LAGCOE '15: A new approach to flange joint maintenance

Companies operating in the oil and gas industry have seen significant improvements in the safety plans, policies and practices over the last couple of decades. This has partially been introduced out of necessity but also due to advancements in the technology and equipment which is being deployed. Legislation has also been a driver for safer working practices and there are various laws with implications for working with and maintaining pipelines.

The up-, mid- and down-stream energy sectors have all seen radical changes in the way hydrocarbons and their derivatives are found, exploited, transported and refined and one only has to attend some of the large industry trade shows to see and experience how these activities have been improved. The majority of these enhancements have been due to technology developments, from an engineering, manufacturing or processing perspective.

The focus of these is obviously founded on doing things quicker, better, more efficiently, cost effectively and more safely. But there are similar developments within the pipeline servicing market which aren’t as high profile or receive the same level of publicity, yet they bring similar bottom line benefits to those both planning and implementing pipeline maintenance projects, particularly in ageing assets. One example is flange joint management.

Why maintain flange joints?

Any pipeline owner or their third party contractor needs to undertake flange maintenance activities to ensure the optimal performance of the pipeline or to avoid potential reliability or safety issues. The annular gap around the outside diameter of a flange joint is subject to the penetration of debris, damp and other contaminants which can result in the degradation of the flange, gasket and seal. Excessive flange corrosion is dangerous and the resulting maintenance could lead to unscheduled downtime or flange or gasket replacement. Accessing and maintaining flange joints is a key part of any pipeline servicing project and throughout the world, the traditional approach to handling such work is for teams of personnel to utilize equipment and use manual processes which have been in existence for 20 to 30 years. Take the example of a flange joint which has fused together but needs separating or spreading to facilitate essential maintenance work.

Traditional approach

Flanges are manufactured in a range of sizes, and irrespective, they are heavy items which cannot be easily manually manipulated or spread. The traditional, and still commonly seen practice for spreading flange joints involves using ropes, pulleys, tirfors, chains or in some instances small cranes, to support the flange pipe-work, while colleagues physically attempt to separate flange joints with hammers, blocks, or mallets.