Benefits of Integrity Assurance
- A proven approach to preventing leaks
- Your plant turnaround projects kept on schedule - and on budget
- Risks identified before they become problems – eliminating costly rework and multiple tests
- Improved site safety – flange joints assembled right first time
- Industry proven and trusted quality control and assurance
- Programs customized to suit your operations
- Same level of quality control applied to bolted joint assembly as for welded joints
Elements of Integrity Assurance
Gap Analysis
Technical Authority review (at client offices or on site) of all existing Joint Integrity procedures, processes, and management systems, benchmarking against industry best practice, and producing a detailed reporting identifying 'gaps' and recommendations for improvement.
Benefits
Independent assurance that all client processes, procedures, and management systems represent industry best practice.
Contracting Model
- Engineering Consultancy: Yes
- On-site QA/QC Compliance: Yes
- On-site Execution: Optional
Procedure Development
Remote review and development of any client technical or operational procedures, whether task, control, or management based.
Benefits
Client can remain in line with industry best practices through the development of a proper joint integrity program.
Contracting Model
- Engineering Consultancy: Yes
- On-site QA/QC Compliance: Yes
- On-site Execution: Optional
Engineering Support
Ongoing access to Hydratight's global team of Technical Authorities to provide expert guidance, troubleshooting, and support on any Joint Integrity related technical or engineering issue.
Benefits
Expert support wherever and whenever the client needs it.
Contracting Model
- Engineering Consultancy: Yes
- On-site QA/QC Compliance: As Required
- On-site Execution: As Required
Flange Management Software
Bespoke Integrity Data Management System (iDMS) for any asset / plant / site to record data, plan, manage, and provide a project delivery tool for the on site execution of any Joint Integrity workscope.
Benefits
Provides a permanent, searchable record of every joint’s history, along with a means to manage, track and control the status of every bolted joint during the planning / execution of a bolting workscope, helping to avoid errors, improve efficiency, and ensure a client’s procedures are being correctly applied.
Contracting Model
- Engineering Consultancy: Yes
- On-site QA/QC Compliance: Yes
- On-site Execution: Yes
Joint Integrity Inspectors
Supply training and compliance management to any client, contractor, or sub contractor involved in controlled bolting, onsite machining, or flange management activity.
Benefits
Bolting is a specialised skill where training is not a guarantee of competency. Controlling the competence of personnel involved in the assembly and controlled tightening of joints has consistently been proven to be a key factor in preventing leaks
Contracting Model
- Engineering Consultancy: No
- On-site QA/QC Compliance: No
- On-site Execution: Yes
Training and Compliance Management
Supply training and compliance management to any client, contractor, or sub contractor involved in controlled bolting, onsite machining, or flange management activity.
Benefits
Bolting is a specialised skill where training is not a guarantee of competency. Controlling the competence of personnel involved in the assembly and controlled tightening of joints has consistently been proven to be a key factor in preventing leaks
Contracting Model
- Engineering Consultancy: No
- On-site QA/QC Compliance: No
- On-site Execution: Yes
Field Service Technicians
Supply uniquely qualified field service technicians to client sites to directly perform any controlled bolting, on site machining, or flange management activity.
Benefits
The use of specialised bolting personnel minimises rework, with all bolting executed 'right first time'. No 'search & repair'. No 'leak & fix'.
Contracting Model
- Engineering Consultancy: No
- On-site QA/QC Compliance: No
- On-site Execution: Yes
Equipment Rental and Sale
Supply of a comprehensive range of in-house calibrated hydraulic bolt tightening, on site machining, and associated ancillary equipment to support the execution of controlled bolting, on site machining, or flange management workscopes.
Benefits
The use of high quality, calibrated bolting equipment is a key means by which control is applied to the process of bolting, ensuring the correct bolt load, and hence Joint Integrity is achieved.
Contracting Model
- Engineering Consultancy: Optional
- On-site QA/QC Compliance: Optional
- On-site Execution: Yes
Bolt Load Calculations
Informate bolt load calculation engine, which provides optimized bolt load values and torque/tension values for any joint application, whether coded or not. Informate contains an extensive range of joint types, flanges, gaskets, lubricants, and bolting materials.
Benefits
Ensures access to a source of bolt load calculations that is controlled, independently verified, and is in line with industry best practice.
Contracting Model
- Engineering Consultancy: Yes
- On-site QA/QC Compliance: Yes
- On-site Execution: Yes
Joint Integrity Engineers
(On Site) management of any Joint Integrity program, providing supervision, technical resource, training, and management reporting, coordinating the introduction of Flange Management Software, and ensuring full compliance with a clients Joint Integrity program by any personnel involved in Joint Integrity activity.
Benefits
Provides independent assurance that a client’s Joint Integrity processes, procedures, and mandated mechanical engineering standards are being correctly implemented.
Contracting Model
- Engineering Consultancy: Optional
- On-site QA/QC Compliance: Yes
- On-site Execution: Yes
Bolt Load Verification And Assurance
Measure, adjust and record the bolt load induced by the chosen bolt tightening methodology. Follow up with periodic non-invasive bolt load checks.
Benefits
Verify the correct bolt load has been achieved within the specified tolerance. Prevent subsequent joint failure due to vibration, material yielding, cyclic load.
Contracting Model
- Engineering Consultancy: Optional
- On-site QA/QC Compliance: Optional
- On-site Execution: Optional
Equipment Modification & Design Engineering
Where standard tooling is unsuitable, tool modification and bespoke equipment solutions can be provided by Hydratight's global team of Design Engineers, from one of our global technical centers of excellence.
Benefits
The ability to customise allows for needed flexibility and assurance in difficult conditions.
Contracting Model
- Engineering Consultancy: Optional
- On-site QA/QC Compliance: Optional
- On-site Execution: Optional
INCLUDED IN THE HYDRATIGHT INTEGRITY ASSURANCE PROGRAM:
Project Planning & Project Management
Evaluation of Processes and Procedures
Inspectors to Verify Work is to Standard
Fully Trained and Competent Engineers
iDMS Flange Management Software
Ultrasonic Bolt Load Measurement
Turnaround Management
Identification of Training Needs
The Hydratight Joint Integrity Assurance Program is a consultancy, planning and inspection service ideal for plant turnarounds, refinery maintenance, and continuous asset integrity management.
Why Hydratight?
- The leaders in joint integrity, from day one.
- Our proven process and highly competent workforce means our work is guaranteed to be leak free.
- Hydratight ‘invented’ joint integrity.
- Setting the standard for leak-free services and workforce competency is what we do – every day, every year, year after year.
- Our ECITB and ASME certified training and competency programs mean technicians bring the highest level of experience, knowledge and capability to every job task.
- Our technical leadership is built into propriety software - used as the gold standard by the industry.
THE HYDRATIGHT LEAK FREE GUARANTEE
Hydratight offers a Leak Free Guarantee for every joint assigned to us under an assemble and tighten and/or Assurance Services contract. We guarantee, subject to the mutually agreed upon terms and conditions, that every joint will pass its respective integrity test the first time. The Leak Free Guarantee is valid for new construction, repair or maintenance contracts, and equally applicable on very small to extremely large work-scopes. Any joint type can be guaranteed, subject to a review by one of our global Subject Matter Experts.
Testimonials
"The objective of using Hydratight was to achieve a leak free start-up and it was achieved. We have no hesitation to record their commendable performance and recommend them on other requiring bolted joints management."
- Turnaround Manager at Petrochemical Company
"The Hydratight personnel executed their on-site machining duties with skill, professionalism, flexibility and cooperation at all times. Their bolt tensioning personnel completed the de-tensioning, inspection, and tensioning of all of the ANSI 2500 and 2500lb rated flanges on the Hydrocracker and the unit was subsequently started up and has performed to date without a single leak. "
- Shutdowns and maintenance manager at Petroleum Company
"Hydratight delivered our objective leading to leak free start-up of the plant by implementing best practices, using the right equipment, employing trained and highly competent people, and managing all these effectively using a locally based team. "
- Construction director at Oil & Gas Solutions Provider