FLANGE AND COMPRESS JOINT INTEGRITY

OBJECTIVES

•  The participant will gain an in-depth knowledge of flanges and fitting material specifications, fabrication process and influence on mechanical properties of strength and toughness, to help in material selection and failure analysis.

•  The participant will understand the technical background to the design equations, and their application to the design of flange systems and maintenance. The course addresses rules of good practice in layout of flange joint for reliable operation.

•  The participant will gain a practical understanding of flange and pipeline corrosion mechanisms, how to recognize them, classify them and resolve them.

•  The participant will be introduced to the latest techniques and research in flange and pipeline integrity to analyze a degraded condition due to either corrosion or mechanical damage.

•  The participants will review case histories of field failures and will evaluate their cause and solutions to avoid recurrence.

COURSE OUTLINE

Flange joint & system maintenance consist of:

-          Flange & Mechanical joints, Pressure & leaks testing, Repair techniques, Grinding & Welding technique, Etc

-          Theory of component within the Bolted Flange Connection

-          Preparation of bolted flange connection prior to assembly

-          Assembly of bolted flange connection

-          Tightening method by conventional tools & Hydraulic tensioning equipment

-          Demonstration and practical / and safe practice of assembly and tightening

-          Inspection process for component (Flanges, Bolts, Gasket )

-          Theory / Practical alignment procedures of Flange joint installation

-          Bolt and flange strength

-          Stress Analysis and Tightening Joints

-          Flange design and standard

Integrity for Occasional load consists of:

-          Recognizing & Solving Liquid hammer.

-          Pump Station transients.

-          Flange failure.

-          Gas discharge transients

-          Two-Phase Liquid –Vapour Transients

-          Two-Phase Liquid-Gas Transients

Corrosion, Assessment and Repairs consist of:

-          Introduction to Practical Corrosion

-          Practical corrosion, Mechanical damage to flanges.

-          Failure mechanism / Root Cause

-          Classification of Corrosion Mechanisms

-          General wall Thinning

-          Local Corrosion: Galvanic Effects

-          Crevice corrosion

-          Pitting Corrosion

-          Environmental Effects

-          Hydrogen and H2S Effects

-          Microbiological Corrosion

-          Corrosion Protection

Flange and Mechanical Joints

-          Overview of Different Types of Flanges and Application

-          Gasket of Bolt Selection

-          Causes of Flange Leaks and How to Resolve

-          Case Study of Flange Failure

-          Assembly of Flange Joints and Leak Tightness

Pressure and Leak Testing

-          The Difference Between Leak Testing and Pressure Testing

-          Review of Difference Testing Techniques

-          The Purpose of Hydro test

-          How to Conduct a Hydro test

Repair Techniques and Maintenance

-          The New ASME Repair Standards

-          The Fundamentals of Repair package

-          Flange and Component Replacement

-          Grinding and welding

-          Welded Sleeve

-          Flush Patch Repair

-          Fillet Welded Patch

-          Weld Overlay Repair

-          Mechanical Clamp with Sealant Injection

-          Mechanical Clamp without Sealant Injection

-          Insertion Liners

-          Painted and Brushed Liners

WHO SHOULD ATTEND

The course is intended for engineers, maintenance technicians and Supervisor, inspectors responsible for the design, integrity, maintenance and repair of flange and mechanical joints.

INSTRUCTOR

• Dr. Ir. Viktor Malau, DEA & Team
• Ir. In Jumanda Kasdadi, MT & Team
• Ir.  Joko Waluyo, MT., Ph.D& Team