Mechanical Completion and Commissioning Services Ltd …mccsinternational.com/presentation/MCCS_PRESENTATION_Flange_M… · Mechanical Completion and Commissioning Services Ltd

► 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?

M.C.C.S. comprises a team of people

who have specialised in this difficult

area for several years.

The principle spin off from this team

approach is “The Wheel is not

Reinvented”

Maximise cost benefits

M.C.C.S. involvement should be sought

during the early planning and design phase

of a project.

Within schedule and under budget

M.C.C.S. team has an enviable record of

achieving its tasks within schedule and

under budget.

M.C.C.S.INTERNATIONAL

MCCS PROFESSIONAL SERVICES FOR FLANGE MANAGEMENT

FOR EPCC / EPCIC OIL & GAS PROJECTS

JANUARY.2015 CARMEN

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

INTRODUCTION TO 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

BENEFITS 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

BENEFIT OF FLANGE MANAGEMENT SYSTEM

FLANGE MANAGEMENT SYSTEM

PRE-ENGINEERING

JOINT REGISTER

Compilation of Joints to be Managed

PREPARATION OF WORK PACKS

DATA SHEETS

DATA RECORDS

ISOMETRICS

P & IDs

JOB SAFETY ANALYSIS (JSA)

JOINT COMPLETION CERTIFICATE

(JCC)

FLANGE PREPARATION AND INSPECTION

JOINTS LOCATION VERIFICATION

FASTENERS MATERIALS, SPECIFICATIONS AND

CONDITION

GASKETS MATERIALS, SPECIFICATIONS AND

CONDITION

VERIFICATION OF FLANGES PRIOR TO ASSEMBLY

OPEN JOINTS TO BE VERIFIED FOR ITS FLANGE

SURFACES & PIPING CLEANLINESS

INSPECTION CONDUCTED BY CLIENT QA / QC & MCCS

BOLTING

MANUAL BOLT

TORQUING

HYDRAULIC BOLT

TORQUING

HYDRAULIC BOLT

TENSIONING

ASSEMBLY COMPLETION

TAGGING OF COMPLETED

JOINTS

ISSUANCE OF JCC WITHIN WORK

PACKS

UPDATE JOINT REGISTER

** REPAIR / FLANGE BREAKOUT

PERMIT TO WORK (PTW)

JSA

JOINT REGISTER

VERIFICATION OF SYSTEM FOR HANDOVER PRIOR TO JOINT

BREAKOUT

CONFIRMATION OF JOINT / VENDOR(S) SPECIFICATIONS

PRIOR TO BREAKOUT OF JOINTS

VERIFY FLANGE DETAILS AND SPECIFICATION PROVIDED BY

CLIENT

CARRY OUT REPAIR / JOINTS BREAKOUT

MANUAL BOLT TORQUE / HYDRAULIC BOLT TORQUE /

HYDRAULIC BOLT TENSIONING

INSPECTION AND APPROVAL FROM CLIENT UPON REPAIR

COMPLETION

RE-CERTIFICATION ISSUANCE OF JCC WITHIN WORK PACKS

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 IN SEQUENCES AS FOLLOW; ① PRE-ENGINEERING

JOINT REGISTER PREPARATION OF WORK PACKS FLANGE PREPARATION AND INSPECTION

② BOLTING MANUAL BOLT TORQUE HYDRAULIC BOLT TORQUE HYDRAULIC BOLT TENSIONING

③ ASSEMBLY COMPLETION TAGGING OF COMPLETED JOINTS ISSUANCE OF JCC WITHIN WORK PACKS UPDATE JOINT REGISTER ** REPAIR / FLANGE BREAKOUT


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:

① JOINT REGISTER ② PREPARATION OF WORK PACKS ③ FLANGE PREPARATION AND INSPECTION

JOINT REGISTER A Joint Register will be created to compile all Joints data that are to be managed /

tightened / breakout.


PREPARATION OF WORK PACKS The Work Packs will consist of the following documents:

① DATA SHEETS providing information of Joint specifications, tools required, torque and tension values

② DATA RECORDS detailing information of materials, specifications and tools used

③ ISOMETRICS given by Client to be extract to Data Sheets and Data Records

④ P & IDs obtained from Client will be organized to Data Sheets and Data Records

⑤ JOB SAFETY ANALYSIS (JSA) will be designed to suit the project requirements by using Joint Register as a reference

⑥ JOINT COMPLETION CERTIFICATE (JCC) will be created prior to Bolting and Assembly Completion Stage


FLANGE PREPARATION AND INSPECTION ① JOINTS LOCATION VERIFICATION will be conducted by MCCS personnel

during site inspection

② FASTENERS MATERIALS, SPECIFICATIONS AND CONDITION will be inspected by MCCS personnel according to Data Records input

③ GASKET MATERIALS, SPECIFICATIONS AND CONDITION will be carefully examined by MCCS personnel based on Data Records obtained

④ VERIFICATION OF FLANGES PRIOR TO ASSEMBLY to ensured specification are inline with the Data Records and Data Sheet

⑤ OPEN JOINTS TO BE VERIFIED FOR ITS FLANGE SURFACES AND PIPING CLEANLINESS prior to Bolting and Assembly scope

⑥ 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 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:

① MANUAL BOLT TORQUING ② HYDRAULIC BOLT TORQUING ③ 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 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.


** 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 : ① Permit to Work (PTW) ② Job Safety Analysis (JSA) ③ 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: ① Manual Bolt Torque ② Hydraulic Bolt Torque ③ 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


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 SOFTWARE OVERVIEW


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

FLANGE MANAGEMENT SYSTEM SOFTWARE BENEFIT

THANKS FOR YOUR ATTENTION

Documents

Mechanical Completion and Commissioning Services Ltd …mccsinternational.com/presentation/MCCS_PRESENTATION_Flange_M… · Mechanical Completion and Commissioning Services Ltd