Products & Services

Flange Management and Joint Integrity

James Walker companies supply industry worldwide with professional flange management and joint integrity programmes and services that go well beyond the accepted norms in terms of...

  • Professional advice and planning
  • Quality of on-site and off-site workmanship
  • Standards of safety and care
  • Customer satisfaction from initial survey to completion and beyond

Flange Management and Joint IntegrityA James Walker Flange Management Solution evaluates bad actors, problematic and critical path joints using the knowledge gained from over 30 years of dealing with clients’ most important bolted connections. Using limit analysis software, James Walker calculates the operational stresses of the gasket, fasteners and flanges throughout the operational cycle to create a detailed picture of the most stressed areas and provide a fastener load that is optimal for the bolted joint in its entirety.

James Walker’s Joint Integrity Programme (JIP) is predominantly a site based service that builds on the information gleaned from our Flange Management offering by identifying, evaluating, inspecting and signing-off as mechanically complete and operationally fit for service all types of bolted flange connections for industries both onshore and offshore. The service also offers Root Cause Analysis for all incidents of leakage, providing detailed reports on how and why such incidents may have occurred.

The service covers all bolted flange connections from pipework, pressure vessels, heat exchangers, valves and many other fixed and rotating plant equipment, to gear boxes, pumps, wind turbines, virtually all joints that rely on a bolted flanged connection.

James Walker’s JIP approach of ‘Evaluate, Design and Apply’ delivers long-term solutions rather than short-term fixes that need to be repeatedly applied at considerable cost. Our aim is to ensure that when high-integrity joints have been assembled, they stay that way.

Flange Management and Joint Integrity

JIP comprises a series of modules that can be tailored to suit each client's requirements. The full programme can be incorporated, or simply a selection of those modules that are found to be most beneficial:

These modules include but are not limited to...

Pre-Engineering
An evaluation of the bolted connection, its flanges, fasteners, gasket, operating and design conditions through the engineering drawings to ascertain the criticality rating.

Critical Database
Once defined, critical joints are logged on a Critical Joint Register (CJR) using a rating of 1, 2 and 3, with 1 being the most critical.

Calculations
Joints given a criticality rating of 1 are calculated using EN1591-1 limit analysis software. This allows us to view the operational stresses of all components of the joint and provide the optimal fastener/gasket/flange load for continued operations. Joints with a critical rating of 2 and 3 are calculated using standard calculation practices.

Inspection (Disassembly)
The flange and flange sealing areas are inspected in accordance with the ASME PCC-1 Appendix C and D guidelines for continual operational suitability.

Recommendation
If any damage or defects are found that do not conform to the tolerances recommended in the ASME guideline, any remedial work such as flange facing will be recommended. Also, any recommendations such as change of gasket type/materials, bolt materials or tightening accuracy found to be of benefit after completion of calculations will also be advised.

Supervision
James Walker can supply highly trained engineers to supervise the works to ensure that the assembly and bolting processes are completed to the highest industry standards. James Walker can also supply senior engineers to manage the entire project and at client’s request can complete a turnkey service from evaluation to sign off.

Final Inspection
A final inspection will take place upon completion of the joint assembly and bolting to ensure that the flange joint alignment guidelines outlined in ASME PCC-1 Appendix E have been adhered to in full.

Sign Off/Punch
Once the joint has been supervised from disassembly through assembly and bolting, and conforms to the standards outlined in the ASME guidelines, then James Walker will punch the joint as mechanically complete and suitable for continued operation.

The purpose of following the modules of the James Walker JIP programme is to...

  • Build a history of your site’s bolted connections
  • Gain full traceability including who disassembled the joint, who assembled the joint, what equipment was used, was it calibrated and what bolt loads were used etc.
  • Eliminate unwanted downtime by ensuring a ‘right first time’ attitude
  • Ensure critical path and critical joints are given the best opportunity to remain leak free
  • Keep product loss to a minimum improving health and safety and environmental performance

James Walker also offers and advises many other complimentary services such as...

Permanent and Shutdown Tagging using P&ID’s to assist with identification and reporting. We collect data from your site that can help lead to general improvements in plant efficiency.

The input of data into flange management programmes to improve traceability and data management.

James Walker are experts in heat exchanger and pressure vessel bolted joint solutions. We evaluate, report and provide engineered solutions to keep loss of primary containment (LOPC) and fugitive emissions at a minimum. This service can involve analysis, on-site measurement, dismantling, machining, installation, bolting and on-going site support.

James Walker has been in business for over 135 years. Our industry leading skills in gasket and bolting technology, high integrity fluid sealing and site engineering are second to none and are utilised in their entirety for the JIP service.

ArrowDownload the Joint Integrity Programme Guide

Flange sealing improvement

The vital role of the flange gasket is too often overlooked. Our on-site and workshop-based services are based on the vast technical expertise of James Walker companies in the selection, manufacture and supply of the optimum gasket products and flange sealing capabilities. Moreover, our protection devices are well-proven products that help extend the operational life and long-term sealing efficiency of bolted flange joints.

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