Pressure Systems Integrity Management
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Transcript of Pressure Systems Integrity Management
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11 Furmanite Confidential - 1/9/04
Pressure Systems Integrity Management
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22 Furmanite Confidential - 1/9/04
Pressure Systems Integrity Management
Objective - To provide a total flange service
Result - Zero Leaks
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33 Furmanite Confidential - 1/9/04
Fugitive Emissions
Environmental Legislation
PSI Management
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44 Furmanite Confidential - 1/9/04
Fugitive Emissions
PSI Management
Environmental Legislation
Safety Occupational Health &
Safety
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55 Furmanite Confidential - 1/9/04
Fugitive Emissions
PSI Management
Environmental Legislation
Safety Occupational Health &
Safety
Commercial Efficiency
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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
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77 Furmanite Confidential - 1/9/04
Fugitive Emissions
Costs Loss of product
Process inefficiency
Cost of leak repair
Environmental fines
Image
PSI Management
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88 Furmanite Confidential - 1/9/04
PSI Management Sequence
Planning Consultation
Analysis
Site inspection
Specifications
Resources
Documentation
PSI Management
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99 Furmanite Confidential - 1/9/04
PSI Management Sequence
Planning
Site Inspection
Supervision
Manpower
Equipment
Documentation
PSI Management
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1010 Furmanite Confidential - 1/9/04
PSI Management Sequence
PSI Management
Planning
Site
Post Job MDR
Documentation
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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
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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
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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.
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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%
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1515 Furmanite Confidential - 1/9/04
Planning
PSI Management
Site Inspection – Torque to Tension Time
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1616 Furmanite Confidential - 1/9/04
Planning
PSI Management
Specification
Flange Surface Finish
Flange Flatness
Gasket Selection
Bolt Material
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1717 Furmanite Confidential - 1/9/04
Planning
PSI Management
Resources
Right skills for the job
Right equipment for the job
Work scheduled
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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
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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
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2020 Furmanite Confidential - 1/9/04
Post Job
MDR & Documentation
PSI Management
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2121 Furmanite Confidential - 1/9/04
Training
Flange inspection
Flange assembly
Bolting procedures
PSI Management
For non-critical plant
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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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2323 Furmanite Confidential - 1/9/04
PSI Management
Santos
Mobil
TXU
BP
WMC
Caltex
ABF
WMC
PSI Management
PSI Management Past Performance
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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
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2525 Furmanite Confidential - 1/9/04
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
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2626 Furmanite Confidential - 1/9/04
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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2727 Furmanite Confidential - 1/9/04
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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2828 Furmanite Confidential - 1/9/04
Past Performance
ABF 9th Critical Joint Shut
Down
PSI Management
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2929 Furmanite Confidential - 1/9/04
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
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3030 Furmanite Confidential - 1/9/04
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
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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
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PSI Management
Cost of leaks & un-planned re-work is far greater than cost of avoiding it.
PSI Management
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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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