Flange Integrity Management

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

© 2015
© 2016 Halliburton.
Halliburton.All
All rights
rights reserved.
reserved.
 Flange Integrity Management

 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

© 2015
© 2016 Halliburton.
Halliburton.All
All rights
rights reserved.
reserved.
 Flange Integrity Management – Key Elements

International Standards
Engineering Detailed Design
Industry Best Practices

Clear and Concise

Work Packs
Auditable

Trained Competent Personnel

Fabrication Assembly
Certified Equipment

API and ANSI Standards

Tightening
Industry Best Practice

Industry Leading Equipment

Commissioning Testing
Certified Equipment

Industry Leading Database

As Built Records
Auditable

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

© 2015
© 2016 Halliburton.
Halliburton.All
All rights
rights reserved.
reserved.
 Four Part Flange Tag for Maintenance Projects

 Uniquely identify joints that are to be:

 Opened 12000 12000 12000 12000 12000

 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’

© 2015
© 2016 Halliburton.
Halliburton.All
All rights
rights reserved.
reserved.
 1. Blue Tag = Connection Opened or Broken

12000
 Once the flange connection has been
opened, section 1 of the tag system is
removed and logged. The responsible person
L J Abney
enters information on the tag and returns the
tag to the joint integrity engineer
 The joint integrity engineer / supervisor logs DD/MM/YYYY

the information into the database

© 2015
© 2016 Halliburton.
Halliburton.All
All rights
rights reserved.
reserved.
 2. Red Tag = Inspected and Assembled

12000
 Once the flange has been inspected and
assembled, section 2 is completed and the
person responsible enters the information on
L J Abney
the tag and returns the tag to the joint integrity
engineer
 The joint integrity engineer / supervisor logs DD/MM/YYYY

the information into the database

© 2015
© 2016 Halliburton.
Halliburton.All
All rights
rights reserved.
reserved.
 3. Yellow Tag = Tightened

12000
 Once the flange has been tightened,
section 3 is completed and the person
responsible enters the information on the tag
L J Abney
and returns the tag to the joint integrity
engineer
 The joint integrity engineer / supervisor logs DD/MM/YYYY

the information into the database

© 2015
© 2016 Halliburton.
Halliburton.All
All rights
rights reserved.
reserved.
 4. Green Tag = Flange Tested

12000
 Once the flange has been tested,
section 4 is completed and the person
responsible enters the information on the tag
L J Abney
and returns the tag to the joint integrity
engineer
 The joint integrity engineer / supervisor and DD/MM/YYYY

logs the information into the database

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

12000

Visual confirmation on the flange

L J Abney
that all work on the item has been
DD/MM/YY
completed including when, what
  and by who. The flange tag
  number enable cross reference
with the information in the
  database.

 When all flanges have been tightened and tested the flange
management register / system is updated with all of the
information from prior maintenance activities

© 2015
© 2016 Halliburton.
Halliburton.All
All rights
rights reserved.
reserved.
 Flange Integrity Management

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

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