3 Interesting Applications of Xtegrity- Flange Integrity System

Xtegrity™, The Equalizer™ Flange Integrity System is a world first, providing a unique solution to the industry-wide issue of heavily corroded or degraded bolts within flange joints. Xtegrity™ is applicable to those concerned with flange maintenance or integrity issues. In scenarios where bolts are heavily corroded, there can be uncertainty about true bolt strengths and operators are faced with choices over hot bolting or shutdown or postponing the decision on how they will address the issue. This problem now has a solution in the form of Xtegrity™ which provides a means of restoring the flange joint integrity back to its original state in a safe, efficient and cost effective manner.

Problems-

1.Many bolted joints are operating beyond their design life.
 2.Carbon Steel bolts are heavily corroded.
3.True strength of bolts are unknown 
4. Bolts categorized by visual inspection 
5.Shut down and replacement is a substantial task and results in a major loss of production.
6.Budgeting for traditional bolt replacement is almost impossible.

Solution-

Xtegrity™ takes away the need to remove corroded bolts by "replacing" them with a new set of bolts which clamp round the outside of the flange and are then held in place by a floating frame. It can therefore replicate the same bolt size, quantity and specification used during the initial flange joint assembly. Installation of the system is simple and quick, with a typical four bolt flange joint taking less than one hour to set-up. Taking away the need to remove old bolts also reduces the risk of flange joint leakage. The system can be used on carbon or stainless steel, duplex or cunifer flange joints.

Xtegrity has significant operational and commercial benefits. It can be used in situations where alternative solutions cannot be used, for example on high pressure, larger diameter flange joints. In these circumstances the only current solution is to carry out maintenance during shutdown resulting in potential loss of production and revenue. By effectively providing a 'replacement' set of bolts around the flange joint it also provides peace of mind to integrity engineers about the reliability of their bolted joints.

Product Video-

Applications-

1.Integrity-

Leave the corroded flange bolts in place and apply the Flange Integrity System to prevent joint failure.
In the event of flange stud failure, the load will transfer to the Xtegrity system maintaining joint integrity • A “temporary repair” maintaining flange joint integrity until corroded bolts can be replaced.

2.Maintenance-Hot Bolting-

Temporary application to enable the corroded flange bolts to be replaced via hot bolting.
flange bolts are removed, and replaced one by one in accordance with the hot bolting procedure 
• Xtegrity geometry maximises access to the flange bolt for maintenance tools.
• Precision hot bolting
•Utilises ultrasonics and the Xtegrity system to gauge load
•Replicates individual bolt loads
•Restores original gasket compression in the joint
•Allows for a thorough assessment of the joint

Ultrasonic Monitoring-
•Ultrasonic probe is used to accurately measure the System Stud length 
• Changes in length correspond to changes in loading
 • By monitoring the system studs throughout the hotbolting process the flange stud loading can be accurately replicated

3.Intervention-

Apply the Xtegrity System following a loss of joint integrity 
• The Flange Integrity System is available at short-notice for emergency call-out
 • The system may be applied to facilitate increased gasket load as a temporary measure without the risks associated with tightening corroded bolts