- John M. Jenco
Charlotte, NC. USA
Looking back, 2012 was a
good year for FADU sales and
continued market penetration
for this advanced training
technology. We delivered
another 13 units to customers
last year, with several of those
un its to in ternat iona l
customers in Singapore,
China, and the United
Kingdom. Late last year, we
also began delivering new
FADU with the much-
requested strain-gauged bolt
(SGB) protective shroud. For
those that do not have this
Across The Desk...
Summer 2013Summer 2013
FADU Training UpdateFADU Training Update
Points of Interest:
Installing v2013 Successfully
The New Paradigm in v2013
FADU User Group Interest?
Inside this issue:
Is It Time For a FADU Users
Group? 2
The New v2013 FADU User
Interface Software 3
The New Gasket Compres-
sion Study (GCS) 4
The New Torque-Preload
Study (TPS) 5
The New Mechanic’s Judg-
ment Study (MJS) 6
The New Assembly Method
Comparison Study (AMCS) 7
GCM/TPM Setup Using the
RTJ Spacers 7
Copyright © JJENCO, Inc. 2013. All Rights Reserved.
very useful device, it is
avai lab le as a h ighly -
recommended option that can
be easily installed by the user
and prevents expensive
accidental damage to the SGB
electrical connections.
In addition to adding to the
international user base, the
FADU training technology
continues to be adopted by
Installing v2013 Software Successfully Before jumping right into
talking about all the great new
features included in the new
v2013 FADU software
release, a few words up front
are necessary to assure that
you make the transition easily
and as pain-free as possible.
First, to avoid any problems
later, you’re going to want to
do a ‘clean’ install of the new
software. This involves
removing all of the old
software components from
your computer. Some of this
Windows can do for you
automatically, but a few steps
are going to be necessary for
you to do manually. Don’t
worry. They’re easy.
To begin, from the ‘Start’
menu, launch the Windows
‘Control Panel’ and select
‘Uninstall Programs’. (Use a
more direct means if one is
available to you.) Scroll down
the l i s t o f in s t a l l e d
applications and select ‘FADU
Version...’. Click on the
‘uninstall’ button and follow
any screen prompts that arise.
You want to uninstall the
entire application and any
related components.
Next, repeat the same
procedure for any National
Instruments applications, such
as ‘National Instruments
Sof tware ’ . (32 -b i t OS
installations may also need to
delete ‘Personal DAQView
D r i v e r s ’ , ‘ P e r s o n a l
DAQView’, and ‘PostView’
applications as well.)
Once Windows has finished
automatically deleting these
applications. Close these
dialog boxes, open Windows
Explorer, and navigate to
‘C:\JJENCO\’. Delete this
directory entirely.
NOTE: IF YOU HAVE
SAVED ANY LOG FILES TO
THIS DIRECTORY (*.TXT),
MOVE THEM TO ANOTHER
Con’t on Page 6...
Con’t on Page 5...
Is It Time For a FADU Users Group?
Page 2
FADU Training Update
Copyright © JJENCO, Inc. 2013. All Rights Reserved.
Flange Assembly Demonstration Units (FADU) are now in use on every continent except Australia
and Antarctica. Heavily concentrated in the commercial centers and industrial areas of southern Cali-
fornia, throughout the Houston, TX metroplex, the eastern United States, and Britain, FADU are also
in use in Brazil, Spain, South Africa, Kazakhstan, Thailand, China (Taiwan), and Singapore.
End-users represented are engaged in refining, petrochemical, power generation, metals & mining,
trade unions, and of course, gasket manufacturers. Given the broad geographic distribution of FADU
and the diverse representation of end-user interests and applications, the question begs whether it
might be useful to form a FADU Users Group for the purpose of sharing tips, standardizing training
concepts, and furthering the education of those interested in understanding gasket joint behavior, as-
sembly considerations, and improving the quality of bolted joint assembly techniques and associated
instructional training.
An additional area of application and interest, of course, lies in the performance of various basic re-
search pertaining to various assembly considerations with gasketed flange joints. A number of current
FADU users have applied their imagination in order to achieve some impressive research results using
their units.
As the manufacturer, JJENCO would be happy to facilitate a Users Group organized and directed by
end-users. In addition to this annual newsletter, we can envision additional UG communications bene-
fiting end-users, as well as perhaps an annual training seminar or workshop focusing FADU operation,
standardization of training concepts, improving training effectiveness, research applications and results,
and suggested improvements to the FADU platform itself.
Anyone interested in leading or participating in a FADU Users Group beginning in 2014, please contact
John Jenco ([email protected]) to discuss your interest or offer your suggestions.
FADU Global Market Penetration
The New FADU v2013 User Interface Software
Page 3
Summer 2013
Copyright © JJENCO, Inc. 2013. All Rights Reserved.
The new FADU v2013 User Interface Software represents a major step forward for FADU users everywhere. The
software is a complete, “from the ground up” rewrite of the existing software. This was necessary in part because
we never envisioned that the FADU would be as successful and widely adopted as it has proven to be. Originally, we
designed the FADU to address a specific request from Browns Ferry Nuclear Plant (Decatur, Alabama) for a
reliable, easy to use, and state-of-the-art training mockup capable of illustrating all the key points related to effective
assembly of industrial pressure-boundary flange joints. It was going to be a ‘one off’ project.
The design, test and evaluation effort took several months, during which time we received an order for a second
FADU for Chevron Refining (El Segundo, California). The original software was not written to be particularly
expandable in terms of functionality. Likewise, both the software and hardware were developed for these [US]
customers only, and with no knowledge that the global computer industry was preparing to change from 32-bit to
64-bit operating systems. As such, when word of the FADU began to spread through trade shows and general word
-of-mouth, orders began to stream in from across the country and around the world. From that time until now, we
have had to work to overcome inherent limitations in the original software and hardware platforms. With the v2013
release, not only has the user interface been redesigned, but the more important underlying software code has been
rewritten to optimize the software and position it as a solid foundation for a well-defined software development
strategy going forward.
The New Paradigm
After the application is launched, and after the brief appearance
of the JJENCO ‘splash screen’ indicating the software version
and FADU serial number, the software opens to a redesigned
‘main screen’, which is titled the ‘Gasket Compression Study’
screen. This screen consists of the same three (3) major
elements (flange circle, stress vs. compression graph, and
vertical column chart) laid out in a more useful fashion, as well
as a few new changes and additions to the interface.
The most important change to the new user interface is a basic
change in the paradigm used. Beginning in v2013, we have
changed from a ‘main’ screen and one ‘subscreen’ (the previous
Torque-Preload screen), to the concept of ‘Studies’. In this
concept, a ‘Study’ is a standalone screen designed to support
the required data collection and display associated with a
particular experiment or demonstration. In addition, Study screens will also perform needed calculations
automatically to drive the desired display of demonstration results. Some Study screens may also provide a manual
input to enable the user to perform ad-hoc comparisons requiring calculations based upon specific user-selected
data, all on the fly. Thus, the user can tailor illustrations to specific learning points in the training.
In v2013, there are three (3) specific Studies included, in addition to the main Gasket Compression Study screen.
We envision that new Studies will be developed and added in future releases, based directly upon the needs and
suggestions of the FADU users themselves.
Another change that goes hand-in-hand with this new Studies paradigm is how screens are titled and named. You
will note that on the main screen, the screen title (appearing in the blue title bar at top) is ‘Gasket Compression
Module’, while the Study name (appearing on the gray screen itself) is ‘Gasket Compression Study’. This naming
convention was adopted to provide an easy method for end-users to quickly determine which FADU hardware
module is designed to support a particular Study. We presently only offer two hardware modules, the Gasket
...Con’t on Page 4
Gasket Compression Study Screen
Page 4
FADU Training Update
Copyright © JJENCO, Inc. 2013. All Rights Reserved.
The New FADU v2013 User Interface Software, con’t Compression Module (GCM) and the Torque-Preload Module (TPM), and not counting the RTJ flange module which
is really a alteration of the GCM.
However, it is easy to envision that if
more hardware modules were added
in the future, as well as additional
Studies, it could quickly become
difficult for the user to be assured of
selecting the correct module.
Unlike previous versions, the default
screen size is now 1024x768, rather
than 1280x800. This was done to
make the software compatible with
older or less expensive LCD
projectors in the marketplace whose
resolution was limited to the lower combination. Thus, v2013 software is now easily compatible with virtually any
LCD computer display on the market, making its ease of utilization more user friendly than before. This change did,
however, require that we redesign the screen element layout to accommodate this slightly smaller display format.
Finally, if a sensor is damaged and requires replacement, it is no longer necessary for JJENCO to regenerate the
entire software load. Beginning with v2013, we are now able to simply generate a new encrypted configuration file
incorporating the new sensor calibration data. This represents a significant savings in time and money for everyone.
The New Gasket Compression Study (GCS) Screen
As mentioned, the layout of the GCS screen has changed, but we have retained all of the functionality from
preceding software versions. In addition, we have moved a some items to the Edit>Options menu to clean up the
‘desktop’ and added a couple new features that users have requested. Preexisting functionality will not be covered
here.
First, we have moved and separated the ‘Zero Sensors’ and ‘Log Data’ buttons, placing them on opposite sides of
the flange circle element. We hope users that inadvertently zeroed their sensors instead of logging, or stopping
logging, their data collection will find this helpful.
We also moved the data collection input rate and control to a panel in the Edit>Options menu in an effort to clean
up the interface a bit. We hope you approve.
In addition to adding a dedicated ‘Clear’ button specific to the ‘Snapshot’ feature displays, we have also added a
display for the average percent loss for stress values around the flange circle. While the user can still see individual
values at each bolt location, for the purpose of looking at high/low values around the flange, we think that the
average display of stress lost over time will be much more meaningful in general instruction to students.
Another user requested feature that came out really well is the ‘Add
Trace’ button located in the upper right corner of the stress vs.
compression graph. Using this feature, users can automatically add a new
‘trace’ representing a different gasket to an existing trace collected for a
previous gasket. This facilitates easy comparison of both compression and
creep relaxation curves for different gaskets.
The software automatically selects a color for the new trace that is
different from any of the previous traces. There is no limit to the number
of different traces and colors that can be added to a single graph, although
more than a few might tend to make for a very ‘busy’ data plot.
Addressing one more user request, the stress vs compression graph and
the vertical column chart can now each be individually output straight to a
connected printer or PDF file, according to the user’s preference.
...Con’t on Page 5
Module vs Study Naming Convention
‘Add Trace’ Illustration
Reminder: For companies owning
multiple FADU, be sure
that the software serial
number on the opening
splash screen matches that
stamped on the FADU
itself. Software is unit-
specific and will only work
correctly with FADU to
which it is assigned.
A final requested feature added to the GCS screen is an alternative version of the stress vs
compression chart. When ’Time Chart’ option is selected from the ‘Studies’ menu item list, the
stress, vs compression chart is replaced with a stress vs elapsed time chart. This enables you to
record changes in bolt stress over some period of time. The exact time scale has been difficult to
define. We are still working on fine-tuning this particular feature
to optimize its value to users, so we invite your feedback. To
return to the previous stress vs compression chart, simply
return to the ‘Studies’ menu and select ‘X-Y Chart’ from the
listed items.
The New Torque-Preload Study (TPS) Screen
As with the GCS screen, the new TPS screen retains all of its
previous functionality, but boasts an array of new features that
both improve and expand upon that functionality.
While the basic input value table and Load Cell Preload output display appear unchanged, we have in
fact worked a bit of magic behind the scenes to make the users job easier and more accurate. In
v2013, you no longer have to select a cell with the cursor, tighten the fastener in the TPM, and then
watch carefully to double-click in the selected cell as soon as the displayed preload value ‘tops out’
and begins to fall in order to register the maximum preload value. In v2013, simply right-click on the
desired cell and select ‘Start’. Now, the software
will automatically monitor the ascending preload
values and insert the maximum value obtained in
the cell. Then, simply right-click on the cell (now
filled in green) and select ’Stop’ to record the
value and move on to the next cell of interest.
(The cell returns to a white fill color.)
Additionally, almost every torque manual gives
you the equation to determine what torque to use for a given bolt
area, desired preload, and a given Nut Factor (‘K’ value). However,
The New FADU v2013 User Interface Software, con’t
Installing v2013 Software Successfully, con’t
Did You Know?
If you want to change the scale
on either the ‘X’ or ‘Y’ axis for
most charts or graphs in the
software, simply click on the
maximum value for that axis,
type in a different maximum
value, and press ‘Enter’. The
software will automatically
rescale the axis according to
the new maximum value
specified.
Page 5
Summer 2013
Copyright © JJENCO, Inc. 2013. All Rights Reserved.
DIRECTORY WHERE THEY WILL BE SAVED FOR FUTURE REFERENCE BEFORE DELETING THE
‘JJENCO’ DIRECTORY.
Next, navigate to the ‘C:\Program Files\FADU\’ directory on 32-bit computers, or the ‘C:\Program Files
(x86)\FADU\’ directory on 64-bit computers. Once again, delete this directory completely.
You’re almost one! Now, reboot your computer. MAKE CERTAIN THAT THE FADU USB CABLE
CONNECTING YOUR FADU TO YOUR COMPUTER IS UNPLUGGED. When your computer has
finished booting up completely and all device drivers have finished loading, insert your v2013 software
CDROM into the computer drive bay and follow the screen prompts to install the software. We strongly
recommend that you review the ‘v2013 Software Installation Screenshots’ file located on the CDROM
before installing the software.
When the installation is complete, reboot your computer again. After the computer has finished rebooting
completely for a second time, connect your FADU USB cable to the computer and launch the software. If
your computer did not automatically install the correct device driver for your FADU, follow the directions
contained in the above-mentioned installation screenshots file to manually install the driver.
That’s it! You’re now ready to begin using the new v2013 FADU software. Enjoy!! Call John Jenco
(+1.704.944.5568) if you run into any problems.
Con’t on Page 6
New Input Method Illustration
Nut Factor Inputs and Output
Page 6
FADU Training Update
Copyright © JJENCO, Inc. 2013. All Rights Reserved.
The New FADU v2013 User Interface Software, con’t few tell you how to determine ‘K’ in order to use the equation. By simply selecting the bolt size used in the TPM,
and entering the torque value used, the software will calculate ‘K’ for the fastener configuration tested.
The Mechanic’s Judgment Study (MJS) Screen
The MJS screen is really a great demonstration and a wonderful piece of software programming. Based upon one of
the core training demonstrations I developed almost 20 years ago, it conveys in a simple, yet elegant manner one of
the most important concepts in assembling bolted
connections, or any other mechanical maintenance
practice for that matter, and that is the importance of
following a good procedure.
Now, almost everyone recognizes and acknowledges
the value of following a good procedure in order to
obtain a desired outcome as part of any mechanical
maintenance practice. Invariably, this often leads to
procedure writers attempting to put every
conceivable step and notation in a procedure to
assure that they have covered all the bases and every
eventuality. This is akin to why you some game with a
shotgun instead of a rifle; a better chance of hitting
your target.
However, the downside to this strategy is that both
experienced and novice maintenance technicians tend
to not follow procedures that are TOO detailed. In
fact, they are prone to skip over steps that may actually be important to achieving the desired outcome.
To continue the hunting analogy, procedure writers then realize that you can’t use a shotgun effectively for all game.
So, in an effort to streamline the overblown procedure, they begin stripping out everything that seems like it ought
to be obvious, as in ‘mechanic’s judgment’. The problem, here, is that some things that really are so simple
frequently get overlooked because they ARE so simple. And unfortunately, they can be critical to both reliability and
repeatability for the assembled connection.
The MJS screen enables the instructor to give each student the exact same instruction for tightening a bolt. This
exercise is done in private, one student at a time, so as to not enable students to calibrate their level of effort from
that expended by those they watched perform the experiment previously. By selecting the first cell in the input table
and pressing ‘Record’, much like the TPS screen previously, the software monitors the rise in bolt preload and
inserts the maximum value achieved in the cell. By pressing the button for ‘New Student’, the instructor is able to
add a new line for each successive student until all students have finished the exercise. Now this is where the
software programming gets fancy.
When ready, the instructor can press the ‘Graph Results’ button and the software will automatically sort all the
values in the input table in the background from low to high, group them into ‘tightness group ranges’ of 10ksi each,
count the number of values in each tightness group, redraw the chart to accommodate the maximum number of
students in any one tightness group, and finally, plot the tightness groups as a vertical bar chart! Because of all this
behind-the-scenes software magic, the instructor almost invariably ends up with a nicely developed bell curve to use
in discussing the results of the demonstration with the class, regardless of the order the values are entered. Voila!
Experience has shown that for the exact same verbal instructions on how to tighten a flange bolt with a standard
combination wrench until the student ‘thinks it is tight enough that a corresponding flange will not leak’, there is
usually a 4-5X range from low to high among any 15 students. Bringing this piece of newly developed knowledge full
circle, this illustrates the importance of assuring that each step in a procedure, no matter how trivial it may seem, if
it is important to achieving a reliable and repeatable result, must be included in the procedure. Everything else is
secondary.
...Con’t on Page 7
Mechanic’s Judgment Study Screen
Standard GCM and RTJ Spacers
Page 7
FADU Training Update
Copyright © JJENCO, Inc. 2013. All Rights Reserved.
The New FADU v2013 User Interface Software, con’t The Assembly Method Comparison Study (AMCS) Screen
The AMCS screen is also based upon another of my own core demonstrations for teaching effective bolted joint
assembly. This Study enables the instructor and class to jointly determine, from among the three principal methods
for assembling a flanged pipe joint, which method is best in terms of efficiency, accuracy, and repeatability. The
three default methods presented in the Study are assembly by Mechanic’s Judgment, Controlled Torque, and
Measured Compression.
As with the previous study, this Mechanic’s Judgment
exercise provides a technician with a standard
combination wrench and asks that they assemble the
GCM using their experience and best practices. When
the instructor presses the ‘Start’ button on Row 1
(corresponding to this exercise), a timer starts and
the software begins to collect data from the FADU.
When technician has completed the assembly to his
or her satisfaction, the ’Stop’ button is pressed and
the software records the elapsed time and
automatically calculates several pertinent performance
benchmarks for the exercise, based upon predefined
targets for desired bolt preload in the joint and the
desired gasket compression to be achieved.
These benchmarks are (i) total time required to
assemble the flange, (ii) uniformity of preload around
the flange, (iii) accuracy in achieving the target preload for the flange bolting, and (iv) accuracy in achieving the
desired gasket compression.
The AMCS provides two additional rows for comparison of the controlled torque method of assembly, where a
torque wrench and procedure are followed, and the Measured Compression method where calipers and feeler
gauges are used to ‘measure’ the gap between the flange ears as it is tightened to achieve the desired degree of
gasket compression. The AMCS also provide two additional rows to facilitate ad-hoc experimentation to compare a
different method or variation to any of the previous methods.
The Ring-Type Joint (RTJ) Option requires longer bolts than the standard FADU. Accordingly, special spacers are
included with the RTJ Option to accommodate the standard GCM and TPM hardware when the RTJ flanges are not
installed, as shown in the following illustrations. The GCM sensor is transferred to the lower RTJ flange when used.
GCM/TPM Setup Using the RTJ Spacers
Standard TPM and RTJ Spacers
Assembly Method Comparison Study Screen
University Research Park
10130 Mallard Creek Rd.
Suite 300
Charlotte, NC USA 28262
Phone: +1.704.944.5568
Fax: +1.704.944.3101
Website: www.jjenco.com.
Since 2001, JJENCO has successfully provided contract technical research, new technology develop-
ment, personnel training, and business and technical consulting principally to multi-national corpora-
tions, US Fortune 500 Companies, and large private institutions primarily on topics related to large
industrial plant maintenance. With headquarters located in Charlotte, North Carolina USA, JJENCO’s
mission is to provide ‘world class’ expertise through the utilization of both in-house resources and a
network of subject-matter experts around the world to assist clients in understanding and resolving
their most important issues in the most practical and cost-effective fashion.
To learn more about how JJENCO can help resolve your issues, contact John Jenco
([email protected]) to discuss your particular requirement.
JJENCO, Inc.
software release introduces
“Studies’, a completely new
paradigm for conducting
specific training demonstrations
using the FADU.
In v2013, users can now take
advantage of purpose-built
separate screen displays
designed specif ica l ly to
accommodate a particular
demonstration.
As an example, in addition to
the traditional main screen
showing the flange circle, stress
vs. compression chart, and
stress vertical column display,
the former Torque-Preload
screen found in the v2011 and
earlier versions now appears as
a separate ‘study’ under a
menu item of various studies.
For the v2013 release, we have
added two new studies to
complement the standard
Gasket Compression Study and
the Torque-Preload Study, for
a total of four (4) studies in this
release. As a result, JJENCO
can use this new paradigm to
create new studies to support
specific user-suggested training
demonstrations in future
labor unions to support their
trade mechanical training and
certification programs. We
believe that we finally have
enough FADU in the field to
have reached a tipping point
where it is not widely
recognized as the de facto
standard training technology
for the assembly of pressure-
boundary bolted f lange
connections. As such we are
expanding our 2013 marketing
efforts to include technical
colleges, trade schools,, and
additional labor union locals.
We hope that this effort
results in cementing this
technology’s place in future
mechanical training going
forward.
This year, we are excited to
have completed a ‘from the
ground up’ revision to our
already successful FADU User
Interface Software. In addition
to being written especially to
take advantage of the Windows
64-bit operating system, and
showcasing completely new
‘look’ and feel”, the v2013
software releases, thereby
further increasing the value of
the FADU training technology
to the mechanical training
community.
This newsletter focuses
primarily upon showcasing the
new v2013 software. However,
we want to also continue to
focus on expanding the user
base for the FADU training
technology. In this regard,
please read carefully the article
on the idea of establishing a
FADU User Group and
potential benefits to be derived
therefrom.
Thank you for your continued
support of the FADU training
technology platform.
Across The Desk… Delivering Value in a Demanding World
Copyright © JJENCO, Inc. 2013. All Rights Reserved.
...Con’t from Page 1
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