Flange Management
Ensuring Leak-Free Integrity in Critical Piping Systems
Our Flange Management Services provide end-to-end support for safe, leak-free, and efficient operations across upstream, midstream, and downstream oil & gas facilities. We implement a structured, fully traceable process to manage flanged joints during construction, shutdowns, turnarounds, and commissioning phases.
Core Capabilities
Flange Register Development
We establish a comprehensive, digital flange register that serves as the single source of truth for all joint-related information throughout the asset lifecycle. Each flange is uniquely tagged and recorded with full traceability, capturing critical data such as:
Location & System Reference – precise identification of where each flange is installed within the piping system.
Technical Specifications – including size, rating, material grade, pressure class, and design codes.
Joint History – details of installation, disassembly, inspections, maintenance activities, torque/tension values, and personnel involved.
Associated Components – gaskets, bolts, nuts, and lubricants used, along with batch numbers and certifications.
Criticality Assessment
We apply a risk-based methodology to evaluate and prioritize flanged joints across your facility. Each joint is assessed based on key factors such as operating pressure, temperature, service media, and location, along with the potential consequences of leakage or failure.
This structured ranking process allows us to:
Identify high-risk joints that require greater attention during inspection and assembly.
Optimize maintenance and resource allocation by focusing efforts where they matter most.
Enhance safety, reliability, and compliance, while minimizing unplanned downtime and environmental impact.
Engineering & QA Planning
We provide structured engineering and quality assurance planning to ensure every joint is assembled correctly and performs reliably. Our approach covers:
Specification Reviews – verification of design data, material compatibility, and compliance with client/industry standards.
Gasket & Bolt Selection – careful matching of components to operating pressure, temperature, and service media.
Torque & Tension Calculations – precise load calculations to ensure correct clamping force and uniform stress distribution.
Method Statement Preparation – clear, step-by-step work instructions to guide safe and consistent execution.
QA/QC Integration – alignment with client quality systems, ensuring traceability and regulatory compliance.
Controlled Disassembly & Inspection
We follow strict protocols for the safe and efficient disassembly of flanged joints, ensuring zero damage and full traceability at every stage. Our process includes:
Safe Joint Opening – controlled depressurization and stepwise unbolting to prevent mechanical stress or safety hazards.
Flange Face Inspections – detailed checks for corrosion, pitting, scratches, or misalignment that could compromise sealing integrity.
Cleaning & Surface Preparation – removal of debris, rust, or gasket remnants using approved methods that protect sealing surfaces.
Condition Assessment – evaluation of flange components, bolts, and gaskets for reuse or replacement as per standards.
Zero-Damage Protocols – strict adherence to best practices that safeguard equipment and maintain operational reliability.
Assembly & Controlled Bolting
We ensure every flanged joint is assembled to the highest standard using precision techniques and fully calibrated equipment. Our controlled bolting services include:
Accurate Bolt Installation – stepwise tightening sequences to achieve uniform load distribution across the joint.
Torque & Tension Application – use of calibrated torque wrenches and hydraulic tensioners to meet exact design requirements.
Compliance with Standards – execution in strict accordance with ASME PCC-1, client specifications, and international best practices.
Use of Verified Materials – bolts, gaskets, and lubricants checked for conformity, batch certification, and proper condition before use.
On-Site Specialist Teams – trained technicians ensuring safety, precision, and traceability throughout the process.
Documentation & Flange Tracking
We provide comprehensive digital documentation and tracking systems to ensure full transparency and traceability of all flange-related activities. Our process includes:
Digital Data Capture – recording torque values, bolt loads, gasket types, and flange specifications in real time.
Personnel Tracking – logging the names and certifications of technicians performing assembly, inspection, and testing.
Material Verification – documenting batch numbers, material certificates, and usage of bolts, gaskets, and lubricants.
Completion Status Updates – real-time progress reporting to monitor work completion across construction, shutdowns, or turnarounds.
Auditable Records – generating reports that meet client, regulatory, and industry compliance requirements.
Testing & Leak-Free Startup
We provide end-to-end support during the final testing and startup phase to ensure every joint achieves leak-free performance under operating conditions. Our services include:
Hydrostatic Testing – pressurization with water to verify joint integrity and overall system strength.
Pneumatic Testing – controlled air or gas pressurization for systems where water cannot be used.
Helium Leak Detection – ultra-sensitive testing to identify even the smallest leaks in critical systems.
On-Site Bolting Teams – rapid response technicians available during pressurization to re-check torque/tension and correct any issues immediately.
Startup Support – continuous monitoring during initial pressurization to ensure joints remain stable and leak-free.
Standards & Compliance
We operate in full alignment with leading international standards and client-specific requirements, including:
ASME PCC-1
API 570
Shell DEP, Aramco, Total, and other client specifications