Flange leakage solution for a refinary client

Background

Our client is a refining plant, due to the unrigorous flange joint assembly of the hydrogenation reactor, the flange warping deformation under high temperature, high pressure operation, The effective load of the bolts was large, leading to long-term leakage of the flange.

Case study

In the overhaul installation of oil refining and chemical plants, due to the varying quality of construction personnel, the number of managers and technicians is small, the overhaul period is short, and the installation process of flange joints lacks supervision and quality control, resulting in the risk of leakage after the completion of flange joint assembly.

1, The construction personnel do not have standardized workflow and professional installation knowledge;

2, Managers and technicians do not have a strong sense of management, and there is no uniform implementation standard;

3, The fastening machine is single and few in number, which can't meet the requirement of bolt fixed torque fastening;

4, Process control without supervisors, quality standards can not be put into place.

Our solution

We developed standard operating procedures according to FLANGE JOINT INTEGRITY MANAGEMENT

Trained Personnel: 3

Supervisors: 1 on-site control technician

Bolt cleaning: inspect and lubricate disassembled bolts to remove rust

On-site machining: Machining of warped and deformed flange surface

Operation plate: bolt fastening process card

Installation tools: drive shaft wrench PU-20 two synchronized fastening

Complete the flange assembly according to the standardized workflow of flange joint, after testing the pressure and tightness, flange operation without leakage.