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The High Cost of Flange Management Failures
A single flange leak can cost over €100,000 in production losses, not counting safety risks or environmental impact.
Yet most turnarounds still manage critical flanges using:
- Paper checklists stuffed in pockets
- Disconnected spreadsheets with no traceability
- Handwritten torque values and parameters
- Unlinked photos stored on personal devices
The results are predictable - and preventable.
The Real Cost of Paper-Based Flange Management:
NO
Risk
Consequence
Business Impact
What It Solves
Missed or incorrect torquing
Leaks during startup
Production delays, safety incidents
End-to-end management from scope development through execution to lessons learned
Incomplete documentation
Failed QA/QC audits
Compliance violations, rework
End-to-end management from scope development through execution to lessons learned
Untraceable anomalies
Unresolved flange issues
Unexpected failures during operation
End-to-end management from scope development through execution to lessons learned
No real-time oversight
Reactive management
Schedule delays, resource inefficiency
End-to-end management from scope development through execution to lessons learned
"Before implementing the FIM App, we had three flange-related incidents during a single startup. Since implementation? Zero."
Turnaround Manager at a major refinery
Introducing: FIM App by RB Powersystems
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Complete digital lifecycle
From disassembly to sign-off
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Mobile-first design
Built for field technicians
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Real-time dashboards
For supervisors and QA/QC teams
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Standardized procedures
Ensuring consistent execution
Lorem ipsum dolor sit amet, consectetur adipiscing elit. Suspendisse varius enim in eros elementum tristique. Duis cursus, mi quis viverra ornare, eros dolor interdum nulla, ut commodo diam libero vitae erat. Aenean faucibus nibh et justo cursus id rutrum lorem imperdiet. Nunc ut sem vitae risus tristique p<svg width="49" height="45" viewBox="0 0 49 45" fill="none" xmlns="http://www.w3.org/2000/svg">
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Full traceability
of every action on every flange
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QR tagging
for instant flange identification
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Works offline
when network connectivity is limited
The Real Cost of Paper-Based Flange Management:
NO
Phase
Paper Process Pain Points
FIM App Solution
What It Solves
Disassembly
No record of who did what, when
Log who disassembled which flange with automatic timestamps
End-to-end management from scope development through execution to lessons learned
Inspection
Photos lost, findings not documented
Record findings, attach photos, flag anomalies in one place
End-to-end management from scope development through execution to lessons learned
Reassembly & Torquing
Torque values recorded on paper
Enter torque method, tool, parameters; digital sign-off via QR code
End-to-end management from scope development through execution to lessons learned
Cleaning
No verification of surface condition
Confirm surface condition with digital checklists and QC verification
End-to-end management from scope development through execution to lessons learned
Testing & Closure
Test results missing from documentation
Attach all test results; confirm mechanical completion
End-to-end management from scope development through execution to lessons learned
Documentation
Manual compilation of fragmented records
Create complete digital flange dossier with one-click export
End-to-end management from scope development through execution to lessons learned
Field-Tested Features Your Teams Will Actually Use
Field-Tested Features Your Teams Will Actually Use – Practical tools designed for real-world use, boosting productivity and team efficiency.
1. Built-In Work Instructions
Every step follows structured, pre-defined work procedures (WVB), ensuring consistency in the field.
2. QR Tagging of Flanges
Print and scan tags with unique QR codes linked to the digital flange dossier.
3.Tablet & Mobile Version (Online & Offline)
Enter data on-site, even without internet. Syncs automatically once reconnected.
4.Photo & Document Capture
Attach inspection photos, certificates, and technical drawings.
5.Live Dashboards & Filtering
Supervisors and QA/QC teams monitor flange progress and bottlenecks in real time.
6.Anomaly Tracking
Flag anomalies at any step. Assign and monitor corrective actions until resolved.
Beyond Flanges: One Tool, Multiple Critical Components
The FIM App's configurable framework adapts easily to manage:
- Pressure Safety Valves (PSVs)
- Relief valves
- Hot bolting activities
- Hydrostatic and service testing
- Any critical equipment requiring sequential execution
"We initially deployed the app for flanges, but now use it for all pressure-retaining components. The standardization alone has transformed our quality management."
Real Results from Real Users
NO
Phase
Paper Process Pain Points
FIM App Solution
What It Solves
2-3 flange-related incidents per turnaround
Zero flange incidents in last three turnarounds
End-to-end management from scope development through execution to lessons learned
End-to-end management from scope development through execution to lessons learned
40+ hours compiling flange documentation
One-click exports of complete digital dossiers
End-to-end management from scope development through execution to lessons learned
End-to-end management from scope development through execution to lessons learned
25% of anomalies unresolved at handover
100% anomaly resolution with digital tracking
End-to-end management from scope development through execution to lessons learned
End-to-end management from scope development through execution to lessons learned
Limited visibility for management
Real-time dashboards showing status of all components
End-to-end management from scope development through execution to lessons learned
End-to-end management from scope development through execution to lessons learned
Inconsistent execution between technicians
Standardized procedures ensure uniform quality
End-to-end management from scope development through execution to lessons learned
End-to-end management from scope development through execution to lessons learned
Why It Works When Other Solutions Don't
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No paperwork
Everything digital, structured, and centralized
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Standardized execution
Fewer errors, better traceability
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Offline functionality
No network? No problem
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Full progress visibility
real-time dashboards for teams and management
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Field-first design
intuitive and easy to use on mobile or tablet
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Audit-ready output
full flange dossiers exportable for clients, QA, and compliance
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Integration-ready
data flows into Power BI, P6, ERP and central turnaround system
What Our Clients Are Saying
What Our Clients Are Saying – Genuine feedback from satisfied customers highlighting our impact, reliability, and the value we consistently deliver.
Field Supervisor
"Technicians actually like using it because it's simple and makes their work visible."
Quality Manager
"Our QA/QC audits used to take days. Now we can produce all documentation with a few clicks."
Maintenance Director
"The FIM App paid for itself in the first turnaround just by preventing a single leak that would have occurred with our old process."
See It In Action: Limited Demo Slots Available
Q2 2025 implementation slots are filling quickly.
Book your personalized demo today and see how the FIM App can transform your flange management process for your next turnaround.
The demo includes:
- Live system walkthrough
- Custom implementation timeline
- ROI calculation for your facility
- Example dashboards from similar plants
Demos take just 30 minutes • No obligation • Private and confidential
Ready to Eliminate Flange Management Headaches?
Zero flange-related incidents
Complete traceability and documentation
Real-time visibility for all stakeholders
Standardized, high-quality execution