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1Furmanite Confidential - 1/9/04 Pressure Systems Integrity Management
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2Furmanite Confidential - 1/9/04 Pressure Systems Integrity Management Objective - To provide a total flange service Result - Zero Leaks
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3Furmanite Confidential - 1/9/04 Fugitive Emissions Environmental Legislation PSI Management
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4Furmanite Confidential - 1/9/04 Fugitive Emissions PSI Management Environmental Legislation Safety Occupational Health & Safety
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5Furmanite Confidential - 1/9/04 Fugitive Emissions PSI Management Environmental Legislation Safety Occupational Health & Safety Commercial Efficiency
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6Furmanite 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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7Furmanite 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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8Furmanite Confidential - 1/9/04 PSI Management Sequence Planning Consultation Analysis Site inspection Specifications Resources Documentation PSI Management
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9Furmanite Confidential - 1/9/04 PSI Management Sequence Planning Site Inspection Supervision Manpower Equipment Documentation PSI Management
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10Furmanite Confidential - 1/9/04 PSI Management Sequence PSI Management Planning Site Post Job MDR Documentation
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11Furmanite 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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12Furmanite 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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13Furmanite Confidential - 1/9/04 Planning FlangesGasketBolts 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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14Furmanite 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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15Furmanite Confidential - 1/9/04 Planning PSI Management Site Inspection – Torque to Tension Time
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16Furmanite Confidential - 1/9/04 Planning PSI Management Specification Flange Surface Finish Flange Flatness Gasket Selection Bolt Material
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17Furmanite Confidential - 1/9/04 Planning PSI Management Resources Right skills for the job Right equipment for the job Work scheduled
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18Furmanite 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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19Furmanite 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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20Furmanite Confidential - 1/9/04 Post Job MDR & Documentation PSI Management
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21Furmanite Confidential - 1/9/04 Training Flange inspection Flange assembly Bolting procedures PSI Management For non-critical plant
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22Furmanite 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 RECORDS PSI Management
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23Furmanite Confidential - 1/9/04 PSI Management Santos Mobil TXU BP WMC Caltex ABF WMC PSI Management PSI Management Past Performance
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24Furmanite 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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25Furmanite 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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26Furmanite 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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27Furmanite 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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28Furmanite Confidential - 1/9/04 Past Performance ABF 9 th Critical Joint Shut Down PSI Management
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29Furmanite 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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30Furmanite 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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31Furmanite 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
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32Furmanite Confidential - 1/9/04 PSI Management Cost of leaks & un-planned re-work is far greater than cost of avoiding it. PSI Management
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33Furmanite 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
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