flange integrity management - halliburton€¦ · the accurate application of torque or tension to...

© 2015 Halliburton. All rights reserved. © 2016 Halliburton. All rights reserved.

Flange Integrity Management

© 2015 Halliburton. All rights reserved. © 2016 Halliburton. All rights reserved. © 2016 Halliburton. All rights reserved.

Flange Integrity Management – Why?

North America Pressure Vessel Research Council found that each process facility in North America experienced 180 leaks per year, six of which caused a total plant shutdown An API study concluded that of all pipe failures (leaks) approximately 98% were on flanged connections approximately 0.1% were on welded connections the balance were due to damage or corrosion The UK Operators Association (now known as

Oil and Gas UK) completed their own study resulting in the creation of the Guidelines for the Management of Integrity of Bolted Pipe Joints.



A methodology to ensure the integrity of flanged connections, minimizing, and usually eliminating, integrity-related issues (such as leaks) at start-up or re-start

A database with complete history of every flange on a process plant

Registers, work packs, test packs, certificates and drawing mark-up all created and modified in one system, giving increased efficiency and accuracy

A system that assures HSE performance and helps manage risks HSE risk – eliminate leaks Commercial risk – eliminate plant

shutdown due to leaks


Fabrication

Detailed Design

As Built

Commissioning

Flange Integrity Management – Key Elements

Engineering

Work Packs

Assembly

Tightening

Testing

Records

International Standards Industry Best Practices

Clear and Concise Auditable

Trained Competent Personnel Certified Equipment

API and ANSI Standards Industry Best Practice

Industry Leading Equipment Certified Equipment

Industry Leading Database Auditable


Flange Integrity Management – Controlled Bolt Fastening Services The accurate application of torque or tension

to flange stud-bolts and nuts is critical Certified and calibrated equipment is a

requirement All calibration must have tractability to

national standards Trained and competent personnel are

used to operate the equipment

Bolt torqueing Precise control of applied torque Compact equipment design

Bolt tensioning Accurate application of tension State-of-the-art equipment


12000 12000 12000 12000 12000

Four Part Flange Tag for Maintenance Projects

Uniquely identify joints that are to be: Opened Assembled Tightened Tested

Each flange within the project work scope is ’tagged’ The tags have multiple sections The colored sections are perforated to allow ‘tear off’


1. Blue Tag = Connection Opened or Broken

Once the flange connection has been opened, section 1 of the tag system is removed and logged. The responsible person enters information on the tag and returns the tag to the joint integrity engineer The joint integrity engineer / supervisor logs

the information into the database

12000

L J Abney

DD/MM/YYYY


2. Red Tag = Inspected and Assembled

Once the flange has been inspected and assembled, section 2 is completed and the person responsible enters the information on the tag and returns the tag to the joint integrity engineer The joint integrity engineer / supervisor logs


12000

L J Abney

DD/MM/YYYY


3. Yellow Tag = Tightened

Once the flange has been tightened, section 3 is completed and the person responsible enters the information on the tag and returns the tag to the joint integrity engineer The joint integrity engineer / supervisor logs


12000

L J Abney

DD/MM/YYYY


4. Green Tag = Flange Tested

Once the flange has been tested, section 4 is completed and the person responsible enters the information on the tag and returns the tag to the joint integrity engineer The joint integrity engineer / supervisor and

logs the information into the database

12000

L J Abney

DD/MM/YYYY


12000

L J Abney DD/MM/YY

White Tag Check Prior to Restart

Section 5 of the tag will remain on the flange to show visually that all work stages and operations have been completed When all flanges have been tightened and tested the flange

management register / system is updated with all of the information from prior maintenance activities

Visual confirmation on the flange that all work on the item has been completed including when, what and by who. The flange tag number enable cross reference with the information in the database.



Our Goal Leak free bolted connections Trained competent personnel Calibrated and certified equipment Compliance with industry standards

and best practice

Benefits Flawless start-up on time and within budget of process facilities Minimized HSE and commerical risk associated with flanged

connections World class performance and efficiencies on both maintenance and

construction projects

flange integrity management - halliburton€¦ · the accurate application of torque or tension to...

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