Pressure Systems Integrity Management

1. Pressure Systems Integrity Management

2. Pressure Systems Integrity Management • Objective - To provide a total flange service • Result - Zero Leaks

3. PSI Management Fugitive Emissions Environmental • Legislation

4. PSI Management Fugitive Emissions Environmental • Legislation Safety • Occupational Health & Safety

5. PSI Management Fugitive Emissions Environmental • Legislation Safety • Occupational Health & Safety Commercial • Efficiency

6. PSI Management Fugitive Emissions Causes • Damaged sealing faces • Warped sealing faces • Gasket selection • Poor assembly procedures • Incorrect bolt load • Uneven bolt load • Flange rotation

7. PSI Management Fugitive Emissions Costs • Loss of product • Process inefficiency • Cost of leak repair • Environmental fines • Image

8. Planning Consultation Analysis Site inspection Specifications Resources Documentation PSI Management PSI Management Sequence

9. Planning Site Inspection Supervision Manpower Equipment Documentation PSI Management PSI Management Sequence

10. Planning Site Post Job MDR Documentation PSI Management PSI Management Sequence

11. PSI Management Planning Consultation Identification of ‘critical’ plant: • History • Product contained • Temperature / pressure • Strategic (risk assessment) • Physical size/access

12. PSI Management 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

13. PSI Management Planning 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.

14. PSI Management Planning 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%

15. PSI Management Planning Site Inspection – Torque to Tension Time

16. PSI Management Planning Specification • Flange Surface Finish • Flange Flatness • Gasket Selection • Bolt Material

17. PSI Management Planning Resources • Right skills for the job • Right equipment for the job • Work scheduled

18. PSI Management Planning Documentation • Generic Engineering Procedures • Specific Engineering Procedures • DS-155 • DS-156 • DS-158 • Colour Coded Tagging

19. PSI Management Site Typical Site Workscope • Tagging • Unbolting / removing flanges • Inspection • Clocking • On-site machining • Gasket installation & flange assembly • Controlled bolting • Documentation

20. PSI Management Post Job MDR & Documentation

21. PSI Management Training • Flange inspection • Flange assembly • Bolting procedures For non-critical plant

22. PSI Management 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

23. Santos Mobil TXU BP WMC Caltex ABF WMC PSI Management PSI Management PSI Management Past Performance

24. PSI Management 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

25. PSI Management 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

26. PSI Management 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

27. PSI Management 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.

28. PSI Management Past Performance ABF 9th Critical Joint Shut Down

29. PSI Management 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

30. PSI Management 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

31. PSI Management 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.

32. PSI Management PSI Management Cost of leaks & un-planned re-work is far greater than cost of avoiding it.

33. Worldwide Furmanite America Inc. - Corporate Headquarters2435 North Central ExpresswaySuite 700RichardsonTEXAS75080USATel: 001 972 699 4000 Furmanite International Ltd - UKFurman HouseShap Road KendalCumbriaLA9 6RUTel: 00 44 1539 729009Email: infouk@furmanite.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •