Process leaks threaten employees, installations, and the environment

In many territories, installations operate under arduous pressures or even beyond their original design life, elevating the risk of joint leaks. Several government agencies have examined the causes of leaks and concluded their number and severity will increase unless improved management procedures are introduced.

Hydratight has been implementing these technical solutions for years, allowing the operator or contractor to achieve leak-free start up and production. They are known as:

Joint Integrity Management Solutions™ Jims™

Hydratight are committed to ensuring customers’ assets and installations have the safest and most environmentally friendly bolted joints. This commitment is underpinned by a package of initiatives, products and services, supported by experienced engineering teams, available anywhere in the world.

Why is joint integrity so important?

Leaks delay production start-up, cause unplanned shutdowns, and always impact budgets negatively. They are unacceptable and can be avoided.

This is how much leaks could cost you:

• 3” 1500lb gas line shut down due to insufficient service bolt load: Lost production cost $2.25m
• 16” 300lb Valve tightened using untrained operators, subsequently catching fire: Lost production value $1.68m
• 4” 150lb seawater flange critically overlooked causing a
  power generator set to shut down: Lost production cost £3m
• Multi-asset operator evaluated the average cost of all
  their leaks at $100k per leak

Engineering Services

Hydratight works with major engineering contractors to design safe, leak free, and consistent bolt loads prior to shutdown or before project construction begins. This process often requires detailed flange stress calculations as well as identifying any tooling requirements, special procedures and training that may be required.

Bolted joints can leak

In recent years, investigations by the process industries have highlighted the seriousness and importance of preventing leakage:

For example, UK HSE* found that on average 243 leaks occurred per year offshore for the period 1992-2002, 17% of which occurred from bolted joints.

Likewise, the Pressure Vessel Research Council** reported the average plant in North America suffers from 180 leaks per year, 2-3% of which lead to full plant shutdown or major repair.

Both studies also found:

• 29% of the leaks were attributed to poor design or incorrectly fitted components
• 26% attributed to mechanical failure
• 12% due to poor workmanship or lack of competency

As a result, a Leak Reduction Group was formed between owners, contractors, governing bodies and Hydratight to develop a framework document for the management of bolted joints.

In June 2002, the ‘Guidelines for the Management of Integrity of Bolted Pipe Joints’ was published. This document sets out the principles of joint integrity management and examples of best practice.

* UK Offshore Technology Report – OTO 2001/055
** “Flanged Joint User Survey” PVRC 1985

Previous studies into joint integrity have revealed:

• 25% of leaks took place during start-up
• 51% of leaks occurred during operation
• 17% of all releases occurred from bolted joints

The Hydratight philosophy:

• Our processes and procedures will be well planned, safe and lean
• Our procedures will be industry best practice
• Our client integrity tests will be leak free
• Client’s production will be leak-free at all times
• Our leak-free metric will be the best in the industry

Download the JIMS brochure

For services available in your area please contact your local representative.