WCM BRUNEI SDN BHD

Health and Safety

• Fire alarm, assembly points and fire exits

• No smoking policy

• First aid

• PPE requirements

• Hazards present on site

• Designated walkways

• Toilets and washroom

• Manual handling

FM PROJECT ORGANIZATION CHART

DIRECTOROMAR

SAFETY OFFICERSAMSIR

JI ENGINEERAMINUL HAKIMI

HAMZAH

JI ENGINEEREHSAN SUFIAN

JI SUPERVISORMOHD AZHAR

JI SUPERVISORMOHD FAIZUL

JI InspectorILIAS

JI INSPECTORBAHARUDIN

JI INSPECTORMOHD HANIF

JI Snr. ENGINEERAFIMAN ABDUL

RAHMAN

JI ENGINEERMOHD AZIZI

JI ENGINEERNUSRATUDDIN

NAZMI

SAFETY MOMENT

This Hub Connector passed a Nitrogen Helium Leak test but leaked 3 years later causing an explosion. The cause -fitting a Carbon Steel Seal Ring instead of a Stainless one.

SAFETY MOMENT

Explosion At Chevron Refinery, Mississippi

The Root Cause was Identified as Loose Bolts at Inlet Flange on PSV

Joint Integrity Philosophy

All leaks from bolted joints are avoidable

We have a moral and legal obligation to protect safety of employees in the industry

The true cost of leaks from bolted connections is far greater than the cost of avoiding them

We also have to minimise the impact of our activities on the environment

Joint Integrity Solutions

"The final, essential creator of the force is the mechanic, and the time of creation is during assembly. So it's very important for us to understand this process".-John Bickford, "Handbook of Bolts and Bolted Joints"

Joint Integrity Solutions (JIS) by WCM Brunei Sdn Bhd were offered to the

industry as the most comprehensive and sophisticated service to cater all

service and work related to bolted joint integrity and asset reliability. JIS is in

accordance and compliance with most recent requirements by ASME PCC-1

and 'Guidelines for The Management of The Integrity of Bolted Joint For

Pressurised System' by Energy Institute UK.

Joint Integrity Solutions

Joint Integrity Solutions (JIS) by WCM Brunei Sdn.Bhd is considered as the

key elements to achieving prime objectives of flange joint integrity which is to

assure leak-free integrity of the bolted flange joint. An integrated approach

has been adopted to ensure success of the process of joint integrity.

This process shall begin with;

i) understanding of the operating environment

ii) continues with design

iii) selection of the flange components

iv) setting of assembly specifications

v) establishment of best procedures

vi) appointment of competent personnel

vii) quality assurance traceability through complete documentation (using

sophisticated and systematic software for database)

viii) finishes with meeting the goal of leak prevention.

Joint Integrity Solutions (JIS)

Joint Integrity Solutions (JIS)

- Controlled bolting (MTW, HTW, HBT)-Hot bolting

- On-Site Machining - Cold cutting and bavel

- Flange resurface and repair

- Thorough inspection and by competent personnel at 3 major

stages (1-preparation-material selection & purchasing, 2-

Installation- witness and inspection on site during job

execution,3- Handover -Final report and database record)

- Flange Management software

- Leak Testing (Hydrostatic, N2, Helium)

- Leak sealing.

- Real time condition based monitoring (Live monitoring on

critical joint)

- Pipeline related works

INTRODUCTION TO FLANGE MANAGEMENT SYSTEM

WHY do we need a Flange Management program?The program will help improve Plant Safety and Reliability, the Cost of a Leak is enormous in terms of People, Plant and Environment.

WHAT do we need to control?The process used in the construction and operating environment, the components, the assembly and tightening processes.

WHO do we need to control?Anyone who may have an influence on a flanged joint, engineers, supervision, field operatives

HOW do we control? Improve awareness of Best Practice, train personnel to on site based on their role on the project. Adopt best practices for assembly and tightening of flanged joints. Implement a quality assurance database and program that provides traceability and ensures compliance to all Project specifications.

What is Flange Management?

The easiest comparison is to look at a welded joint, if we compare what is required for a welded joint then its easy to see similar requirements for a flanged joint

Materials management and controls Training and competency – look at what qualifications a coded welder needs Process and procedure Documentation and records

Flange Management Overview

Client Ownership

Best Industry Practice

Procedures

Criticality Assessment

Rules

Training & Competence Management

Joint Identification,

Tagging

Data Tracking, Recording

Inspection Compliance

Leak Management

KPIs, Analyze, Improve

Client Ownership

An owner within the Client organization must be appointed.

WCM works with all tiers in the supply chain implementing Flange Management.

WCM can assist clients to implement Flange Management throughout the organization,

through assistance with:

• Gap Analysis

• Procedures

• Risk Assessments

Best Industry Practices & Procedures

Asset Site

Implementation

Industry Standards and

Best Practice

Technical Centre

Assess Criticality, Set Rules

Determine Joint Criticalities

Risk Assessment process; consider process media, temp and pressure

Based on Leak and Loss potential as well as local factors

Joint analysis, bolt loads, rules for use of torque and tension

Leads into Risk Based Inspection

TIGHTENING METHOD BOLT DIAMETER

1 Torque tighten <1 ½”

2 Bolt tension >1 ½”

Low-risk Within alignment tolerances, existing controls are in place, eg procedures,

vendor information, competent personnel; safe to proceed

Medium-risk Additional controls need to be identified, consider the use of specialist

contractors, limit personnel in the area during testing and initial operation,

improve access, re-check after completion.

High-risk Engineering review of piping design and configuration, consider the use of a

specialist contractor or vendor.

TRAINING & COMPETANCY

Specific Training courses for all roles:

WCM training schemes is based on standard training program stated in Energy Institute –Guidelines for the management of the integrity of bolted joints for pressurised systems (Chapter 4).

Personnel Role Includes: Training Course

Direct/Indirect Effect on Flange Integrity FMP Awareness Course

Direct Effect on Flange Integrity Principles of Joint Integrity Course

Involved in Inspection or Assembly Flange Inspection and Assembly Course

Involved in Controlled Tightening using Torque

Equipment

Flange Controlled Torquing Course

Involved in Controlled Tightening using

Tensioning Equipment

Flange Controlled Tensioning Course.

Joint Identification & Tagging

Example Line Number, FlangePRO is configured to match the format of the project

24”-FG-50394-AB1-NI-001

The default joint

size

The pipe spec for enabling a link

direct to joint details

The service code for risk

assessment

Bolt load

calculation

and

tightening

policy

Unique joint

number

FlangePRO Comprehensive Data Tracking

• Records

• Audit

• Identification

• Interfacing

• MRO

• Metrics

• Automation

• Anomaly

• Enforcement

• QA/QC

• Compliance

• Certainty

• Simplicity

• Image plant

• Improvement

• Accuracy

• Analysis

• Prevention

Inspection Compliance

In-service Inspection of bolted joints

is an integral activity to ensure the

continued integrity of the joints and

as such should be built in to all

relevant inspection programmes.

This section looks at the possible

damage that can occur, the

inspection methods available for

detection of defects and mitigation

measures that can be put in place to

minimise such degradation.

Leak Management

“The objective of a correctly designed and installed bolted joint is to provide a long-term tight seal and prevent ingress or egress of fluids through the joint.

However, leaks can occur and managing the investigation and repair of the leak is essential to avoid recurrence.

It can also provide useful data for prevention on other projects.”

A defined process is in place for Leak Management Investigation shown on the right

KPI’s, Analyze, Improve

Analysis of leakage and inspection data coupled with

formal reviews of the management system should

occur at agreed intervals by the owner and users.

The results obtained from commissioning, incident

analysis and in-service inspections should be used

to generate ideas for continuous improvement.

Easily monitored but meaningful performance

standards should be put in place at launch to

quantify the contribution being made by the

management system and evaluate user satisfaction.

Feedback on good practice in integrity issues and

causes and solutions to incidents should be provided

both internally and to industry to contribute to

continuous improvement.

Collect Data

Analyse

Improve

0 100 200 300 400 500 600 700 8000

0.25

0.5

0.75

1

Bolt Stress Relaxation from BS4882:1973 - Fig 9

100%

0

.res.B7

.res.B16

.res.B8

.res.B8M

8000 temp .B7 temp .B16 temp .B8 temp .B8M

PROJECT TRACK RECORD

Major Operators Global Projects Total No of Joints Monitor

Exxon Mobile Tapis R/MMHE 4, 030

BP BP Tangghu LNG 9, 530

Woodside & Conoco/Phillips

Cossack/Goodwyn/Laminaria 15,300

Qatar Gas South Hook Terminal 7,340

Basrah Gas Plant Shutdown 9, 880

JOINT DATA MANAGEMENT SOFTWARE

THE KEY ELEMENT OF FLANGE MANAGEMENT SOFTWARE & BENEFIT 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 REPORTINGSKILLS

AN ADDITIONAL VALUE ADDED DESIGNED FEATURES IS THE ABILITY OF ITS PROGRAM TO TRANSFER DATABASE FROMFMS TO THE FOLLOWING SERVICES:

NITROGEN / HELIUM LEAK TESTING SERVICES PIPELINE COMMISSIONING SERVICES HOOK-UP AND PRE-COMMISSIONING AND COMMISSIONING SERVICES

JOINT DATA MANAGEMENT SOFTWARE

WCM BRUNEI SDN BHDBlock C, Unit 3 , 1st (First) Floor,Lot 8981-8982, Kg.Pandan,Jalan Kerma Negara,Kuala BelaitKA1931, P.O Box 715, Seria KB1190,Negara Brunei Darussalam.

Website: www.wcmbrunei.com CONTACT US:Tel: +67(3) 334 2536Fax: +67(3) 334 2536Email: enquiry@wcmbrunei.com

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