Why does the industry need PSI Management?

10% of critical joints leak on start-up
17% of hydrocarbon releases on offshore sites are from leaking joints – onshore this could be higher
Incorrect bolt loads and uncontrolled tightening methods are two main causes
Inappropriate gasket selection and flange distortion are further prime causes
Safety standards worldwide have to improve to protect the health and safety of plant operatives (UKOOA – United Kingdom Offshore Operators Association, have introduced guidelines for the management of integrity bolted pipe joints)
Leaking joints are costly, hazardous to health, safety and the environment, and reduce operational efficiency

Goals and Objectives of Furmanite’s PSIM Program

Zero leaks at plant’s start-up and throughout the working life of the mechanical joint
Provide an end-to-end managed service that is focused on minimizing joint related expenditures
Ensure work and project management is performed by experienced technicians that are onsite and always available
Streamline the communication process by providing a single point for storing and accessing supporting project documents and historical joint condition data
Provide ongoing, yet unobtrusive maintenance that fits into your plant’s production schedule

4 Satges of Pressurized Systems Integrity Management – PSIM

Stage 1 – Pre-site preparation

Stage 2 -Site preparation

Stage 3 -Post Start-Up

Stage 4 – Flange box-up and final inspection

Full traceability at all times

Furmanite has developed a unique user-friendly software programme to manage all data and provide full tracability to the customer.

Authorised users (Furmanite staff and customers) can access the system over the Internet using any standards compliant web browser
This provides the most widespread access to the system and allows Furmanite staff to use the system even when in the field or when connecting from inside customer networks
Data is accessible to you at all times during and post-shutdown
Data builds to create full detailed catalogues all critical joints
Identifies current work status in real-time
Intuitive user interface that promotes easy and accurate data entry
Open data architecture to allow the system to be extended easily and integrated with other information management systems as required
Access to the system is restricted to valid user accounts
The system is hosted on a server with a server certificate allowing all data exchanged between the server and client browsers to be encrypted using 128-bit SSL technology
Reporting – Joint condition surveys and full histories in pdf format and browse/view supporting docs

User benefits

Provides an effective project management tool for joint integrity projects
Streamlines the process for surveying flanges, and maximises data accuracy by generating survey forms with pre-filled information
Increases customer confidence by providing secure access to up-to-date status of individual flanges and overall project progress
Facilitates project management by providing a single point for storing and accessing supporting project documents
Provides access to historical data e.g. joint condition and maintenance, to support engineering decisions and increase value to customers

Pressurized Systems Integrity Management (PSIM) – Start maximizing operational efficiency of mechanical joints from day one

Throughout your plant’s operational lifecycle you expect to have leaks, to perform general maintenance and occasionally replace equipment. It’s all a part of doing business. But what you shouldn’t expect – or tolerate – are leaks that occur at initial start-up. Unfortunately, however, that’s just what many plant managers around the world are doing.

According to a recent UKOOA/HSE (Health and Safety Executive) investigation undertaken in the North Sea, more than 25 percent of all bolted joints leak at their initial start-up. Furmanite considers joint leaks at any operational stage to be unacceptable, and so should you.

Furmanite’s comprehensive Pressurized Systems Integrity Management (PSIM) program will enable your plant to realize immediate and ongoing benefits throughout the working life of your plant’s mechanical joints. Furmanite can ensure zero leaks at start-up, as well as provide ongoing maintenance to prevent future leaks. Companies that partner with Furmanite and execute PSIM are able to reduce fugitive emissions and the related testing costs, reallocate resources (including personnel and equipment), and decrease downtime.

PSIM – the first and last word in leak prevention

Incorrect bolt loads and uncontrolled tightening methods are two of the main reasons for leaking joints. A bolt that is correctly tightened will prevent emissions, avoid connection loosening due to vibration, and inhibit joint damage and failure.

Furmanite’s PSIM program addresses every stage and every possible situation – from engineering analysis, unbolting and inspection to machining as required, gasket installation, assembly, and controlled bolting, plus full documentation for traceability.

As part of the program, our skilled technicians can apply various techniques in order to meet your specific bolting requirements, such as bolt tensioning using advanced hydraulic technology and/or torque tightening, fastener breakout, hot bolting, stud change out, and bolt stress measuring. Any and all of these techniques will make for a more accurate and safer bolt tightening process, eliminate the need for re-bolting, and ensure zero leaks at start-up.

PSIM can also be applied to a wide variety of critical bolted connections, including pipework flanges, heat exchangers, pressure vessels, pumps and compressors, reactors. Furmanite can also apply PSIM when managing the removal, overhaul and re-installation of flanges during scheduled plant shutdowns.