A Flange Joint Management Service package will typically include:
Work Pack Development
Set up of Flange Register with each joint having a unique identification and referencing
All tooling and bolt loads identified and included in the Flange Register
Joints tagged before start of turnaround activities
Supervision and Technicians mobilised
QA & HSE Coordinator records all work carried out during the turnaround
Bolting and On-site machining equipment mobilised in customised 20′ containers
De-brief with client with all work documented for clients records
Flange facing can be used for a multitude of applications. Traditionally it is used to re-machine flange or heat exchanger faces in-situ when they have become worn, warped or damaged. The newly machined surface then allows for an improved seal, preventing leaks. Flange facers can also be used for machining pump bases, crane pedestals, manways, or any flat surface that is contained within the swing of the machine.
As a result of our specialised Flange Joint Management and Flange Facing services, BLJ In-situ Solutions has an excellent reputation as a Mechanical Maintenance and Shutdown Services provider. To learn more about our Flange Joint Management services, take a look at our FAQs below.
Flange Joint Management involves the systematic approach to ensuring the integrity and reliability of flanged connections in industrial piping systems. It includes activities such as inspection, maintenance, and optimization of flange joints to prevent leaks, improve safety, and enhance operational efficiency. Flanged joints are critical components in a piping system and are subject to wear and tear over time, so regular maintenance is crucial. At BLJ, we have specialised methods for accurately and precisely maintaining flange joints to minimise downtime.
Flange Facing is the process of machining the contact surfaces of flanges to create smooth and flat mating surfaces. It involves removing imperfections, such as corrosion, roughness, or damage, from the flange faces to ensure a proper seal when the flanges are bolted together. BLJ technicians perform field flange-facing services using specialised machines and tools.
Flange Joint Management is needed in various situations, including during the initial installation of flanged connections, regular maintenance intervals, system modifications or upgrades, and in response to leaks or integrity issues. It is essential to ensure the performance and reliability of flange joints throughout their lifecycle. Timely repair and maintenance of the flange can help plants avoid corrosion and leakages in industries such as oil and gas, petrochemical, construction, and more.
The Flange Joint Management process typically involves several steps. BLJ technicians start with an assessment of the flange joints, including visual inspections and measurement of critical parameters. Based on the assessment, necessary repairs or maintenance activities are identified, which may include flange facing, gasket replacement, or bolt tightening. After the repairs, the joints are tested for leakage using appropriate methods, and records are maintained for future reference and monitoring.
Flange Joint Management offers several benefits including helping prevent leaks and associated safety hazards, reducing downtime and maintenance costs, extending the service life of flange joints, and enhancing overall system integrity. Proper management ensures compliance with industry standards and regulations, improves operational efficiency, and minimises the risk of environmental contamination.
Hiring a professional for Flange Joint Management is essential to gain access to a qualified professional’s expertise and experience in handling flanged connections. At BLJ, all our on-site technicians possess knowledge of industry standards, best practices, and specialised tools required for effective maintenance services. They can accurately assess the condition of flange joints, identify potential issues, and perform necessary repairs or maintenance activities with precision, ensuring optimal performance and safety of the system. This efficiency translates into cost savings by prolonging the life of the system, reducing downtime and avoiding potential equipment damage caused by improper handling.
QCLNG Train 1 June / July Turnaround: BLJ was engaged by Shell (Curtis Island) to undertake a large site maintenance project which involved the isolation of the plant, machining 140 damaged flanges of varying sizes and then de-isolating the plant.
Shell’s QGC venture is located on Curtis Island near Gladstone in Queensland and acts as one of the leading onshore natural gas producers in Australia. Tapping into the Surat Basin, this operation consists of over 3000 production wells, 6 processing plants, 25 field compression stations, 2 water treatment plants, all connected to a two-train LNG export facility. Queensland Curtis LNG (QCLNG) Train 1 is part of the two-train LNG development operated by Shell.
Utilising BLJ’s comprehensive knowledge and experience in our most sought-after service, Flange Joint Management, 4 supervisors and 34 technicians were able to successfully maintain all 140 flanges which required attention. All site safety requirements and conditions were met by our dedicated team as they worked on flanges of all different sizes. Shell valued our efficiency and effectiveness in maintaining their Train’s flange joints.
BLJ successfully managed to supply cost-effective maintenance solutions to 140 flanges including over 1000 broken joints. There were 0 leaks detected upon start-up – a commendation to our hard-working and dedicated team.