Launch the Integrus application by clicking the Integrus Max launch icon on the desktop.

The main menu will display as below.

To open an existing local database click the Find icon which will open a browser window.

Navigate to the location of the required database and click Open.

The database will display in the database selector field.

Click one of the five options (Flange Management, Leak Testing etc.) and the application will open in that service line.

To create a new database, start the application from the IntegrusMax launch icon, then click the New button to open the New Project window.

The fields marked with asterisks * are mandatory, as are the Project Type and the Project Year fields.

The two Project Type options are Commissioning and Construction.

Specifying the Project Type as ‘Commissioning’ will set the first operation activity to be a Disassemble activity for all new flanges.

Setting the Project Type as ‘Construction’ will set the first operation activity to be a Assemble activity for New flanges.

Complete the remaining required fields.

To create a new Flange Management workpack, click the Work Packs tab to navigate to the Workpack Register.

In a new project, there will already exist a Default Project Workpack to which flanges can be added immediately. This Default Project Workpack cannot be deleted.

Click the Add Workpack icon to open the Add Workpack window.

The Flange Management workpack setup only consists of this single Document tab. Complete the required information and click the Create button.

The new workpack will display in the Work Packs register.

Select a workpack and click the Edit Workpack button to open the workpack’s dialog.

Edit any required fields and click the Save button to save changes.

The register displays the updated changes.

NOTE: the user may wish to force a refresh by using the Refresh icon if required.

The Functional Breakdown Structure (FBS) hierarchy consists of 3 levels:
– Systems,
– Sub-Systems and
– Line Numbers.

To create an FBS hierarchy in a new project, open the Settings tab.

The Functional selection will display by default.

Click the + icon to create a new System and edit its name as required.

Press the ENTER key on the keyboard to save the new System node and its name.

Users can add an optional Description to the nodes as they are created by selecting a node and clicking the respective ‘edit’ icon.

Enter a description and click save to close this window.

With this new System still selected, the user can create Sub-Systems and Line numbers in the same way:
1. Select the System for which to create Sub-Systems;
2. Click the Add + button to create a Sub-System;

3. Edit the Sub-System’s name and press ENTER on the keyboard to commit (temporary Save) this name;
4. Add a description (optional).

The user can create additional Sub-Systems under the same System in the same way.
1. Select the original System;
2. Click the Add + button to create another Sub-System;

3. Edit this new Sub-System’s name and press ENTER on the keyboard to commit (temporary Save) this name;
4. Add a description (optional).

The user can finally use similar steps to create Line Numbers as children of the Syb-Systems.

1.3.1.1 – Deleting FBS/PBS nodes

The delete icons will delete the currently selected node, provided that the selected node has no child nodes beneath it.

Select a node to delete and click its own respective Delete icon.

To confirm the deletion, click OK in the dialog which appears, and the node will be deleted from the FBS hierarchy.

1.3.1.2 – Allocating Nodes to flanges.

When creating flanges, these nodes can then be allocated within the flange form, as shown below.

1.3.1.3 – Parent Node Rules

Nodes which have ANY number of child nodes cannot be deleted.

In the example below, the user is being informed that the Sub-System ‘HVAC Sub-System 152/A.02’ cannot be deleted. This is because it has 4 child nodes (Line Numbers 145-148).

For this Sub-System to be deleted, all Line Numbers must first be deleted.

Similarly, if a user is trying to delete a System which has Sub-System children, these must first be deleted.

Both the Functional Breakdown Structure (FBS) and the Physical Breakdown Structure (PBS) can be viewed either as a list or as a tiered ‘tree’ layout.

1.3.2.1 – List View

Open the User Preferences window and within the bottom User Interface section select List from the two available options and click OK.

The list structure as shown below consists of 3 columns from left to right: Systems, Sub-Systems and Line Numbers, as shown in the image below.

1.3.2.2 – Tree View

To switch to the alternative ‘Tree View’ of the LBS, select Tree in the User Preferences and click OK.

The layout of the FBS will immediately switch to a tree-like layout.

FBS levels System, Sub-System and Line Number now display as cascaded nodes as shown below.

To expand nodes in order to display child nodes, click on the expand/collapse arrows indicated in the image below.

Clicking on same arrow again will collapse the node and therefore hide the child nodes.

1.3.2.2.1 – Add a New Node

To create a new System node, click Add New Item.

A new System node will appear on the top level.

Edit the node’s name and click ENTER on the keyboard to save the new System’s name.

1.3.2.2.2 – Edit a Node

To edit a new, hover the mouse pointer over the node and the Edit icon will appear as shown below.

Click this icon, edit the node name and press ENTER on the keyboard to save the change.

1.3.2.2.3 – Delete a Node

To delete a node, hover the mouse pointer over the node and the Add, Edit and Delete icons will appear again.

Click the Delete icon.

Provided this no has no associated child nodes then it will be deleted immediately.

If this node DOES have associated child nodes, then the message below will appear.

The Calculation Profiles for new flanges can be selected from the Project Preferences. The standard profiles that Integrus Max uses are PCC-1 and North Sea.

Open the Project Preferences from the main Settings icon.

The third preference in the list is the Default Calc Profile. Select the required option and click OK to save the change and close the Project Preferences.

New flange specifications will now use this calculation profile.

Create a new flange and click the Specification button to open the calculator as shown below.

As shown above, this flange uses to PCC-1 calculation profile. This cannot be changed within the calculator now for this flange so the specification will be calculated based upon the PCC-1 calculation process.

To change the calculation profile, re-open the Project Preferences window and select a different required profile. In the image below, North Sea profile has been selected.

Click OK to save this selection and close the Project Preferences.

Now if the user creates a new flange and specification, it’s calculation profile will display as North Sea as shown below.

NOTE: flanges which already have a saved specification will be unaffected by the user changing the default Calculation Profile, which only affects NEW specifications.

The units used in the calculator can be configured in the Calculator Units section of Project Preferences as shown below.

Users can select either Imperial or Metric units for the majority of parameters used in the calculator.

In the below example, the user has changed the units for Torque Input field to be metric units (Nm), and for the Pipe ID and Pipe OD fields to be imperial units (inches).

Small red ‘flags’ indicate that the user has changed the particular setting from it’s previous value.

Set the units for any required fields and click OK to close Project Preferences.

If the user then creates a new flange specification, these calculation parameters will be defined using the units above.

Torque Inputs in the calculator are now in newton meters (Nm) and Pipe ID/OD dimensions are expressed in inches (in).

Torque is expressed in Nm:

Pipe ID and Pipe OD are expressed in inches:

As with other project Preferences, existing flange specifications are not affected, however newly created flange specifications will use the set units.

Flange component materials which initially display upon creating a flange can be specified in User Preferences.

From the Settings icon, click to open the User Preferences.

The top table – Calculator Defaults – displays the flange component materials:
– Default Flange Material
– Default Bolt Material, and
– Default Gasket Material.

In the image below, the user is selecting a Default Flange Material of SA-105N Carbon Steel (Normalized).

With this flange material now pre-selected, SA-105N Carbon Steel will be the default material that will display where applicable.

In the example below, the user has set the Default Bolt Material to A320-L7M.

With this bolt material now pre-selected, A320-L7M will be the default material that will displays.

Thirdly, in the image below, the user is selecting a Default Gasket Material of Graphite.

With this gasket material now pre-selected, Graphite will be the default material that will display where applicable.

For some specifications, the material that the user has selected in the User Preferences may not be applicable. In such cases, the material will not appear in the dropdown list of materials for that flange component.

In the example below, a 1500lb 20” flange is being specified, however the bolt material A320-L7 is not available for this combination. In this case, an actual notification message displays to inform the user.

The default Torque and Tension tools which the calculator displays can also be set in User Preferences.

Open User Preferences and in the top Calculator Defaults section select a Tension Tool from the 30+ options in Default Tension Supplier. Click OK to save the preference and close the User Preferences.

The selected tensioner tool now displays in the calculator when a new Tension specification is being created. This is the case in the below new flange.

For Torque tools, the user can select and save any of the Default Torque Supplier options to display by default for new Torque-tightened flange.

The selected torque tool now displays in the calculator when a new Torque specification is being created. This is the case in the below new flange.

Open the Joint sub-section within the Specification section to display the initial fields for defining the joint. The Joint sub-section comprises the following fields:

Calc Profile: there are a selection of calculator profiles available including Standard, PCC-1 and North Sea. NOTE: these are selected from the Project Preferences, rather than from within the calculator itself.

Type: available flange types include ANSI B16.5/B16.47 Series A, B16.47 Series B, Heat Exchanger [Shell Cover/ Tube Sheet] and Special flanges.

For this manual section, ANSI B16.5/B16.47 Series A joints will be discussed.

Model: for these ANSI flanges, the model field includes the options of Standard, Wafer Check and Spade and Spacer.

Standard simply refers to a standard joint connection while Spade and Spacer should be selected if the flanged joint is fitted with a spade and spacer (sometimes referred to as spectacle blind).

Wafer Check this should be used if the flanged joint is fitted with a wafer check valve. Wafer check valves and Spade and Spacer valves have 2 gaskets.

The flange Class and Size determine the pressure rating and dimensional information of the flange.

Material: select from all of the flange materials included in the calculator. This field will defaults to “ASTM SA-105N Carbon Steel Normalised” but this default can easily be changed using User Preferences.

After defining the flange rating and size, open the Bolt section of the calculator. This will display the bolt Size and Quantity calculated automatically from the flange size.

The ‘Use Metric’ dropdown option can be used to switch between expressing the bolt in either Metric or Imperial format. In the example below, the 5/8” bolt is now displayed as an M16 bolt.

The Size of the bolt, the Across Flats “A/F” and the Quantity will usually be generated automatically, however, there are certain cases where there may be a choice of applicable metric bolt sizes.

The example below is an ANSI Standard, 150lb ¾” flange. In this case the user has the option to select either an M12 or an M14 bolt.

Select a Bolt Material from the next drop-down menu. The material A320-L7 has been selected in the below example.

Based upon the bolt material selected, the nut material options will be filtered and may offer only one or two nut materials options as applicable.

Any coating on the bolt can be manually entered into the cell provided. Zinc has been specified in the example below.

The nut thickness will be auto-filled based on the size of the bolt selected.

If washers are required, click the Washers button.

Select a washer material and then proceed to specify the Upstream washer type and the washer ID, OD and thicknesses. The washers Material menu is populated by washers materials which are compatible with both the bolt and the nut materials.

Select the washer Type from: None, Flat, Belleville and Flat/Belleville. Then ID, OD and Thickness fields will be generated automatically. They can however be changed by the user as shown below.

Open the Pipe section and populate the fields as required.

The Working Pressure and Test Pressure of the pipe will be auto filled based on the class of the flange selected. The user can however over-ride these values to better suit the exact specification of the flange being analysed.

Insert an Operating Temperature. This will enable the elevated temperature analysis in the Heat Analysis section of the calculator.

Inner/Outer Diameter

The user can use the Diameter Specified field to select either ‘Inner Diameter’, when the inner diameter is known, or ‘Outer Diameter’, when the outer diameter is known.

In the example below, Outer Diameter has been selected.

The Outer Diameter can be edited to suit the exact specification of the flange or pipe.

Similarly, when the Inner Diameter option is selected, the Inner Diameter cell is available to edit.

Next, select the Pipe Schedule from the dropdown options as shown. Doing this will automatically calculate the pipe wall thickness as shown below. This defaults to PCC-1 however this can be changed in the Project Preferences.

The user can however also change the pipe wall thickness value manually. Editing the Wall Thickness value changes the Schedule field to ‘Project Spec’, as shown below.

Open the Gasket specification section of the calculator.

Select the gasket Type from the drop down-menu of available options. In the example below, a Spiral Wound gasket has been selected.

Next select the gasket Material. This material list will have been automatically filtered based on the gasket Type selected.

In this example, Stainless has been selected as the gasket material.

If any additional description of the gasket is required, this can be entered into the available Description cell.

The Initial Compression field will be populated automatically with a typical value depending on the gasket selected, however, this also can be overwritten if required to better suit the gasket specification.

If the user wishes to create only one single flange, the Save button will simply save the new flange and then close the flange form window.

Create a new flange and populate all mandatory and required fields so that the Save button becomes selectable.

The user can also enter a full flange specification before clicking the Save button, or they are free to create the flange only at this point, and user the Edit Specification button to create the joint details at a later time.

The Save and Continue button at the bottom of the flange form is useful if the user wishes to create multiple flanges in succession without opening the New Flange form for every new flange.

Create a new flange and populate all required fields so that the Save and Continue button becomes selectable.

NOTE: the user can also enter a full flange specification before clicking the Save button. Alternatively, then can create the flange only at this point, and use the Edit Specification button to create the joint specification later.

Click the Save and Continue button to save the flange. This will result in the flange saving to the register in the background. The form will also clear for the user to enter the details of another new flange.

The most important fields of flange form can be edited in bulk – in one operation – which can save the user a great amount of time.

Click the left-hand side checkboxes to select multiple flanges which you wish to edit and then click the Edit Flange icon.

This will open the Bulk Edit window as shown below.

NOTE: Editing any fields within this window will affect ALL of the selected flanges.

For a field to be edited, the user must first select it’s checkbox.

As an example, to set all of the selected flanges’ Pipe Specifications click the Pipe Spec checkbox to activate the text box.

Next, input the pipe specification.

Now, when the user clicks the OK button, all of the selected flanges will have this pipe specification.

Individual drawing files can be uploaded to the Drawings Register which holds all the drawing files for a project.

Navigate to the Drawings Register and click the Add icon.

This will open the New Installation Drawing window.

For Projects which have multiple constituent installations, select the applicable installation from the dropdown bar.

Next click the Select File icon which will open a browser window.

Select the required drawing file which will then automatically display in the File field.

The Number, Name and Revision fields beneath it are entered manually by the user to give further details about the drawing content and its current revision.

The revision field becomes important should users need to update drawings for more current revisions.

The drawing must be identified as being either an Isometric (ISO), a P&ID or ‘Other’ in cases where the drawing is neither one of these options, for example approach drawings, routing maps or any other type of schematic.

Select one of these three drawing type options.

In the special case of uploading an Isometric drawing, the isometric drawing file can be assigned to a Parent P&ID from the Drawings register.

Select drawing type Isometric and the Parent P&ID field will become selectable, listing all available installation P&IDs.

This option to assign a parent P&ID to an isometric drawing carries some benefits within Flange Management drawing editing and for Leak Testing. For example; if a flange joint tag or item tag is marked-up on an isometric drawing, then it will automatically be linked with the parent P&ID.

Also, when a parent P&ID is used in Leak Testing, all ‘child’ isometric drawings can be listed automatically.

The Update function can be used at any time to:
– edit the details of installation drawings,
– replace a drawing file itself for an updated revision.

The ability to replace the drawing file is useful in that all drawing mark-ups will be retained while the underlaying drawing is replaced with a more recent revision of the drawing.

Select an installation drawing and click the Update icon to open the Change Installation Drawing window.

This window contains all the information specified when the drawing was uploaded.

Click the Select File icon to open a browser window and then search for the new drawing file.

In the example below, the drawing of revision C01 is being replaced by the drawing of revision C02.

The selected file will be updated in the File field as shown below. (‘C02’ has been highlighted for clarity.)

At this point the user should update all other information, for example the Revision field, and any applicable Notes.

Click Save to update the drawing in the Installation Drawings register.

Individual or multiple installation drawings can be opening in a viewing window prior to editing.

Upon selecting an installation drawing, a thumbnail preview will display in the info panel on the right-hand side.

To enlarge the drawing within the preview window, use the Zoom In/Out buttons. To return to a full-window view of the drawing, clicking the ‘Centre Drawing’ icon.

Fully open the drawing in a simple ‘Read-only’ window by selecting the Read Only option.

This is an effective way to inspect the base installation drawing, without any joint tag mark-ups. Use the mouse wheel to zoom in/out and click-and-drag the drawing using the mouse left-click. Close the viewer by clicking the top-right ‘X’.

3.3.1.1 – Viewing Multiple Installation Drawings

Returning to the main installations drawing grid, users can view multiple drawings together within a single pop-out drawing window.

Select any number of drawings by using the checkboxes on the left of the register, then click the Open in New Window icon.

As in the above image, thumbnails of the selected drawings can be clicked on and viewed in the main drawing pane for closer inspection. Use the scrollbar if many thumbnails are included.

To create joint tags and other mark-up items on drawings, a drawing must be opened in the v3.1 Drawing Editor. This new drawing editor has all the drawing tools as the previous GD Viewer/Editor, plus some additional new features which will be covered below.

In the drawing preview toolbar click the Edit option.

The drawing will open in the v3.1 editor.

Below are some of the top-level groups of mark-up tools.

3.3.2.1 – Flange Tag Mark-up Functions

Marking up joint tags on the drawing. These may be either:

– tags for flange joints currently existing in the register, or

– brand new joints that can be created within the open drawing editor window.

3.3.2.2 – Joint Tag Colours

The colour of the joint tag represents the current activity-cycle status of the joint.

An Assembled joint for example, will display with a RED tag, whereas a Leak Tested joint tags will display with a GREEN tag.

Assembled joint:

Leak Tested joint:

Joints which have a status of New are marked-up on a WHITE background:

The commonly used tag colours are as follows.

IMPORTANT: users should SAVE the drawing regularly by clicking the Save icon. This is to prevent any changes being lost, should the editor close unexpectedly for example.

The Search bar in the Register Settings window can be used to filter the Available Fields column. This makes finding fields much easier.

In the example below, the user is searching for all fields containing the word “Torque”.

From this point they may move and re-order the field in the Selected Fields column and click Apply.

Click the Custom Fields icon to create and manage Custom Fields.

Create new Custom Fields and click Add to add them to the Custom Fields list.

To edit an existing custom field from the list, select the field and make a change and click Modify.

Click OK to save Custom Field additions and changes.

Now if the user searches the Available fields list, the new Custom Fields will display along with the standard fields.

Move and re-order them in the Selected Fields list so that they display in the register as a column.

To edit a single flange simply select the flange and click the Edit flange icon.

The Edit Flange form will open. Make any changes to any of the fields and click Save to save and close the form.

While flange details are often specified for individual flanges, the user may select multiple flanges together and ‘bulk-edit’ them in one operation. This can save the user much time and effort.

Click the checkboxes of multiple flanges and click the same Edit Flange icon.

The Edit Flanges window will now open, similar to as shown below.

To enable any field for editing, the user must select its adjacent checkbox. For example, to set the System, Sub-System and Line Number for the selected flanges, click the System checkbox and then select from the available dropdowns for the 3 FBS fields.

In this next example, the user has activated the P&ID Ref checkbox and so can now select a P&ID drawing to bulk-associate the selected flanges to.

Additionally, user-defined Custom Fields also display in the Edit Flanges window and so the user can define values to these fields too.

IMPORTANT NOTE: Take care when using this Bulk Edit form to make widespread changes to flanges. If some flanges already have values for fields, these will ALL be over-written by values the user selects when using the Bulk Edit form.

The flange history tab displays both the flange activities and the operational activities that have been carried out on the flange to date.

When a flange is created and given a bolting specification, these flange activities are displayed as shown below. The date of the activity is recorded alongside them.

Operational activities are recorded in the same frame. The flange in the example below has had a Disassemble, Assemble and a Torque activity carried out upon it.

Clicking any of the flange or operational activities will display the details of the activity in the pane below where users can inspect them.

In the image below, the user is inspecting the specification which has been added to the flange. The Activity log records the User who logged the activity, the Date and whether there was any anomaly recorded during the activity.

In this second image below, the user is inspecting an Assemble operational activity.

Integrus Max has a setting within the Project Preferences which, if set to TRUE, allows the user to edit historical operational flange activities.

To do this, open the Project Preferences and check the Allow Edit Historical Activities preference and save this selection.

With this preference selected, the user may click the Edit icon for any operational activity and edit it.

The Drawings tab lists the drawings which the selected flange is associates with.

Drawings can appear in this list if they have been selected in the flange form or if they are physically marked-up on a drawing.

Prior to commencing work on a flange, select a flange and print a Work Instruction for it.

The Work Instruction will open automatically as below.

Save the Work Instruction to a location and if required and print a paper copy of the report to complete.

To print a Work Instruction for multiple flanges, select all required flanges using the checkboxes in the left-most column and repeat the Work Instruction generation process.

The generated document will include a separate Work Instruction report for each selected flange.

Save and print off the reports file to be completed as required.

A Work Instruction report can be generated which covers all flanges currently displayed in the flange register grid.

Open the reports menu and select the Work Instruction (Grid) option to generate the report.

One document consisting of a Work Instruction report for each flange in the grid will open automatically.

The file can be saved as a single document and all reports may be printed in hard copy format for completion as required for upcoming flange activities.

5.1.2.1 – Filtering the register for a Grid report

If the user has used the column filters to display only specific flanges, the Work Instruction (Grid) report generated will reflect this.

In the example below, the flange register has been filtered for flanges of Joint Type ANSI and Flange Sizes ¾” and 10”.

Selecting the Grid version of the Work Instruction report will generate a report for only these displayed seven flanges.

Navigate to the Personnel Register and click the ‘Add’ icon to open the Add Personnel window.

Using the right-click of the mouse will similarly bring up the context menu which can be used to open the same Add/Edit Personnel window.

5.2.1.1 – Basic personnel identification and Job Description

Complete the fields for the person’s Name and allocate a Job Description from the four options of Technician, Supervisor, Inspector and Engineer.

Designating a person as a Technician will enable them to carry out flange activities, while Supervisors may also be configured to do this by way of the project preference “Supervisors are Technicians”.

Only persons designated as ‘Inspector’ can be selected for inspection activities.

The Company field will store previously entered company names and offer them as available options as the user enters some valid characters.

Enter the name of the person’s Company; this is the last of the mandatory fields. This Company field will store previously entered company names and will offer them as pre-selected options as shown below.

To add qualification details to a person, click the Select File icon and then browse for and upload a qualification document applicable for the person.

The two icons on the left of the Select File icon allow the user to View and also Delete an uploaded qualification document at any time.

Each qualification document should have a Certification Expiry date. Once this date has passed, the certificate is no longer valid and the user is made aware of this.

Click the calendar and select the expiry date for the person’s qualification certificate.

The certificate will expire at midnight at the end of the selected date, inclusive. So as 23:59:59 hours on 26/05 turns to 00:00:00 hours on the 27/05 in the above example.

5.2.3.1 – Certificate Expiry Warning Period – Project Preference

The personnel register uses a colour-coding logic to indicate the state of the certificates of all personnel.

The colour coding is summarised in the table below.

The above colour coding is displayed on the left-most column of the Personnel Register

As can be seen, the application allows for technicians to be without certification as per customers’ requests.

Not all fields in the Personnel window are mandatory but they can be populated for completeness.

A photograph of a person can be uploaded by clicking the Add Photo ‘Select’ icon.

Once uploaded and saved, the image is displayed on the right-hand Info Panel in the location indicated above.

The user can manually enter a Vantage Number for the person in the Vantage # field, however this is also not a mandatory field.

A person can be deleted from the personnel register at any point by selecting the person and clicking the Delete icon, OR by using the right-click context menu.

A confirmation window will appear, and if the user clicks OK, the person is deleted from the Personnel Register.

After deletion, the technician/person will no longer be selectable for carrying out flange activities, however all historical records of activities carried out by the person will remain unaffected.

All torque tools available for an installation are accessible via the Tools tab.

To create a new tool, click the Add icon in the Tools register and the Add Tool window will open.

Nearly all fields are mandatory and so are appended with an asterisk* to signify this.

Select Torque from the first dropdown menu.

Next, specify the Supplier and Model of tool required.

5.3.1.1 – Search Bar Function

The list of torque tool Suppliers and Models can be filtered which makes finding tool options easier.

Type a tool Supplier of interest into the search bar and the list will filter to display only those Suppliers containing those characters.

In the image below, simply by typing in the characters “En” has filtered the Supplier types to display only ‘ENerpac’, ‘Manual Torque WrENch’ and ‘WrEN’.

In the Model dropdown, the user has entered the value ‘10’ which has reduced the list down to 3 tool models containing the digits ’10’.

Begin a flange activity by selecting a flange a clicking the Record Activity icon in the main toolbar.

In the activity cycle window which opens, select an activity.

At the top of the activity’s form, choose a Start Date for when the activity is to be carried out.

The chosen date becomes the default date for all preceding activities in the current activity cycle, however the user if free to change this date as applicable for each separate activity in an activity cycle.

The Tag Number of a flange may be changed from within any activity, and the tag new will be updated in the flange register.

Enter a new tag number in the New Tag field.

This new tag will then be displayed the adjacent Current Tag field when the next activity in the cycle is selected.

Upon completing the activity cycle, this Temporary Tag will display in the register.

A minimum of one Technician must be assigned to any activity in order for the activity to be carried out.

Select a Technician from the dropdown lists, Technician 1 being mandatory and so is denoted with *.

For lists containing many technician names, type the name into the Search bar to find technicians easier.

Repeat with the Technician 2 field, if a second technician is required.

The activities Assemble, Inspect, Torque and Tension have optional Inspector fields.

5.4.3.1 – Creating Personnel within Activity Form

Technicians, Inspectors and Supervisors can be added to the Personnel register from within an activity cycle, and these added personnel may be used immediately for the activity in progress.

Select the Add Technician icon in the top right of the activity form to open the Add Personnel window. Enter the new person’s information as shown below and click OK button to save the technician.

The new technician is now selectable in the current activity.

Inspectors can be added in the same way as shown below.

It is often necessary to edit personnel details within a live activity cycle. For example, a person’s Certificate Expiry date can be updated easily if in a case where it had expired.

This technician’s Certification Expiry date has lapsed, as signified by the “Expired” alert message.

Click the ‘Edit’ (pencil) icon to update any of the person’s details, then click OK to save.

The warning message has now disappeared, and the technician can be used for the activity.

In the example above, the technician’s Certification Expiry date has been validated, however changes to any fields or file attachments can be made this way. Any changes will automatically be refreshed in the Personnel register also.

Every activity has a comments box where users may enter any relevant comments regarding the activity.

Scroll down to the Comments section and enter comments as required.

Comments entered here will display in a few places including in the right-hand-side Info panel and Joint Completion Certificates as shown below.

History panel displaying comments added during an Assemble activity:

Joint Completion Certificate displaying comments for both an Assemble and also for a Torque activity:

The comments box is an optional field for all activities, however, is becomes a mandatory field if an anomaly is noted for an activity.

During an activity cycle, the last activity created may be removed by clicking the Remove Last Activity button. This could be in cases where a change must be made to a flange for the activity cycle to proceed further.

In the example below, the user has begun a Torque activity that the now wish to remove, leaving the joint as being in the state of Assembled.

Clicking the Remove Last Activity button removes the last activity in the cycle, and so in this case the last activity will be Assemble.

The Remove Last Activity button may be clicked again if the user requires to remove the Assemble and even the Disassemble activities in the above cycle. Once an Activity Cycle has been completed and saved however, activities cannot be removed, and so a new activity cycle must be started to make additional changes to the flange.

The Inspect activity is accessible to flanges which are currently in a Disassembled state (or indeed to disassembled flanges which have since also been through a Remachine activity). The date of the inspection will be carried through to certain reports, for example the Flange Sign-off report.

5.4.8.1 – General Section

The Inspect activity comprises sections:

General section: for recording the general conditions of elements of the flange. Users can enter condition of the flange faces themselves, fasteners and gaskets.

General Condition: general comment of the condition of each upstream and downstream flange.

Further sections Face free from Damage, Face free from Corrosion, Line free from Stress and RTJ Groove Condition may also be applicable depending on the nature of the flange being inspected. Select applicable values from the dropdown menus or click the ‘All Good’ checkbox which set all fields in the section to display ‘OK’.

The Assemble activity can be assessed from any Disassembled flange, or indeed any flange which has been disassembled and then inspected or remachined.

The short General section of the Assemble activity covers the assembly method and the alignment of the two flanges with respect to each and to the pipeline.

The Checks section includes the various fastener elements and whether the correct lubricant has been used.

The final After Fitting Gap section record the distance between the mating flange faces at 12, 3, 6 and 9 o’clock positions around the flanges following assembly. The centrelines of each of the two flanges relative to the pipe centreline are recorded also.

Test Details and Test Results

When a Hydro Test activity is selected, chose the applicable Test Workpack. This will automatically populate the mandatory fields Test Pressure and Test Medium with the values from that Hydro Test workpack’s setup. The remaining fields (Test Method, Test Temperature and Test Duration) are free text which the user must enter manually.

The results of the test can be recorded as either Passed First Time, Fail and Passed after Re-test.

If the Hydro Test has failed, the user should then specify the Reason for Failure from the adjacent options.

The user may select See Comments options also and then detail the reasons in the Comments box below it.

Test Details and Test Results

When a Leak Test activity is selected, chose the applicable Test Workpack. This will automatically populate the mandatory fields Test Pressure and Test Medium with the values from that Leak Test workpack’s setup.

As with Hydro Test, the results of the test can be recorded as either Passed First Time, Fail and Passed after Retest.

If the Leak Test has failed, the user should then specify the Reason for Failure from the adjacent options.

The user may select See Comments options also and then detail the reasons in the Comments box below it.

Select Service Test for a flange which is currently in a state of Assembled as a minimum.

Test Details and Test Results

The section specific to the service Test activity is the General section.

Select the result of the Service Test and then populate the outcomes of the other fields including the service test periods 1 – 3.

Flanges which are in an assembled state (at a minimum) can be Temporary Tightened.

The Temporary Tighten activity is a multi-part activity consisting of:
a) Disassemble
b) Assemble
c) Torque/Tension Tightening ‘sub-activities’, depending on the specification of the flange.

Each of these three sub-activities are required to be completed.

Firstly, complete the Disassemble activity, completing all mandatory fields as a minimum.

Complete the second sub-activity, – the Assemble activity. This sub-activity is an exact duplicate of a normal stand-alone Assemble activity.

Lastly, complete the Tightening section. This tightening sub-activity will be either a torque or a tension activity depending upon the flange’s specification.

Torque sub-activity:

Tension sub-activity:

Once all three sub-activities are complete, the user may click Complete Activity button to save the Temporary Tighten activity.

Edit Spec

During an activity cycle, users are permitted to edit the actual flange specification if a user selects any of the activities: Remachine, Torque or Tension tightening, or indeed a Temporary Tighten activity.

In any of the above activities, click the Edit Spec sub-menu icon which will open the Edit Flange window as below.

Some aspects of the specification – namely the tooling – can be edited this way mid-activity. In the below example the user is changing the torque tool specified for the flange.

After changing the tooling, click the Save icon in the Edit Flange window. The window will close and the activity form will reflect the tool changes made. In the above example, the flange now has a Hytoc – Edge-5 torque tool specified.

Add Tool

Torque and Tension tools, – and also Torque and Tension Pumps, – may be during an activity by clicking the Add Tool sub-menu icon.

Clicking the icon will open the Add Tool window.

Complete all required fields (for Tools, most fields are mandatory) and click OK.

The tool will be added to the Tool Register however it is also immediately available for use in the current activity as shown below.

Add Technician

Technicians, Inspectors and indeed Supervisors can all be added to the Personnel Register from with activity cycles by clicking the Add Technician icon.

Select the discipline of the person you are adding and enter all required details.

In addition to being added to the Personnel Register, the technician is also immediately available for use in the current activity cycle. This is by way of the Enabled checkbox (above image) being selected by default. NOTE: if the user de-selects this checkbox this disables the person – and they will not appear in the dropdown options for Technicians/Inspectors until the user ‘enables’ this checkbox again.

Under some circumstances, multiple flanges can be group-selected and have the same activities carried out upon them together in the same activity cycle.

Group-selected flanges must ALL be in the same activity state (Assembled, Torque/Tension Tightened, Disassembled etc). If selected flanges are at different activity states from each other, a message will display – see image below – if the user attempts to begin an activity cycle with them.

All three flanges in the below image are currently Disassembled.

Group-selecting them by clicking their respective checkboxes and then clicking the Record Activity icon will begin an activity cycle involving all three flanges.

NOTE: the activities Assemble, Disassemble, Remachine and Inspect can invariably all be carried out on grouped flanges in this way, as these activities do not depend upon the flanges having the same specification as each other.

Once any permitted activities are carried out click the Complete Activity button as normal and the register will update the status of all selected flanges.

The flanges in this example above have been Assembled in the same activity cycle and this is reflected in the Status column of the Flange Register.

Tightening activities (both torque and Tension) require the flanges to have identical specifications. If the user attempts to torque/tension flanges of different specifications from each other will display an error message.

In the example image below, the three flanges are all in a Disassembled state which allows them to be Inspected, Remachined and Assembled in the same activity cycle. However, if the user then clicks the Torque activity button, an error message displays the fact that the flanges are of different flange classes and therefore cannot be tightened together in the same cycle.

Similarly, if group-selected flanges are of the same specification but have been designated different tightening tools, with user will receive the same massage, highlighting the fact that they cannot be tightened together.

In the example below, the two selected flanges are both 900lb 12” specifications. They have been disassembled and assembled together, but because they have been assigned different Torque Tool Types, they cannot be tightened together in the same cycle.

To allow the above flanges to be tightened together, the specifications or one or both flanges must be edited so that they are identical.

Document files can be attached to activities using the Upload Document button which is present at the bottom of every activity form.

Scroll to the bottom of any activity, click the Upload Document button and using the browser window which opens, upload a required document file. Supported document types include PDF and Word formats.

The document will display in the Document ‘carousel’ and the Total Documents count will display “1”.

Multiple documents can be added to any activity. Documents are added to the carousel and reviewed by clicking the LEFT/RIGHT arrows as shown below.

Remove documents from the carousel by clicking the Remove Document button. The document currently displaying will be deleted immediately.

Viewing documents attached to activities

Documents added to activities can be reviewed in the History tab on the right-hand side of the screen.

Click the activity to which the document was added and click Open to view the document.

Similar to adding documents, photo files can be added to activities using the Upload Photo button which is present at the bottom of every activity form. Supported photo file types include jpg, png and tiff formats.

Scroll to the bottom of any activity, click the Upload Photo button and using the browser window which opens, upload a required photo file.

In the image below, four image files have been uploaded to this Disassemble activity and display in the photo carousel.

Each photo can be previewed by clicking in the LEFT/RIGHT arrows or by simply clicking on the thumbnail view of the photo.

Remove photos from the carousel by clicking the Remove Photo button. The photo currently being previewed will be deleted immediately.

Viewing photos attached to activities

Photos which have been added to activities can also be reviewed in the History tab on the right-hand side of the screen.

Click the activity to which the photos were added and scroll down to the Photos section.

Clicking the LEFT/RIGHT arrows here also allows the user to view all photos added to the activity.

Completion Certificates for joints can be generated from the Reports menu icon.

Select an individual flange and then in the reports menu, click JCC (Selected).

The single-page report will generate and display automatically.

This MS Word format document can be saved to any location.

To generate a batch of JCC Reports for multiple flanges, use the left-hand-side checkboxes (highlighted in green below) to select the flanges of interest and click JCC Report (Selected).

One MS Word file is generated containing all the selected flanges.

If a single JCC report is required for all flanges in the current register, the JCC Grid option outputs this in a single action.

There’s no need to select any flanges, but simply click the JCC Grid option from the reports menu and the report will be generated and displayed.

This grid version of reports has uses include for example if a user filters the Flange Register for certain joint features of interest and requires JCC reports for all of them.

In the image below, the user has used the Column Filter to filter only for flanges of Flange Size 2.1/2”. Selecting JCC Grid will now generate a JCC report for all results in this filtered flange register.

The top section of the Engineering tab displays four totals: Total Flanges, Flanges on Isometric drawings, Flanges on P&ID drawings and the total number of Leak Test packs.

In the example below, these totals are 44, 40, 39 and 2 respectively.

As flanges are created or deleted, or added/removed from drawings, these counts will update.

Also, every dashboard area had a Refresh icon (green-highlighted icon in the image below) if required to re-display any of the dashboard charts.

The Operations tab includes a breakdown of joint Status by System. The three status categories displayed are Disassembled, Assembled and Tested.

NOTE: The vertical axis displays percentages of flanges in each system and not the actual number of flanges.

In the example above there are 3 Systems in the project: systems 591, 601 and 701. Currently, System 701 contains no flanges with any of these 3 activities against them.

6.1.2.1 – Displaying Operational Activity Status Changes

If the user logs an operational activity against a flange in System 701 for example this will display in this Systems chart.

As an example, the user logs a Disassemble activity against one System 701 flange and an Assemble activity against another System 701 flange.

User logs a Disassemble activity against flange FJ001:

User then logs an Assemble activity against flange FJ002:

Now the dashboard updates automatically to reflect that System 701 now contains 2 flanges; 50% of which are Assembled while 50% are Disassembled.

The Operations tab displays the key operational activities which have been carried out on flanges. They are expressed in terms of Systems, Workpacks, Modules and Areas.

It also graphs them as activities performed over the previous 30 days, as highlighted in the green box below.

This ‘Last 30 Days’ chart displays today’s date on the left-hand side and the date 30 days ago on the right-hand side.

In the example below, several different types of activities have been carried out on flanges in the past few days, as indicated by the green arrow.

On the right-hand side, some activities were carried out approximately 1 month ago.

In the chart below, no activities have been carried out today.

Now, if the user carries out one Disassemble activity on a single flange and then they re-open the dashboard’s Operations tab, a new Disassemble activity is now visible against today’s date.

Any anomalies which are recorded during operational activities are recorded in the Quality Control (QC) tab charts.

6.1.4.1 – Recording an Anomaly

The charts record anomalies for all flanges in the database. In the example below, there are no flanges with operational anomalies currently.

A flange is put through a Disassemble activity, and the user records an anomaly against it.

Upon re-opening the Digital Dashboard’s QC tab, the Anomalies Raised count now displays ‘1’.

6.1.4.2 – Resolving an Anomaly

If an anomaly is then resolved, the Anomalies Resolved count increases.

The above anomaly has been resolved, and so the Anomalies Resolved count increases to ‘1’ also.

NOTE: while a flange has an unresolved anomaly, no further activities can be recorded against it until the anomaly is resolved.

The Overall Status chart in the Operations tab displays the general status of joints in the flange register.

The overall Status chart displays flanges which are in the states of:
– Disassembled
– Assembled
– Tightened
– Temporary Tightened
– Leak Tested.

Hover the mouse over any of the coloured status segments. This will display a tooltip containing the number of flanges with that particular status.

In the example below of a very small database, there is only one Assembled flange.

If required, click the Refresh icon in the top right corner to redraw and update the chart.

The four doughnut charts in the QC tab display the numbers of activities which have had inspections performed during/post-activity.

As an example, the Assembly Activities Inspected chart displays that there have been 2 Uninspected Assembly Activities carried out.

If the user runs an Assembly activity and assigns an inspector to it as shown below, the dashboard chart will update to display that there is now one flange with an Inspected Assembly activity in the database.

Use the checkboxes to select a flange(s) to generate Work Instruction Reports for. Click the Work Instruction Report (Selected) option and the report will generate automatically.

Save this file with a suitable name to a location to open from.

To generate a Work Instruction for all flanges in the Flange Register, click the Work Instruction (Grid) version of the report. If there are multiple pages of flanges, they will all be included in the report.

Use the checkboxes to select a flange(s) to generate Joint Completion Certificate for. Click the JCC (Selected) option and the report will generate automatically.

Save this file with a suitable name to a location on your computer.

To generate a Joint Completion Certificate for all flanges in the Flange Register, click the JCC (Grid) version of the report.

If there are multiple pages of flanges in the Flange Register, they will all be included in the report.

To generate Datasheet (Selected) reports, click the checkboxes of the flanges of interest and select Datasheet (Selected).

The datasheet report will generate automatically.

Save this report with a suitable filename to a location on your computer.

To generate a single Datasheet report for all flanges in the register, click the Datasheet (Grid) option. This will include all flanges across all pages in the Flange Register.

To generate a MTO (Material Take Off) Summary report for some particular flange(s), select the checkboxes of the flanges of interest and click MTO Summary (Selected) from the reports icon.

The report will generate automatically as shown below.

Save the MTO Summary excel file to a location on your computer using a suitable filename.

To generate a single MTO file for all flanges in the register, select the MTO Summary (Grid) report option.

For flanges which have been through a Remachine operational activity, a Remachine Report can be generated which shows the material removed from various surfaces of the flange.

6.2.5.1 – Identify Remachined Flanges in the Flange Register

To quickly identify all remachined flanges in the project, use the flange register category filter shown below and select Remachined Joints.

This filters the flange register and display only joints which have completed a Remachine activity.

Select the flange(s) of interest and click the Remachine Report (Selected) option.

This will generate a Remachine Report as in the example below.

The Flange Identification table displays the values which the user manually inputs during the Remachine activity. In the example below, the Raised Face Height has been machined down from 5.65mm to 5.4mm.

6.2.5.2 – Remachine Report (Grid)

Instead of using the Remachined Joints filter (above), or even manually selecting every remachined flange, the user can also simply select the Grid option.

This will output a Remachine report for every flange in the register, whether they have been remachined or not.

There are 2 types of Flange Sign-Off reports: As Planned and As Carried Out.

Subsequently, both report types can also be generated for Selected flanges and also for the complete flange register Grid.

6.2.6.1 – As Planned Sign-Off Reports

As Planned Sign-Off reports include the torque or tensioning values which are planned for tightening the respective flange(s) during a Torque/Tension activity.

Select a flange(s) and click As Planned (Selected). The report will generate and open automatically.

As shown above, tooling and tightening pressure values will be populated.

Instead of the Selected version of the report, clicking As Planned (Grid) will generate for all flanges in the flange register grid.

6.2.6.2 – As Carried Out Sign-Off Reports

By contrast, As Carried Out Sign-Off reports include empty spaces for the same fields. In these spaces, technicians should manually record the ACTUAL values that are achieved during Torque/Tension tightening.

Select a flange(s) and click As Carried Out (Selected). The As Carried Out report will contain blank spaces in the Torque/Tension tightening activities as below. Here the technicians will manually record actual values from the activity.

And similar to other report types, instead of the Selected variation of the report, clicking As Planned (Grid) will generate for all flanges in the flange register, across all register pages.

Excel files versions of the flange register can be produced using the two Export to Excel report options.

The first option is Export ALL to Excel. If the user selects this, this will generate an excel file which will contain all flanges across all pages in the flange register.

The second option – Export to Excel – will generate a report containing only flanges displayed on the currently viewed page.

So for example, below is the second of two pages of flanges, which displays only the final 19 flanges in the register.

If the user selects Export to Excel here, the report will only generate this page of 19 flanges

There is one single option for exporting the flange register to a PDF file.

Simply select the Export to PDF option, specify a suitable filename and location to save the report and click Save.

Opening the exported PDF file displays similar to the below example.