Real-time quality assurance and progress tracking for bolted joint assembly

Smart Torque System™
Real-time quality assurance and progress tracking for
bolted joint assembly and maintenance
© 2021 Cumulus DigitalSystems – Proprietary & Confidential

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• SOC 2 certification
along with regular
penetration tests
• Mobile application
available to work in
offline mode.
• Eliminate Leaks @ Startup !
• Reduce CO2 emissions
during field execution
• Single source of truth for all
activities on each flange
• IS/EX tools supporting manual
and hydraulic tightening
• IS/EX tablets with available glove
mode
• Android tablets for use in extreme
temperatures (-20C to 60C)
Safety Benefits – EliminateRework & Reduce Exposure Hours

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Quality Assurance is a in DIGITAL TRANSFORMATION
Current Industry 4.0 solutions tell us the status
of people and equipment, but do not assess
work quality
Industry 4.0
Market
Needs
Are my
machines
working
properly?
How much
energy am
I using?
Where are
my
things?
Where are
my
people?
Are my
workers
qualified?
Was the
work done
right?
THE NEED
• A digital solution for planning, tagging, and
tracking specific field activities
• Real-time progress tracking and quality
assurance
• Full accountability at individual worker level

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Full Situational Awareness
Complete Paperless QualityWorkflows
• Specific work instructions and data
will be at the fingertips of craft
• Tool data provides source of “truth”
• Smart tags locate joints with higher
accuracy

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We started with BOLTED JOINT management
• Significant opportunities for cost savings
• Primarily paper-based, siloed, and lack accountability
• Current processes result in significant unproductive work
costs & lack adequate quality verification
>30% of work is rework
• Unplanned downtime costs owners $260,000 per hour
• Top Three Reasons for Unplanned downtime:
1) Mechanical Failure
2) Technology that is not Integrated
3) Human Error

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Diversified worldwide customer base focused in North America and Asia Pacific
Shell
ExxonMobil
Bechtel
Petronas
OneSubsea
McDermott
ClearStream

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– covid-19 response
Assuring quality through remote inspections
Smart Torque System (STS) was
used at global oil & gas operator
offshore Tension Leg Platform
(TLP) during a critical turnaround
(TA) event in April 2020.
Due to COVID-19 travel
restrictions, QA activities required
an onshore team to remotely
assist an offshore team to
manage and oversee the TA
100Km offshore.
Scope of TA was in constant
motion as priorities and scope
were changing daily. TA had to
complete on-time due to
deteriorating world health
conditions.
”The role of QA should
theoretically lie with someone
who is on-site who can witness
the torqueing, but since we are
using Smart Torque and the
values are recorded, then it
should not be an issue to
approve the process flow on-
shore by just reviewing the data.”
TA Project Manager
“The torque value as per
QC report were reviewed
and is acceptable. Flange
tightness check as per site
photo and is acceptable”
QA Inspector Working
Onshore Overseeing
Offshore TA
The TA was highly successful with
the organization of the project and
integrated use of STS.
• Confirmed zero leaks on start-up.
• TA completed on-time within
scope with no unplanned downtime.
• Operator QA Inspector remotely
monitored activity and data from
onshore in STS Control Center.
• Site QA inspector was able to
remotely inspect and approve the
joints for startup without being at
offshore platform.

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Initiate a significant step change in your Company

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Does not include the value of preventing accidents, including worker safety, environmental impact, unplanned downtime, and equipment replacement costs

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$127,500
$243,000
$6,900,000
$57,670
Easy LookUp & Recording
Reduced QC/QA Wait
Reducing Paperwork / Seamless Aggregation
Fewer Reworks
$-
$2,000,000
$4,000,000
$6,000,000
$8,000,000
$10,000,000
$12,000,000
$14,000,000
$16,000,000
Year 1 Year 2 Total
Total Costs Total Benefits
686%
ROI
1,427%
ROI
938%
ROI
Annual Savings by Category

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$637,500
$2,430,000
$21,450,000
$1,365,293
Easy LookUp & Recording
Reduced QC/QA Wait
Paperless & Seamless Aggregation
Fewer Reworks
$-
$10,000,000
$20,000,000
$30,000,000
$40,000,000
$50,000,000
$60,000,000
Year 1 Year 2 Total
Total Costs Total Benefits
890%
ROI
2,280%
ROI
1,298%
ROI
Annual Savings by Category

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How we help: STS reduces overall flange management time
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Traditional Bolted Joint Management
Smart Torque System
Joint
Tagging
Bolted Joint Assembly, QC
Unit
Startup
QA
Data
Calculation
Joint Tagging Bolted Joint Assembly, QC Data Aggregation
Unit
Startup
Joint
Identification
QA
Aggregate data in real-time
Project status and metrics available
wherever, whenever
Reduce QC/QA effort and paperwork
Digital torque report removes paper, saves
time, and improves recordkeeping
Easily identify joints in scope
Sortable and filterable cloud database
easily identifies joints by area/unit and
other filterable data elements
Reduce repetitive data calculations
Re-use joint data from project to
project, see the full historical record

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Breakdown Assemble Tighten QC
Tag
Real-time visibility for each step-in workflow and full data managementfor each joint in database
STS manages the entire flange management workflow
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© 2019Cumulus DigitalSystems, Inc.
QA
In STS mobile app, each operation can be configured for roles such as Fitter, QC Inspector, and QA
Inspector with available actions. Actions can be added to each operation to create a workflow.
OPERATIONS
and management
Auto-generate digital work
completion reports
Real-time visibility into workflow
and full activity history
management for every joint in
database
Untouched
Easily upload
joint data via
Excel or API
Initial joint state
at beginning of
workflow
Ensure proper
scope and scan
tag at joint. Add
photo, checklists
per site
procedure
Work history with
date/time,
worker details
with photo,
checklists and
hold points per
site procedure
Final make-up of
joint, with
checklists,
pictures, and
hold points per
site procedure
Tightening of
joint by fitter
either manually
torqued,
hydraulically
torqued or
tensioned.
Contractor QC
with tighten
check, checklists,
and photos per
site procedure
Operator QA with
tighten check,
checklists and
photos per site
procedure

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Smart Torque System
Connect: Tool Suite
• Commercially available
connected manual and
powered torque tools
• Intrinsically Safe and
ruggedized options available
• Automatically set target
torque value
Collect: Mobile App
• Use to communicate directly with
tools to acquire data in real-time
• Online and offline modes for mobile
devices (iOS and Android)
• Configurable and customizable
workflows
Manage: Cloud-Hosted Control Center
• Traceability and accountability of all joint
data including worker metrics
• Real-time quality and progressmonitoring
• Automatic generation of digital completion
report for reporting and record keeping

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STS THE LATEST
Manufacturers are building connectivity into
tools, but there is no OEM-agnostic quality
management system utilizing this capability
STS bridges the gap and enhances the tool
manufacturers original vision
Two-way communication with automatic control
of torque value and data transfer
Manual Torque Options:
• IS/EX Snap-On manual torque wrench available
in three (3) models with max torque of 135Nm,
400Nm, 650Nm
• Audio, visual and haptic feedback
• Torque multiplier friendly
Hydraulic Options:
• IS/EX WIKA digital pressure gauge
• Hytorc Lithium Series II electric tool
• Hytorc Vector pump

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Loyd Patterson
713-203-5482
loyd.Patterson@cumulusds.com
www.cumulusds.com

Real-time quality assurance and progress tracking for bolted joint assembly

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