

Work scheduled

Page 18: Pressure Systems Integrity Management

1818 Furmanite Confidential - 1/9/04

Planning

PSI Management

Documentation Generic Engineering Procedures

Specific Engineering Procedures

DS-155

DS-156

DS-158

Colour Coded Tagging

Page 19: Pressure Systems Integrity Management

1919 Furmanite Confidential - 1/9/04

Site

PSI Management

Typical Site Workscope Tagging

Unbolting / removing flanges

Inspection

Clocking

On-site machining

Gasket installation & flange assembly

Controlled bolting

Documentation

Page 20: Pressure Systems Integrity Management

2020 Furmanite Confidential - 1/9/04

Post Job

MDR & Documentation

PSI Management

Page 21: Pressure Systems Integrity Management

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Training

Flange inspection

Flange assembly

Bolting procedures

PSI Management

For non-critical plant

Page 22: Pressure Systems Integrity Management

2222 Furmanite Confidential - 1/9/04

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 RECORDSKEEP RECORDS

PSI Management

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PSI Management

Santos

Mobil

TXU

BP

WMC

Caltex

ABF

WMC

PSI Management

PSI Management Past Performance

Page 24: Pressure Systems Integrity Management

2424 Furmanite Confidential - 1/9/04

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

PSI Management

Page 25: Pressure Systems Integrity Management

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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

PSI Management

Page 26: Pressure Systems Integrity Management

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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

PSI Management

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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.

PSI Management

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Past Performance

ABF 9th Critical Joint Shut

Down

PSI Management

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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

PSI Management

Page 30: Pressure Systems Integrity Management

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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

PSI Management

Page 31: Pressure Systems Integrity Management

3131 Furmanite Confidential - 1/9/04

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.

PSI Management

Page 32: Pressure Systems Integrity Management

3232 Furmanite Confidential - 1/9/04

PSI Management

Cost of leaks & un-planned re-work is far greater than cost of avoiding it.

PSI Management

Page 33: Pressure Systems Integrity Management

3333 Furmanite Confidential - 1/9/04

WorldwideFurmanite America Inc. - Corporate Headquarters2435 North Central ExpresswaySuite 700RichardsonTEXAS75080USATel: 001 972 699 4000

Furmanite International Ltd - UKFurman HouseShap Road KendalCumbriaLA9 6RUTel: 00 44 1539 729009Email: [email protected]

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