Robert Noble

8/13/2019 Robert Noble

1/17

Hydrocarbon Leak Reduction in

Bolted Joints

Robert Noble: Technical Director: 1tegrity


2/17

Hydrocarbon Leak Reduction in Bolted

Joints

Lessons Learned in the North Sea

Evolution in Management Systems

Energy Institute Guidelines for Management of

Integrity of bolted joints in Pressurised Systems

Discussion on simple real issues.


3/17

Lessons Learned -Case Study

Courtesy of Chevron

Step Change HCR workshop June 2011

Erskine NUI -Ignition and fire

Jan 2010.

No Injuries or

environmentalloss

15M lost

production +

reinstatement


4/17

Erskine Case Study Why it happened

Why?

Loss of containment due to corrosion of

carbon steel seal ring in hub connector.

Why

?

Why

?

Wrong Seal ring material installed during

construction many years earlier.

Why

?Lack of understanding of assembly issues

associated with hub connectors

Confusing colour codinggrade markings and

identification of seal ring

materials.


5/17

Industry Lessons Learned

Competence on hub connectors

lagged behind ANSI flanges in

previous best practice training

Identification of Seal ring material

was inconsistent across industry

Systems including Positive Materialidentification within bolted joints

need updating.

LESSON INDUSTRY ACTION

WIP

UPDATE IN PROGRESS

NEW BEST

PRACTICE

A CLASSIC ASSET AGEING ISSUE!


6/17

Management of Integrity of Bolted Joints - Evolution

DNV Guidelines

Published 2011

ASME PCC-1-2010

Published 2010

EI GUIDELINES

Published 2007

HSE SAFETY

NOTICE 2/2000UKOOA GUIDELINES

Published 2002

EI GUIDELINES

Updating 2012/13


7/17

Bolt Load Calculations - Evolution

VDI 2230

ASME PCC-1-2010

Appendix O

Published 2010Update in Progress

% YIELD

EN1591-1 Revision in

progress due(2013)

ASME VIII BPVC

TAYLOR FORGE

PD5500

PVRC

TRENDS.

FOCUS ON GASKET NEEDS

MORE GASKET DATA

FEA OF FLANGE

HIGHER BOLT LOADS

TIGHTNESS CLASS


8/17

Training & Competence Bolted Joints - Evolution

ECITB PF010

ECITB PF018

ECITB PF019

UKCS

PF Competence> MJI

Competence

NORWAY

? > OLF118

training

2000

ASME

? PCC-2010

App A (2012/13)

EUROPE

Var>Training

Spec

>Competence

standard

2005 2010

ECITB

PF015MJI UNITS

EN1591-4

ASME PCC-1

APP A


9/17

Guidelines for Management of Integrity of

Bolted Joints in Pressurised Systems Review

2012/13

2002

2007

Working Group Active

Chair and SectionChampions appointed

5thMeeting June 2013

Progress good Target Issue Q4 2013

2013


10/17

Guidelines for Management of Integrity of Bolted Joints in

Pressurised Systems Review 2012/13 Proposed Sections

Ownership, Support andIntegration

Management Process

Technology and Practice

Criticality Assessment Training , Competence

and Awareness

Records, Data

Management and

Tagging

In-service Inspection

Management of Leaks

Analysis, Learning and

Improvement

Integrity Testing.

Lessons Learned. Hot bolting and bolt

replacement.


11/17


Pressurised Systems Review Key updates identified to date

Material control/PMI for joint components.

Colour coding and marking of materials.

Hot Bolting increasing due to asset

ageing and bolt change-outs.

Paint under nuts on new build.

Hardness of RTJ rings versus grooves

Definition of Technical Authority role.

Types of bolts and re-use of bolts.

Bolt Load selection.

Washers !


12/17


Pressurised Systems Review Key updates identified to date

PTFE Coated Bolts

Training and CompetenceKey Update.

Criticality assessmentBring in Aging.

Disassembly as important as assembly

Hub Connectors more focus Special Flanges add guidance on new

flange types.

Data Management & Tagging (Spec Blinds!) Extend Lessons Learned and Knowledge

sharing.


13/17

Hot Bolting

Desire increasing due to Asset Aging.

Risk increasing due to Asset Aging.


14/17

Criticality Assessment

Table2002 2007 Matrix 2013


15/17

REAL ISSUES

15


16/17

The importance of Nuts

USS Iwo JimaEn route to

Operation Desert Shield 1990

10 US Navy Sailors killed by 8

Nuts

Why

?

4 Valve Bonnet blew

releasing superheated

steam to manned

compartment

Valve repaired in local

shipyard en route -wrong material nuts

installed

Box said High StrengthFastenersassumed

good enough!

Why

?

Why?

Alloy Steel

Coated

Brass

Courtesy of NASA and US NAVY


17/17


Pressurised Systems Review Industry Input required

Industry grows and becomes safer when weshare knowledge and lessons learned, if you

have anything to contribute to the rewrite of

the Energy Institute Guidelines for

Management of Integrity of Bolted Joints in

Pressurised systems please contact:

[email protected]@energyinst.org
mailto:[email protected]:[email protected]

Robert Noble

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