Flexitallic to the Rescue with the Flange Rescue Gasket
02 February 2010
Set to revolutionise offshore asset maintenance, Flexitallic has launched the first-ever solution to sealing damaged flanges without the need for replacement or machining - the Flange Rescue Gasket (FRG).
The FRG is a unique invention developed in response to customer demand for a sealing solution to reduce the lengthy and costly process of flange maintenance in corrosive offshore environments. The FRG negates the requirement for flange replacement or machining, potentially reducing every flange inspection by 24hr.
Utilising Flexitallic's revolutionary sealing technology, highly compressible Sigma®, ensures the FRG conforms to damaged flange surfaces to seal and prevent further deterioration. Restructured Sigma PTFE bonded to the high-integrity serrated metal ring provides a leak-free seal and blow-out resistance. The FRG has a PTFE coated body which is corrosion resistant and features integral bolt holes for ease of installation. Superior mechanical integrity allows the use of the full range of torque, reducing the risk of operator error to meet stringent HSE standards.
For asset managers in the oil and gas industries the fight against corrosion is a constant battle, as internal corrosion of flanges has a major impact on operating costs, particularly on older assets.
Previously, sealing issues with corroded flanges have discouraged frequent inspection. Now, flanges can easily be inspected and sealed effectively enabling fast, accurate assessment of internal corrosion. The high load-bearing characteristics of the FRG mean that it can withstand high levels of tightening, reducing the risk of operator error and failed repair. To install the FRG there is no need for special permits; all that is required is a wire brush to clean off the surface before the FRG is fitted.
The FRG is the ultimate corrosion management tool. By reducing leaks and slowing corrosion, the possibility of shut-downs with associated HSE visits are dramatically reduced, as is the huge loss of revenue associated with a stop in production. Full closure of the corroded area prevents further damage, with operators able to open flanges for inspection and confidently resume operation using a new FRG.
A revolution in flange inspection and maintenance
From corrosion management to health and safety, through environmental impact to incident avoidance, the FRG is poised to dramatically change flange inspection and maintenance forever.
Russ Currie, applications engineering manager at Flexitallic, reports: "Shutdown season is rapidly approaching and the FRG offers engineers an exciting solution for upgrading equipment and processes especially when faced with the challenges which increased demands from health, safety and environmental legislation bring."
"Engineers and asset managers are instantly identifying that the FRG offers an opportunity to increase production up time, reduce maintenance down time, positively affect past and future corrosion damage to ultimately improve the profitability especially on ageing offshore assets. Feedback on the FRG from the industry includes many positive comments on the simplicity of the design, material development, innovative use of available technology and ease of installation," he adds.
Flexitallic has invested in a sophisticated marketing campaign to brand and launch the new gasket. Aspect Design & Marketing has been appointed to maximise awareness among engineers and asset managers. Aspect has given the FRG a unique brand – a highly recognisable industrial-styled FRG 'stamp' logo.
Phil Kelshaw, sales and engineering director at Flexitallic, comments: "The Flexitallic team has designed and manufactured an incredible product in the flange rescue gasket and rather than relying on traditional engineering gasket industry style marketing we felt the FRG warranted a striking brand and marketing communications which reflect the FRG's innovative features."
"We maintain our position as an industry leader in sealing solutions through engineering expertise, pioneering gasket design, materials development and setting industry standards. We have strong, valued, long-term partnerships with customers to identify problems and provide fast, innovative solutions. They rely on our knowledge of current health and safety and environmental issues affecting the industry. FRG is a great example of Flexitallic's commitment to offering a superior sealing solutions package," adds Mr Kelshaw.
Raising awareness of the Flexitallic suite of products and services to the oil and gas sector will be newly appointed regional sales manager for Scotland, Rachel Armell.
Commenting on her new role, Rachel said: "Flexitallic has an excellent reputation and offers a comprehensive package of services and an exciting suite of products. I am looking forward to highlighting Flexitallic's capabilities to both existing and new customers. Our partnership approach means we develop strong relationships enabling us to achieve the best results possible for our customers."
The FRG is the latest in a long line of sealing technology innovations from Flexitallic which began with the invention of the spiral wound gasket nearly a century ago and include Thermiculite® for ultimate performance in fire-safe, high temperature applications and the flexible Sigma range of high integrity, low maintenance gaskets across the pH range, and a wide range of temperatures and pressures.
For more information about the FRG contact Flexitallic.
