fai services overview (compressed pictures)
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2 Furmanite Confidential - 1/9/04
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3 Furmanite Confidential - 1/9/04
Our Mission and History
Where We Operate Today
Safety Discipline
Our Industry Solutions
Why Choose Furmanite?
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Maximizing Asset Uptime
Everything we docenters around keeping
yourassets operational
Furmanites definitionof an Asset anything andeverything that can impacta customers bottom line
Furmanites definition ofUptime keeping the Assetproductive andprofitable at all times
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For a complete listing of regional and global
Furmanite locations, visit us online at www.furmanite.com
Western Division
Gulf Division
Northeastern Division
Corporate Headquarters
Southeast Division
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USA
Canada
S. Africa
Australia
NZ
UAE
Japan
China
HongKong
Neth.
Belg.
France
SingaporeMalaysia
Qatar
Kuwait
6 Continents
70+ Locations
1,400+ TechniciansSouthAmerica
Germany
Norway
England
For a complete listing of regional and globalFurmanite locations, visit us online at www.furmanite.com
Azerbaijan
Finland
Portugal
Sweden
India
Indonesia
Thailand
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Furmanite has a full-time safetydirector and a comprehensivesafety program
Every technician must be certifiedin safety training
In 2008 reached milestone of 6million man-hours without a lost
time accidentExperience Modification Rating
(EMR) is currently at 0.50 andcontinues to trend downwardsover previous years
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MAN-HOURS TRIR
0
200,000
400,000
600,000
800,000
1,000,000
1,200,000
1,400,000
1,600,000
1,800,000
2004 2005 2006 2007 2008
535,3
99
549,761
1,
519,
618
1,
674,
680
1,
747,
202
0.00
0.20
0.40
0.60
0.80
1.00
1.20
1.40
1.60
2004 2005 2006 2007 2008
1.
49
1.
46
1.
32
0.
60
0.
57
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New hire (8 hours)
HAZWOPER (24 hours)
OSHA (10 hours)
Annual refresher (8 hours)
Area safety councils
Supervisors training (four days)
Computer-Based Training (CBT) (monthly)
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On-site job reference manual
Daily job safety analysis
Weekly safety meetings
Equipment safety logs
Corporate safety audits
Site specific SOPs
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401K with company matchingfor all employees
High potential
employee program
Constant training to providemotivation and growth potential
Pay grades based on experience
and knowledge
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Engineering Support Services
On-Line Leak Sealing
On-Site Machining
Pipe Isolation and Weld Test
Bolt Torquing & Tensioning
Hot-Tapping and Line Stopping
Valve Repair Shop or On-site
Trevitest On-line
Valve Testing Specialty Concrete Repair
Field Polymers and Coatings
Tank Roof Repair
Heat Treatment Services
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Turnkey problem solvingexpertise
Design to ASME, API or
ANSI standards
40 years of industrial servicedesign experience
Worldwide network of in-house
designers and engineers Support to the entire range of Furmanite
services disciplines
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Original developers ofon-line leak repair services
Leak repair for steam,
hydrocarbons, gas, air,chemicals and liquids
Engineering solutions for leaksfrom 1600 F to cryogenic
Leak repair from vacuumup to 6300 PSI
Sub-Sea leak sealing
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Vast experience with high-severity leaks
Pioneer of technology over 75 years ago
Many applications and lessons learned globally
Industry leading leak sealing compounds 1:1 compression ratio results in less
compound usage than other compoundsfor same application
Custom and stock clamps and enclosures
More PEs than any other leak sealing
company for clamp and enclosure design ASME material and standards; certified weld processes
Company-owned manufacturing facilities
Cross trained technical experts
Valve repair, machining knowledge, etc.
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Holes in pipes or valves
Cracked welds
Packing glands
Flange leaks
Valve bonnets
Threaded fittings
Exchanger leaks
Pressure seal valves
Turbine horizontal joints
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Cost effective, qualitysolutions for routine andcomplex applications
Global reputation andexperience base
Enhanced by our ownershipof machine manufacturerSilk
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Flange facing
Drilling / tapping
Line boring
Milling
Pipe cutting and beveling
Specialty grinding and polishing
Shaft turning
Stud drilling
Other specialized applications
Drilling, Trepanning, Fine Boringand Reaming, for example
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Flanges
Heat exchangers
Cover joints
Boiler manways
Industrialpipelines
Vessel joints
Hub profiles
Front and backof heat exchangers
Oval manways
Oval handholes
Sealing surfacesof pressure vesselsand boilers
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Turning machines for allsizes of flange facing
End-mounted turning machines
Heavy duty drillingand boring machines
Orbital milling machines
Linear and X-Ymilling machines
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Line Isolation Capabilities to isolate pipe sizes from 0.5
to 120
Isolation back pressure can be rated to theburst pressure of the pipe; standardisolation back pressure to 25 psi for all toolsizes
Standard Tooling includes both locking jawand locking lug designs; dependent on size
Advantages of FurmaniteTools
Wider Sealing Elements providethe ability to isolate in conditionswhere the pipe is pitted,corroded, out of round and evenallow us to maintain seals onseamed pipe
Ability to monitor the annulararea of the tool to verify isolation
Ability to through-port any up-stream gas, vapor or pressuresaway to a safe environment
Can be utilized as a pressure
rated back-pressure isolationdevice
All Tools are multi-schedule
Smaller footprint allows for easyinstallation and removal
FILL, VENT, &
ISOLATION BYPASS TUBES
SEAL NUTS LOCKING JAW MECHANICAL SEAL
JAW RETAINER O-RINGS
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Weld Testing Standard tool sizes to test welds from 0.5
to 24 pipe size; custom designs availablefor larger sizes
Standard tooling test pressures to 1150 psi
Available tooling test pressures to 5000 psi
All tools are multi-schedule to facilitateeasy removal past the root
Localized Hydrostatic Test uses minimalwater and provides a high degree ofaccuracy and safety
Nozzle Testing Hydrostatic Weld Testing of
nozzle additions to existingcolumns, vessels, tanks or liners
No confined space entry required
Capable of testing the flange tonozzle weld as well as the full-penetration weld simultaneously
OD Nozzle tester replicates all ofthe same hydrostatic pressuresand stresses of a conventionalhydro-test
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Furmanite provides completeBolt Torquing and Tensioningservices, from design to finaltightening and measurement.
Able to accommodate torqueloads up to 80,000 ft lbs.
Services include:
Hydraulic Bolt Torquing
Hydraulic Bolt Tensioning
Stud Removal
Bolt Stress & Elongation Measurements
Joint Alignment
Nut Splitting
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Ease the activity of opening andclosing valves
Reduce injuries to operators
Inexpensive system for ensuringsafety
Operating procedures
accepted by safety
departments of majorrefineries for the use of
pneumatic tools to assist in
the operation of gear box
actuated isolation valves
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Onsite valve repair and testing
In-House valve repair & testing
In-service valve testing
Routine repairs duringoutages/turnarounds
New valves and parts available at all locations;
select locations are licensed assemblers forTycoTM, CrosbyTM, Anderson GreenwoodTM,KunkleTM, SpenceTM, AshcroftTM, FarrisTM,SuperiorTM and GlobalTM products
Manufacturer of Wilson Snyder coker switch valvesranging from 6 to 16
- the largest, single-owned andoperated valve repair organization in NorthAmerica, with over 20 repair shopsnationwide
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Furmanite can provide servicesfor all valve repair needs
Perform in-service set pressure calibrations
Perform routine scheduled valvemaintenance in shop or field
Repair defective valves duringturnarounds and outages
Emergency response
A large variety of valvescan be repaired
Globe, Control, Plug, Gate
Safety, Safety Relief
Check, Butterfly, Pressure Seal
AOV and MOV Actuators
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Recognized as an industryleading program
Every repaired valve iscertified and then tagged
FURMANITEDtagged valvesbacked by Furmanites iron-cladcustomer warranty
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The Furmanite Guarantees:
That the service was performed safely byprofessionally trained and certified technicians
Our guarantee of the quality of repair in restoring the
valve to like new condition
Our guarantee that all replacement parts used in therepairs are approved and accepted by the NBICRepair Program
Our guarantee that all repairs have beendocumented and records maintained.
Our guarantee that all repairs have been performedin accordance with applicable ASME Codes and theNBIC Repair Program.
Our Warranty to you covers any defect that mayoccur due to workmanship or defective parts thatmay have been installed during the repair.
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Cleaning &SandblastingEquipment
Machining Lathes &Tools
Grinding Equipment
Drill Presses
Air & Water TestStands
Lapping Equipment
Work Benches
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Developed and patented worldwideby Furmanite to test safety and reliefvalves in place and online
Accurately tests valves 1 and larger on-lineand under normal operating pressure and
temperature
No operational interruptions
Valve can be tested remotely for safetypurposes
State of the art technology measures
force, pressure, lift or displacementand sound via acoustic detection
PC based system with data and documentstorage capability, using proprietary software
Permanent graphical record for customer
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Hot Tapping
Line Stopping
Line Freezing
OEM Fittings / Repair Clamps Weld-on and bolt-on designs
Manufacturer (OEM) ofWorld Class Equipment
IPSCO brands
Engineering Solutions
Welding Procedures for allapplications
All fittings, equipment & accessoriesare 100% interchangeable with
alternative vendor options
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Diameters:
Through 72
Pressures:
Up to 2800 PSI
Temperatures:
To +/- 750 Degrees Fahrenheit
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Open pre-job communicationbetween both parties is integralto a successful completion
Hot Tap Data Sheet
? Size
? Flow Rate
? Pressure
? Temperature
? Service? Etc.
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TYPICAL HOT TAPOPERATION
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Once the cutter isthrough by calculatedmeasurement,machine is stoppedand cutter advancedto confirm tapcompleted
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Vent offProduct
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Vent offProduct
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Vent offProduct
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Product
cleared
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Diameters:
Through 84
Pressures:Can Exceed 1000 PSI
Temperatures:
To +/- 750 DegreesFahrenheit
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Line Stop Data Sheet
? What type of stopwill be employed
? What SealingElements will beused
?Etc.
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Install Plugging Tees
Install Bypass Tees
Install Vent Points
Fabricate Bypass
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Install Temporary
Sandwich type valves
Drill and Tap allconnections
Install bypass and commission
pipework
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Upstream plugging
housing ready for installation
Downstream plugging
housing ready for installation
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Downstream head goes infirst to reduce flow
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Upstream head goes in
second to isolate section
of pipeline
Mid-section de-pressurized
through vents
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Mid section can now be cut
out and modified/repaired
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After modification/repair, the
mid section is connected tothe plugging housing
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Mid section can now be
re-pressurized through thevents and the plugging housing
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Mid section can now be
re-pressurized through thevents and the plugging housing
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Upstream head is
removed first
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Followed by Downstream
plugging head
Bypass can now be
de-commissioned
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Completion plug is loweredthrough valve into throat of flange
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Drive Segment is advanced tosecure plug in position of flange
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O Ring provides pressure seal
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All fittings blanked off -
Job Complete
Pivoting Head
High Pressure Line Stop from 3 to 48
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High Pressure Line Stop from 3 to 48
Folding Head
Low/Medium Pressure Line Stop from 12 to 84
Sure-Stop
Positive Seal Line Stop from 2 to 42
HTP (High Temperature/Pressure)
High Temperature & Pressure Line Stop from 3 to 14
Line Freeze Plugging
Up to 48
FloStop
Water Main Line Stops from 4 to 16
EZ Valve Insertion Assembly
From 4 to 12
How do we select SealingElements?
Temperature
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Temperature
Time at Temperature
Type of Service
Pressure
Type of Sealing Elements
Buna-Nitrile
EPDM
Viton GF
Typically, elastomer seals arereplaced with a metal-to-metal orteflon seals at or above 350oF
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Sure Stop design can be usedfor pipe that is out-of-roundand/or has large amounts ofinternal buildup
Cuts line in half
Stopping headexpands into placein the line
Stopping head expands andlocks into place (safety
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Uses metal to metalseal in most cases
Cuts line in half
Stopping head expands andlocks into place (safetyvalue)
Current capabilities up to 750degrees Fahrenheit and 1000 psi
Water
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WaterWastewater
Air
Chemicals
Boiler water/steam
Natural gas
Oil/fuels
Performed on virtually alltypes of pipes and vessels
Full Encirclement
Weld-on
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Weld on Bolt-on (Mechanical)
Shaped Nozzle
Three-Way Tees
Perma Stops
Special Types
Spherical
Bottom out
Typical Delivery Times
Routine: 10 to 14 Days
ASAP: 7 to 10 Days
Split Sleeve Repair
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Split Sleeve RepairClamps
Flange Repair Clamps
Pinhole Leak Clamps
Flanged EndConnectors
Pipe End Connectors
Completion Plugs with
Scarfed Nipple Outlets Flow-Through
Completion Plugs
Structural Repair and Expansion Joints
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Structural Repair and Expansion JointsWater Control (Leak Stoppage)
Surface Repair (coatings and linings)
Epoxy Injection
Pump and Motor Base Repair Soil Stabilization
Pipe Penetration
Tank Roof Repair
Secondary containment Restoration projects
Applications
Heavy machinery base
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Heavy machinery baserepairs
Pump and motor base repair
Structural support baserepair
Epoxy pressure injectionmethod
Holes drilled into concrete atstrategic locations
Two part epoxy resin isinjected
24 to 72 hours for final cure
Polymer cementitious
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Polymer cementitiousproducts and chemicalresistant coatings repairsurface damage as aresult of:
Corrosion
Chemical Attack
Freeze/Thaw
Wear & Abrasion
Physical damage
Solution for problemssuch as:
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Repair sealantcapabilities:
Thin enough to penetratehairline cracks
Work in flowing waterBond to wet surfaces
Remain flexible and inert afterquick curing
Solution for problemssuch as:
Freeze / thaw damage
Corrosion of reinforcing steel
Erosion of the structure
Mineral deposits
Loss of dry environment
SurfaceOverlayments &
Toppings
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pp g
Expansion Joint
Design & Repair
Spall Repair WithEpoxy Adhesive &Polymer Concrete
Permanent pipe repair
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Permanent pipe repair
Stronger than the existing material
Pipe rehabilitation
Small-bore pipe repairs
Nozzle repair
Tank repairs
Structural repairs
Applied on site
No Workshop
Simple Preparation
Simple to Apply
No Hot-Working
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No Hot Working
Conformable
Non-Hazardous
Back-fill in 2 hours
Smart Pig Detectable Features Available
Cost-Effective Alternative
DOT Compliant
Meets ASME PCC-2 Code and AEATechnology / ISO Standards
Pressure to 3031 PSI
Temperatures from -13oF to 410oF
Sizes from 3/8 to 132
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Specialized Product:
FurmaWrap-FW2
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Durable and cost-effective solution forpermanent reinforcement and repairs
Resin-impregnated fiberglass composite wrap
Stronger than steel, high tensile-and highflexural-strength product
Increases axial load strength and load bearingcapabilities in steel (pipe) and concrete
Remediates pipes, elbows, tees and concretestructures
Inhibits corrosion and restores pipeline integrity
Resistant to a wide range of dangerous chemicals
Works in wet or dry conditions, including underwaterrepairs
Classified according to ANSI/NSF 61standards for drinking water safety
FurmaWrap FW2
#1 Assess #2 Sand Blast #3 Apply Putty #4 Apply Coating
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#5 Wrap Pipe #6 Compact Wrap #7 Remove Compaction #8 Coat Repair
Flexible materials
conform to
difficult shapes
Structural repair
provided by
carbon fiber
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difficult shapes
Materials formed
to shape on site
with no pre-
fabrication
Lightweight
repair kits are
easy to transport
& handle
Epoxy bond to
steel provides
leak sealing
capability,
chemical &environmental
resistance
Repairs are close
fitting & can be
applied in confined
spaces
Repairs are classed as Permanent
No hot work required
No interruption to plant operation
Riveted or screwed steel plates,
sometimes injected with aspecifically developed compound
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jspecifically-developed compound
Able to seal and repair under themost demanding conditions, includingcorrosion defects and weld crackson lap joints
Repairs done while tank is in service,eliminating downtime
Full pre-job risk assessmentand method statement
Applications for both floating
roofs and fixed roofs usingplates and composites
Welding Preheat Heat Shrink/Expansions
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e d g e eat
Localized Electric PWHT
Combustion Gas PWHT
Fixed-Hearth Furnaces
Temporary Furnaces
Hydrogen Bake-Outs
Line Thawing
Coating Cures
eat S / pa s o s
Space Heating
Process Start-Up
Refractory Dry-Outs
Equipment Sales
Equipment Rentals
Equipment Calibration
Turbine WarmingSystems
100+ Man-Years of Heat Treating
Management Experience
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g p
10-Year Average TechnicianExperience Level
Best of the Best
Applications Include:
Maintenance
Outages
Turnarounds
Capital Projects
Call-Outs
24 Hour Service, 365 Days per Year
Preheating During WeldingProvides:
Reduces the levels of thermal stress
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Compensation for high heat losses
Minimize the rate of weld hardening
Reduced porosity in the weld
Reduced hydrogen cracking
Improved microstructure of heat
affected zone
Post Weld Heat TreatingAccomplishes:
Relaxation of Residual Stresses
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Relaxation of Residual Stresses
Relaxation of Thermal Stresses
Tempering (Softening)
Removal of Diffusible Hydrogen
Refractory Dry-Out Provides theLining:
Improved Refractory Strength
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Improved Refractory Strength
Elimination of Refractory Separation
Removal of Mechanical Water
Minimization of Explosive Spalling
Reduction of Thermal Stress
Basic design and technology of the standardHeat Treatment Console has not changed
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Heat Treatment Console has not changedsince the mid 1970s
Largest design improvement to date hadbeen the move from Dial-a-Pak Controllers toUniversal Display (UDC) Controllers
Standard technology continues to utilizegraphical 12 or 24 point strip chart recordersallowing for only one continuous heat cycleper machine
Many of the standard consoles still being
manufactured and used today continue toallow for only 75 volt output, resulting insevere line loss issues and the necessity todouble-stack heaters in order to maketemperature
UDC Controllers and Strip Chart Recordersare replaced with Programmable LogicControllers (PLC) and SCADA (Supervisory
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Controllers (PLC) and SCADA (SupervisoryControl and Data Acquisition) Software
System is driven by interchangeablecomputer laptops that stores time andtemperature information in encrypted form
In the unlikely event of a laptop failure, theconsole hardware allows for any heat cycleprogram to be completed manually and thebuilt in memory will store the cycleinformation for up to four- (4) days
At the end of each shift, the heat cycleinformation is backed up onto a flash driveand then cataloged for retention
85 volt output, resulting in less equipmentrequirements than many other competitors
http://images.google.com/imgres?imgurl=http://pencomputing.com/images/panasonic_cf29_open.jpg&imgrefurl=http://www.pencomputing.com/frames/panasonic_cf29.html&h=530&w=500&sz=40&hl=en&start=12&tbnid=0qtpo7m3T1pO5M:&tbnh=132&tbnw=125&prev=/images?q=toughbook&gbv=2&svnum=10&hl=en -
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Manual Dial-a-Pak or UDCControllers; may have a
set-point programmer thatwill run automatically but
requires programmedzones to run the samecycle at the same time
Single laptop control is equipped to run 5 independent6-Zone Consoles simultaneously, each console capableof having 6 independent heat cycles with 6 differentstart times and programs; i.e. 30 independent heatcycles can be monitored at one time from a single point
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Potentiometric 12 or 24Point graphical Time &Temperature Recorder,
capable of running a singlecopy of a single chart at
one time; stores no copies
Laptop control electronically creates encrypted Time &Temperature charts capable of running multiple cyclessimultaneously and separating out up to 30 independentthermocouples; stores an infinite number of copies
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Controllers and the fear ofover-temp or heater burn-
out require that atechnician constantly watch
over the Time &Temperature chart,
remaining thereunproductive during the
entire heat cycle
Laptop control can be run wirelessly and remotely; with builtin alarms for any heat cycle deviation, including over tempand heater burn-out, and the ability for a single tech/station tomonitor up to 5 consoles at once, additional workforce can bedismissed or dispatched to more productive functions
Furmanite continues to makedesign and technologyimprovements to benefit ourcustomers
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Our newest design takesadvantage of the reduction ofinternal components created bythe technology advances andreduces the overall footprint of asingle console to 25 x 24 x 35
The smaller footprint allows us touse consoles in constricted areasthat were otherwise unachievablewith traditional equipment andfurther reduces the overallrequired equipment area in largeprojects or turnarounds wherereal estate is at a premium
All new 6-Zone consoles beingmanufactured incorporate thisnew design
35
Thermocouple Wire Triple Cable Sets
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ThermocoupleAttachment Unit(TAU)
Flexible CeramicHeaters
Splitter Cables
Brinell HardnessTesters
Unique ID for electronic retention
Client defined ID
Pertinent job information
Date and time stamp automatically
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p yentered by the software at the startand finish of the heat cycle
Client defined scope references
Microprocessor S/N
TC Interface Board S/N (Recorder)
Calibration Dates and Initials
Calibration Instrument
Heat Cycle Phase Designations
Phase program set values
Actual Phase measured values &
time Thermocouple Reference
Time and Temperature Chart
Time & Temperature Charts arenot limited to the bottom of asingle standard report; their
ability to be printed in variousformats gives you the true QCand oversight you require
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and oversight you require
Heat Cycle charts can beformatted in quarter page orfull-page reports
Charts can be broken downto minute details, smallintervals, or singlethermocouples
When required, the softwareallows for a detailed diagram ofthe setup, describing heater andthermocouple placement for yourrecords
Diagrams such as this one can beentered into a standard report, ascan a detailed note section
Mobile Rigs
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g
18-Points, capabilities to expand
to 36-Point
Fully Enclosed, Sound
Attenuated, Triton Generators
- 202 kW Standby
- 185 kW Prime
- 280 Gallon Fuel Capacity
- Capable of 26 hours of fully
loaded continued use
High Velocity Combustion GasTrains
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Output variable from 100,000 to10,000,000 BTUs per hour
Burner Sizes in Inventory
10 Million BTU
5 Million BTU
3 Million BTU
1 Million BTU
Million BTU
Backing of a publicly traded
company with a global presenceand knowledge base
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Over 75 years of provenexperience in solving unique problemsand managing large projects
Quick response with over 70 locations on 6 continents Diverse and flexible solutions for proactive repair,
maintenance and turnaround support
Experienced, field-proven and motivated technicians
Patented technology
Spending the necessary capital to support yourrequirements with our state-of-the-art equipment and tools
Visit Furmanite
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Or, for moreimmediate answersto your questions
Visit Furmanite
online at
www.Furmanite.com
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