M.C.C.S.

INTERNATIONAL
Mechanical Completion and Commissioning Services Ltd. Formed in
1994 To fill a niche market in the area of Mechanical Completion
and Commissioning
M.C.C.S. Worldwide Ltd. Formed 2000 in the UK
M.C.C.S. Worldwide Sdn Bhd Formed 2001 Kuala Lumpur Malaysia
and renamed to M.C.C.S. International Sdn Bhd 2007
Branch Offices in UK, Spain, Vietnam and Indonesia

What makes M.C.C.S. unique? Maximise cost benefits

M.C.C.S. comprises a team of people M.C.C.S. involvement should be sought
who have specialised in this difficult during the early planning and design phase
area for several years. of a project.

The principle spin off from this team Within schedule and under budget
approach is The Wheel is not M.C.C.S. team has an enviable record of
Reinvented achieving its tasks within schedule and
under budget.
MCCS PROFESSIONAL SERVICES
FOR FLANGE MANAGEMENT
FOR EPCC / EPCIC OIL & GAS PROJECTS

JANUARY.2015
CARMEN
 INTRODUCTION TO FLANGE
MANAGEMENT SYSTEM

PROVIDING SERVICES, SUPERVISION AS WELL AS DOCUMENT

MANAGEMENT (DATABASE / CERTIFICATES PROVIDED) FROM
ASSEMBLY, BOLTING, BREAKOUT, REPAIR UP TO FINAL
INSPECTION.
PROCESS OF WHICH ASSEMBLY OF SYSTEM FLANGES ARE IN A
CONTROLLED MANNER.
OVERSEEING INSTALLATION OF PIPELINES THROUGH INSPECTION OF
FLANGES
DATABASE INPUT AND CERTIFICATION OF JOINTS ASSEMBLE IN
ACCORDANCE TO REQUIRED TORQUE / TENSION VALUES
VERIFICATION OF MATERIALS USED PRIOR TO JOINTS ASSEMBLY
THE TECHNOLOGY COMBINED WITH CAPABILITIES OF MCCS
INTERNATIONAL, RESULTS IN AUDITABLE REPORT CONFIRMING
SYSTEM SAFETY & INTEGRITY AS PER ISO 9001
 BENEFITS OF FLANGE
MANAGEMENT SYSTEM

MANAGEMENT FROM ENGINEERING TO SITE SET-UP

MANPOWER AND TOOLS SUPPORT
DOCUMENTS MANAGEMENT
HISTORICAL DATA TRACKING
ISSUANCE OF CERTIFICATES
PROPER TAGGING SYSTEM
INTEGRITY SAFETY OF PIPELINES
FAILURE PREVENTION OF SYSTEMS DUE TO LEAKING
JOINTS
 BENEFIT OF FLANGE
MANAGEMENT SYSTEM

REDUCE LEAKS DURING START-UP

INCREASE PRODUCTIVITY AND PROFITABILITY TO END-
USER / CLIENT
SAFETY ASSURANCE TO OPERATORS DURING
PRODUCTION - LEAKING JOINTS CAUSED GAS EMISSIONS
REDUCES IMPROPER ASSEMBLY AND TECHNIQUES USED
ELIMINATES INCOMPETENT PERSONNEL OPERATORS
QUALIFIED WITH ECITB OR EQUIVALENT STANDARDS
MINIMISED RISK OF INJURY WITH CORRECT METHODS
AND TOOLS USED
 FLANGE MANAGEMENT
SYSTEM OVERVIEW
FLANGE MANAGEMENT
SYSTEM

ASSEMBLY
PRE-ENGINEERING BOLTING
COMPLETION

MANUAL HYDRAULIC HYDRAULIC TAGGING OF

PREPARATION OF FLANGE PREPARATION ** REPAIR / FLANGE
JOINT REGISTER BOLT BOLT BOLT COMPLETED
WORK PACKS AND INSPECTION BREAKOUT
TORQUING TORQUING TENSIONING JOINTS

ISSUANCE OF JCC PERMIT TO VERIFICATION OF SYSTEM FOR

Compilation of Joints JOINTS LOCATION
DATA SHEETS WITHIN WORK WORK HANDOVER PRIOR TO JOINT
to be Managed VERIFICATION
PACKS (PTW) BREAKOUT

FASTENERS MATERIALS, CONFIRMATION OF JOINT /

UPDATE JOINT
DATA RECORDS SPECIFICATIONS AND JSA VENDOR(S) SPECIFICATIONS
REGISTER
CONDITION PRIOR TO BREAKOUT OF JOINTS

GASKETS MATERIALS, VERIFY FLANGE DETAILS AND

JOINT
ISOMETRICS SPECIFICATIONS AND SPECIFICATION PROVIDED BY
REGISTER
CONDITION CLIENT

VERIFICATION OF FLANGES CARRY OUT REPAIR / JOINTS

P & IDs
PRIOR TO ASSEMBLY BREAKOUT

MANUAL BOLT TORQUE /

OPEN JOINTS TO BE INSPECTION AND APPROVAL
JOB SAFETY HYDRAULIC BOLT TORQUE /
VERIFIED FOR ITS FLANGE FROM CLIENT UPON REPAIR
ANALYSIS (JSA) HYDRAULIC BOLT
SURFACES & PIPING COMPLETION
TENSIONING
CLEANLINESS

JOINT RE-CERTIFICATION ISSUANCE

COMPLETION INSPECTION CONDUCTED OF JCC WITHIN WORK PACKS
CERTIFICATE BY CLIENT QA / QC & MCCS
(JCC)
FINAL INSPECTION AND
APPROVAL BY CLIENT

UPDATE JOINT REGISTER

 FLANGE MANAGEMENT
SYSTEM OVERVIEW

FLANGE MANAGEMENT SYSTEM

JOINT DATA MANAGEMENT

MANUAL BOLT TORQUE
HYDRAULIC BOLT TORQUE
HYDRAULIC BOLT TENSIONING
JOINTS BREAKOUT
 FLANGE MANAGEMENT
SYSTEM OVERVIEW

FLANGE MANAGEMENT SYSTEM IN SEQUENCES AS FOLLOW;

PRE-ENGINEERING
JOINT REGISTER
PREPARATION OF WORK PACKS
FLANGE PREPARATION AND INSPECTION
BOLTING
MANUAL BOLT TORQUE
HYDRAULIC BOLT TORQUE
HYDRAULIC BOLT TENSIONING
ASSEMBLY COMPLETION
TAGGING OF COMPLETED JOINTS
ISSUANCE OF JCC WITHIN WORK PACKS
UPDATE JOINT REGISTER
** REPAIR / FLANGE BREAKOUT
 FLANGE MANAGEMENT
SYSTEM OVERVIEW

FLANGE MANAGEMENT SYSTEM BRIEF in STAGES AS FOLLOW;

PRE-ENGINEERING
Pre-Engineering stage is crucial in Flange Management System prior to mobilizing
the correct personnel and equipment to site due to:
Accurate and precise information to manage service effectiveness
To prioritize and ensure the best use of resources
This stage comprises of:
JOINT REGISTER
PREPARATION OF WORK PACKS
FLANGE PREPARATION AND INSPECTION

JOINT REGISTER
A Joint Register will be created to compile all Joints data that are to be managed /
tightened / breakout.
 FLANGE MANAGEMENT
SYSTEM OVERVIEW

PREPARATION OF WORK PACKS

The Work Packs will consist of the following documents:
DATA SHEETS providing information of Joint specifications, tools
required, torque and tension values
DATA RECORDS detailing information of materials, specifications
and tools used
ISOMETRICS given by Client to be extract to Data Sheets and
Data Records
P & IDs obtained from Client will be organized to Data Sheets
and Data Records
JOB SAFETY ANALYSIS (JSA) will be designed to suit the project
requirements by using Joint Register as a reference
JOINT COMPLETION CERTIFICATE (JCC) will be created prior to
Bolting and Assembly Completion Stage
 FLANGE MANAGEMENT
SYSTEM OVERVIEW

FLANGE PREPARATION AND INSPECTION

JOINTS LOCATION VERIFICATION will be conducted by MCCS personnel
during site inspection
FASTENERS MATERIALS, SPECIFICATIONS AND CONDITION will be
inspected by MCCS personnel according to Data Records input
GASKET MATERIALS, SPECIFICATIONS AND CONDITION will be carefully
examined by MCCS personnel based on Data Records obtained
VERIFICATION OF FLANGES PRIOR TO ASSEMBLY to ensured
specification are inline with the Data Records and Data Sheet
OPEN JOINTS TO BE VERIFIED FOR ITS FLANGE SURFACES AND PIPING
CLEANLINESS prior to Bolting and Assembly scope
INSPECTION CONDUCTED BY CLIENT QA / QC AND MCCS
REPRESENTATIVES to ascertained all information obtained are up-to-
date and witnessed by Client
 FLANGE MANAGEMENT
SYSTEM OVERVIEW

FLANGE MANAGEMENT SYSTEM BRIEF in STAGES AS FOLLOW;

BOLTING
After completion of Pre-Engineering Stage, MCCS will mobilize the sufficient number of personnel and
correct equipment to site in order to perform the Bolting Stage in which would be WITNESS BY CLIENT.
There are three (3) types of bolting methods:
MANUAL BOLT TORQUING
HYDRAULIC BOLT TORQUING
HYDRAULIC BOLT TENSIONING

MANUAL BOLT TORQUING

A Calibrated Manual Hand Operate Wrench with pre-set / adjustable torque values applying twisting force
on fasteners. In accordance to Engineering Construction Industry Training Board (ECITB), manual tightened
should not more than 600 lbf.ft (800Nm)

HYDRAULIC BOLT TORQUING

Twisting force applied on fasteners with Hydraulic Square Drive Power Head / Hydraulic Low Profile Drive
Cylinder by setting its torque value on a gauge assembled on a Torque Pump.

HYDRAULIC BOLT TENSIONING

Tensioning is the direct axial stretching of the bolt to achieve Preload therefore inaccuracy created through
frictions are eliminated. Hydraulic tool used to tighten or loosen fasteners by stretching / pulling force
instead of applying large torque to the nut
 FLANGE MANAGEMENT
SYSTEM OVERVIEW

FLANGE MANAGEMENT SYSTEM BRIEF in

STAGES AS FOLLOW;
ASSEMBLY COMPLETION
Upon completion of assembly under the normal
circumstances, each Joint would have a tag tied around to
confirmed the Joint has been tested and approved by
information gathered from Radio-Frequency Identification
(RFID) Tagging System. This is referred as TAGGING OF COMPLETED JOINT
Upon final inspection and approval obtained from Client, MCCS will conduct ISSUANCE
OF JOINT COMPLETION CERTIFICATE (JCC) within the Work Packs and this will be
signed-off by both parties i.e. The Client and MCCS
The JOINT REGISTER would eventually be updated for safe-keeping and future used
should maintenance of piping / shutdown required
However, should the joint(s) failed during hydro testing or Nitrogen /Helium Leak
Testing, REPAIR / FLANGE BREAKOUT is a MUST to ensure ZERO leaks prior to approving
Commissioning Team commencing their start-up / initiate progress.
 FLANGE MANAGEMENT
SYSTEM OVERVIEW

** REPAIR / FLANGE BREAKOUT

The following documents MUST obtained from Client to ensure relevant data related to
the Joint(s) to be repair / breakout prior to work commence :
Permit to Work (PTW)
Job Safety Analysis (JSA)
Joint Register
Confirmation of Joint and Vendor(s) specifications verified are inline prior to Repair /
Joint Breakout
Verifying flange details and specification provided by Client
Carried out Repairs / Flange Breakout soon after details confirmed by selecting the
correct methods and tools, witness by Client:
Manual Bolt Torque
Hydraulic Bolt Torque
Hydraulic Bolt Tensioning
Inspection and Approval from Client upon repair completion
Final Inspection and Approval from Client
Re-Certification Issuance of Joint Completion Certificate (JCC) within Work Packs
Update Joint Register for Safe-Keeping
 FLANGE MANAGEMENT
SYSTEM SOFTWARE OVERVIEW

INTRODUCTION TO FLANGE MANAGEMENT SOFTWARE

Flange Management Software is crucial and plays a key role in modern Oil
& Gas Industry to achieve an accurate bolt load calculations
To provide timely records to help minimize downtime cost, eliminates
issues such as leakage when combining with Nitrogen and Helium Leak
Testing Services
To increase end-user productivity
FMS Software will be used for planning, managing and recording joint
details in which MCCS Engineers will recommend the correct tightening
methods, tool selection, torque and tension values for each and every
Joint.
The FMS Software is important especially to calculate the torque / tension
value at safety yield percentage for any Special Flanges in which also
categorized a Non-Standard Joints
 FLANGE MANAGEMENT
SYSTEM SOFTWARE OVERVIEW

THE KEY ELEMENT OF FLANGE MANAGEMENT SOFTWARE

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 reporting skills
An additional value added designed features is the ability of its program to transfer database from FMS to
the following services:
Nitrogen / Helium Leak Testing Services
Pipeline Commissioning Services
Hook-Up and Pre-Commissioning and Commissioning Services
 FLANGE MANAGEMENT
SYSTEM SOFTWARE OVERVIEW

FLANGE MANAGEMENT SOFTWARE OVERVIEW

 FLANGE MANAGEMENT
SYSTEM SOFTWARE BENEFIT

FLANGE MANAGEMENT SOFTWARE BENEFITS

Electronically transfers all tensioning pressures, torque values, bolt
material, flange class and rating to Database
Update Joint Completion Reports and Test Certificates
Tracks and Update records as work is completed
A summarized progress / report on condition of flanges which are Open-
Closed-Tightened-Tested-Leaking OR required on-site machining
Import P & IDs and Test Certs
Caters for Work Packs & Test Packs in plant sub-systems
Records joint tightening, pressure testing and leakage statistic
Stores multiple flange records in Banks
Identifies equipment specifications and determine Joints requirement
Provides a complete traceable recording system for total flange integrity
THANKS FOR YOUR ATTENTION