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.

1.2.1 – Set Flange Criticalities

The range of criticalities is from 1-5. By default, new flanges are given criticality of 3. However, the user is free to select their own values to represent the criticalities.

These values are used when creating new flanges.

1.2.2 – Set Report Logos

Click the Upload Main Logo and Upload Client logo buttons to set the logos for Leak Test Workpack reports.

When set, the Main Logo and the Client Logo will display on Leak Test reports.

Once either a local database, or a server database has been selected, click on the icon of the Service Line you wish to open.

The 5 standard service lines are:

In the below example, the user clicks the Flange Management icon, and the application opens in Flange Management mode.

Selecting the Leak Testing service line opens the application in the Leak Test Pack register.

The 5 standard service lines are:
– Flange Management
– Leak Testing
– Hydro Testing
– Purge Pack, and
– Reverse Integrity.

Additional service lines are also available for Integrus Max products upon request, and they include:
– Camera Inspection
– Chemical Cleaning
– Hose Management
– Oil Flushing
– Pneumatic Test
– PSV Management
– Rotating Equipment
– Small Bore Tubing
– Static Equipment

To open the project Information window from within the application, click the Settings ‘cog’ icon and then click Project Information.

Most fields can be edited and the user can click update to save the changes.

Users can:

Edit the Project Number:

Change the Project Year:

Change the Installation:

Customise Project Criticalities:

The project Criticalities can be edited by ensuring their checkboxes are selected and by simply editing the text.

Customise report logos:

Reports which display company logos can be customised to display both a Main Logo and a Client Logo.

Click on the Upload Main Logo/Upload Client Logo icons. Select a supported logo file (png, gif, jpeg) and click Open to amply the new logo.

The selected logo will display in place of the default MTEC logo and will display at the top of generated Leak Test reports.

Finally, click Update and then Yes to confirm and save all changes.

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.

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.

3.1.2 – Allocating Nodes to flanges.

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

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.

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.

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.

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.

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.

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.

4.1.1 – Manually Changing Existing Flange Specifications

The flange in the below example was created using a PCC-1 calculation profile.

The user at this point changes the Default Calc Profile preference to North Sea and then they clear the flange’s specification.

From this point, the flange’s specification has been cleared and is now ready to use the North Sea profile which the user has saved in Project Preferences.

The calculator can be configured to use either the Short Form or the Long Form bolting calculation method.

The Short Form method uses the K-Factor (“nut-factor”) and the Long Form method uses the bolt- nut Friction Coefficient ‘mu’.

Open the Project preferences and select Short Form (K Factor) as the Torque Calculation method and click OK.

Now if the user creates new flange specification, they will see the Short Form calculation method being used to calculate flange stresses.

Alternatively, users can select the Long Form (mu) calculation method in Project Preferences.

While the Long Form selection is selected, all newly created flange specification will use this Long Form calculation method.

NOTE: existing flanges which have already been created will not be affected if the user changes the Calculation Method between Long/Short form. Only new flanges will be affected by the selected calculation method.

Open the Project Preferences locate the Bolt Calculator section.

This section includes four preferences relating to component stresses:
1. Limit Bolt Stress
2. Limit Applied Stress
3. Apply Initial Bolt Stress Min for RTJ
4. Initial RTJ Bolt Stress Min (% SMYS)

4.3.1 – Limit Bolt Stress

This preference allows user to apply a bolt stress limit to either 95% of SMYS or ‘None’.

Select either option and click OK to close the Preferences window. The selected functionality will be reflected in the calculator when creating specifications.

4.3.2 – Limit Applied Stress

This preference allows the user to apply an applied bolt stress limit to either 95% of SMYS or ‘None’.

Click the preference and press OK to confirm.

Select either option and click OK to close the Preferences window. The selected functionality will be reflected in the calculator when creating specifications.

The third and fourth stress-related project preferences are:
3. Apply Initial Bolt Stress Min for RTJ
4. Initial RTJ Bolt Stress Min (% SMYS)

4.4.1 – Apply Initial Bolt Stress Min for RTJ

This preference specifies whether or not there should be a minimum value for bolt stress for RTJ values. This is a simple checkbox option that the user can select if the wish this preference to be enabled.

Click OK to close the Preferences window. The selected functionality will be reflected in the calculator when creating specifications.

4.4.2 – Initial RTJ Bolt Stress Min (% SMYS)

This preference allows users to state what this minimum bolt stress value should be as a % of SMYS.

Specify a percentage value and press OK to confirm.

The selected functionality will be reflected in the calculator when creating 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.

To access the drawing editor options, open User Preferences and scroll down to the Drawing Editor section.

There are a number of User Preferences which relate specifically to the Flange Management aspect of drawing mark-ups.

These are highlighted below.

5.3.1 – Default Mode

This preference gives the user the option of opening drawings in either View Mode or in Edit Mode by default.

Selecting View, will open the drawing in View mode when the user double-clicks a flange or workpack drawing.

Alternatively, selecting Edit, will open the drawing in Edit mode when the user double-clicks a flange or workpack drawing.

In the Edit Drawing mode, all shape mark-up tools, styling tools and flange mark-up tools are available, as highlighted green in the image above.

5.3.2 – Markup Font Size (ISO, PID & Others)

There are three preferences which allow the user to define the font size of text mark-ups on each of the drawing types separately if they require.

Click any of the 3 preferences. Enter a font size, or select the size between 4 and 18 from the dropdown which opens.

In the above example, the user has selected a font size of 10 for the text size on Isometric drawings.

Open an isometric drawing in the editor mode and observe that the font size displays ‘10’.

Select the Text Box tool and create a text box on an Isometric drawing in size 10.

In this below example the user has selected the maximum font size 18 for PID drawings.

The larger size 18 font displays by default now on PID drawings.

The same can be done with the drawing type ‘Other’.

5.3.3 – Number of Undo Levels

This preference allows the user to set the number of undo markup actions the drawing editor is limited to.

In the example below, the user has selected 6 as the number of actions drawing markup actions which can be reverted using the editor’s Undo button.

5.3.5 – Drawing Flange Tag

The Drawing Flange Tag allows the user to display the alternative tag information on a flange markup.

Be default, the Standard option is selected. This means that only the Joint ID will display, as shown below.

If the user selects Customer Tag as the preference option, the flange markups will instead display the Customer Tags of the flanges (if they have one).

Lastly, if the user selects Temp Tag as the preference option, the flange markups will instead display the Temporary Tags of the flanges (if they have one).

5.3.6 – Display Flange Tag with Torque

This preference allows the user to append the bolt Torque, if applicable. By default this selection is turned OFF (None) but the user can chose to display either

If the user selects the Metric option, flange tags will display their torque value – in metric units – alongside the joint’s identification.

If the user selects the Imperial option, flange tags will display their torque value in metric units.

Additional Custom Fields can be created for flanges and managed using the Register Settings.

Open the Register Settings window and click the Custom Fields button.

Create new custom fields and click Add to add them to the Custom Field list.

Custom Fields can be edited by selecting them and clicking the Modify button.

Click OK to save the changes and the Configure Flange Custom Fields window will close.

Manually locate (or use the Search option) the Custom Fields. Single click them and use the arrows to move them into Selected Fields column.

These fields will then display as columns in the Flange Register.

The selected Custom Fields will also display in the New/Edit Flange form.

The Gasket inventory is opened from the Settings windows. Click the Settings icon and then click the Gasket Specification icon.

The Gasket Types window opens as shown below displaying the gasket loads under various loading conditions.

The column headings include:
Gasket Type (name);
Gasket Material;
Pressures: Min Operating, Target, Maximum allowable pressure;
Gasket Factor.

To add a new gasket type, click the Add icon.

In the Add Gasket Specification window which opens, enter the material and stress parameters of the new gasket.

If the user selects the Gasket Min Operating Specified checkbox, they can then manually enter a specific value. Otherwise, this value will be calculated during the bolting calculation process.

The checkbox at the bottom of the window allows the user to hide the gasket from the Gasket Type dropdown menu of the calculator.

If the user leaves this checkbox clear, the gasket displays in the calculator.

However, the user can click this checkbox which will hide the gasket from the Gasket Type dropdown menu and so the user cannot select it.

The values of all default and user-created gaskets can be edited if required.

Select a gasket and click the Edit icon.

The gasket’s values are all editable in most cases. Make any changes as required and click OK to save and close the window.

7.2.1 – Delete Gaskets from the Database

To delete a gasket, select it with a single-click and then click the Delete icon.

Click OK in the confirmation message which displays, and the gasket will be deleted from the Gasket Inventory.

IMPORTANT: this is a permanent deletion of the gasket from the database.

To generate an export of the complete gasket inventory, complete with all gasket values, simply click the Reports Icon and select Export the Excel.

Specify a filename and location and click Save.