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Global Leader in Innovative Gaskets and Seals
Gary Milne, Director, Academy of Joint Integrity – Flexitallic (UK) [email protected]
Graham Horton, Mechanical Maintenance [email protected]
“Avoiding Loss of Containment when Assembling Flanged Connections”
NEPIC – BEST PRACTICE IN INDUSTRIAL ASETT MANAGEMENT – HARDWICK HALL – 20TH Nov 2019
Installation Related Causes of Visible Leaks
Uneven Loading & Non-Uniform
Gasket Stress……..Leaks
Insufficient Gasket Stress means…
Leaks
Ensure Operator Competence with
an Academy Flange Assembly
training course at your
site…..designed for your site.
COMAH Sites - Industry Concerns:
Site SafetyCOMAH CompliancePrimary Loss of Containment Pipe work /Flange Leakages/EmissionsSite / Contractors competenceTorque Figures – No provenanceGasket Specifications Human Factor ErrorAudit trail – life cycle activityCulture – resistance to changeAged Installations - Corrosion
Academy – Integrity Partner – COMAH compliance experienceNu farm case study: Eliminate costly Flange Leakages
Flange Integrity Journey:Nufarm
Top Tier COMAH chemical site, Bradford
November 2019
Flange Integrity Journey - Nufarm
• Intro Nufarm
• Problem Statement
• Strategy and Implementation
• Results
• Next steps
Nufarm UK Ltd, Wyke, BradfordAgrochemical Manufacturer – Top Tier COMAH site
Site History and Context
• Wyke is a historic site dating back to the 19th Century
• Significant investment in the 1970’s through to 1997
• Therefore asset base both structural and production is aged (20 to 50 years old) and in need of care and attention
• 13927 assets in the CMMS (not including motors or manual valves)
• 98 Asset types
• 150000 Meters of pipework
• 75000 Flanges
• 436 PSM Assets
• 1347 Motors
• 543 Pumps
• 100 Glass Lined Mild Steel vessels
• 46 functional plants
Why did Nufarm UK Ltd introduce Flange Management
LOPC – Loss of Primary Containment
Nufarm created a steering group in 2016 to tackle the issue of loss of primary containment. Over a twelve month period a total of 65 actions were created.
They identified systemic issues with the following:
• The integrity of flanged joints
• Hose and bellow management
• Care of glass lined equipment
• Pipe alignment
• Piping Standards
Paul Else Nufarm Site Manager’s Mission Statement for LOPC Improvement Team:
“Maintaining the integrity of primary containment systems is critically important to achieving our target of zero harm to people or the environment”.
Therefore, there was a requirement to provide a ready reference for joint making practices regarding pipe material, alignment, torque value and gasket selection.
LOPC Stats July 2016 to July 2017
0.0%
5.0%
10.0%
15.0%
20.0%
25.0%
30.0%
35.0%
40.0%
Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Mar-17 Apr-17 May-17 Jun-17 Jul-17
% High Severity LOPC
% High Severity Linear (% High Severity)
0
5
10
15
20
25
No. LOPC by root cause
0
2
4
6
8
10
12
14
27
15
34 3
14 5
42
Off-s
ite
Fla
ke
rs 8
Yard
Boile
rs 24
39
W/h
ouse
46
37
R&
D 32
30
1 9 7
18
No. of LOPC by location
NEPIC - Best Practice in Industrial Asset Management - Nov 2019
Strategy
• Engineering Standard Created
– incorporating tagging system, flange record sheets, flange register
• Training – culture change!
• Tools
• Implementation – Structured and steady approach to implementation to allow embedding the training, developing competence and increasing confidence in flange management
Flange Record Sheet
Tagging System
NEPIC - Best Practice in Industrial Asset Management - Nov 2019
Completed Example
Flange Register
Torque Pocket Book Reference Guide
Torque Wrench Calibration Records
Flexitallic/Academy – delivered Training on site – to all personnel involved in making and breaking of bolted joints.
JI010 – Dismantle, Assemble and Hand Torque Flanged Joints – tailored to Nufarm procedures.
Total of 55 personnel trained – Mechanical, C&I, Project Managers and Core Contractors
Certification
Course Feedback
Common themes:
• Coefficient of friction effects on torque settings
• Gasket relaxation - PTFE• Pipe alignment and importance of
bracketry• Re-torqueing of plastic, PTFE
lined and glass-lined equipment after a thermal cycle
• Visual impact of using the Academy Flange Demonstration Unit visuals displaying hand spanner/ versus torque tightening
Implementation Time Line
June 2017 – Action to implement LOPC initiative
July 2017 to Sept 2017 - Engineering Standard, flange record sheets, register and flange tag creation
October 2017 – Training provider engagement for tender – Flexitallic chosen as preferred provider – Academy of Joint Integrity – FADU & Experience.
October 2017 – Torque wrench procurement
November 2017 to March 2018 – Academy /Training roll out across all shifts
May 2018 – Go live date – 75 flanges made in the first month
December 2018 – Mechanical HSE inspection, endorsed our system
Nov 2019 – 1274 flanges managed, ZERO leaks, 5277 signatures
0.0%
5.0%
10.0%
15.0%
20.0%
25.0%
30.0%
35.0%
40.0%
Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Mar-17 Apr-17 May-17 Jun-17 Jul-17
% High Severity LOPC
% High Severity Linear (% High Severity)
LOPC Stats Pre-Implementation
LOPC Statistic Since Implementation
0.0%
5.0%
10.0%
15.0%
20.0%
25.0%
30.0%
35.0%
40.0%
% High Severity LOPC
% High Severity Linear (% High Severity)
Post LOPC
improvements
Pre LOPC
improvements
Next Steps/Challenges Ahead
• 150 Km of pipework on site with approx. 75000 flanges
• Redundant/aged pipework – NDT testing of pipework to assess priorities, 1.5 Km of pipework replaced since October 2017
• Legacy gaskets
• Legacy pipework bracketry and supports
• Pipe bridge upgrades
• Fabric maintenance
• Maintain competence ref work force
