COURSE OVERVIEW:

The integrity of a piping system is only as reliable as its weakest joint. This course provides a technical deep dive into the engineering principles of bolted flange connections, which are the most common source of fugitive emissions and leaks in industrial plants. Participants will explore the mechanics of "the bolted joint" as a system, where the flange, the bolt, and the gasket must work in unison to maintain a seal under varying thermal and pressure loads.

The curriculum covers the diverse landscape of gasket technology, from traditional non-asbestos sheets to advanced spiral wound and ring-type joints (RTJ). We will examine the metallurgy and geometry of flanges, including weld neck, slip-on, and lap joints, as defined by ASME B16.5 and B16.47 standards. Special attention is given to branch connections such as weldolets, nipolets, and sockolets, detailing how these fittings affect the local stress distribution and flow dynamics of the piping network.

A significant portion of this training is dedicated to the human element of installation. Participants will learn the science of torque and tensioning, the importance of flange alignment, and the critical role of surface finish. By bridging the gap between design specifications and field execution, this course aims to eliminate common failures like gasket blowout, bolt fatigue, and flange rotation, thereby enhancing the overall safety and environmental compliance of the facility.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1.  Identify different flange types and their specific pressure-temperature ratings.

2.  Select the appropriate gasket material based on chemical compatibility and temperature.

3.  Interpret ASME and API standards governing flange and fitting dimensions.

4.  Calculate the required bolt torque for a given flange size and pressure class.

5.  Identify the various types of branch connections and their installation requirements.

6.  Assess the impact of flange surface finish on gasket sealing performance.

7.  Execute proper bolt tightening sequences to ensure uniform gasket compression.

8.  Diagnose the root causes of flange leaks in high-temperature service.

9.  Distinguish between different metallic and non-metallic gasket designs.

10.  Implement precision alignment techniques for piping flanges during construction.

11.  Apply safety protocols for the handling and installation of high-pressure seals.

12.  Use ultrasonic bolt tensioning measurement tools for critical joints.

13.  Develop a comprehensive joint integrity management program for the plant.

TARGET AUDIENCE:

Piping Engineers, Maintenance Technicians, Pipefitters, Mechanical Supervisors, and Quality Control Inspectors involved in piping system assembly and maintenance.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.