Assembling Flanged Joints Procedure1
Short Description
Procedure for assembling flange and flanged fittings in pipeline welding process...
Description
Document Number :
OML 58 Upgrade Phase 1
NG22-280-CST-SPD-002101
ASSEMBLING FLANGED JOINTS PROCEDURE Document Type :
PRC
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hold
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Revision : 01 Rev. Date :
Status : IFC 30-Aug-2011 Page 1 of 34
Approval Class : 2
ASSEMBLING FLANGED JOINTS PROCEDURE
ORIGINAL SIGNED Rev.
Status
Rev. Date
Revision Memo
Issued by
Checked by
Approved by
01
IFC
30-Aug-2011
Issued for Approval
R. BALA
C. KUSIOLEK
T. RODRIGUEZ
00
IFC
22-Oct-2010
Issued for Approval
R. BALA
C. KUSIOLEK
T. RODRIGUEZ
D0
IFA
14-Sept-2010
Issued for Approval
R. BALA
C. KUSIOLEK
T. RODRIGUEZ
C0
IFR
04-June-2010
Issued for Review
R. BALA
C. KUSIOLEK
T. RODRIGUEZ
This document has been generated by an Electronic Document System. When printed it is considered as a for information only copy. The” controlled copy” is the screen version and it is the holder’s responsibility that he/she holds the latest valid version.
“This document is the property of TEPNG. It must not be reproduced or transmitted to others without written authorization from the Company”. NG22-280-CST-SPD-002101-011.doc
Document Number :
OML 58 Upgrade Phase 1
NG22-280-CST-SPD-002101
ASSEMBLING FLANGED JOINTS PROCEDURE Document Type :
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hold
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Revision : 01 Rev. Date :
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REVISION DESCRIPTION
Rev. index
Revision Description
C0
Issued For Review
D0
Issued For Approval
00
Issued For Construction
01
Issued For Construction
“This document is the property of TEPNG. It must not be reproduced or transmitted to others without written authorization from the Company”. NG22-280-CST-SPD-002101-011.doc
Document Number :
OML 58 Upgrade Phase 1
NG22-280-CST-SPD-002101
ASSEMBLING FLANGED JOINTS PROCEDURE Document Type :
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Revision : 01 Rev. Date :
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INDEX INDEX
3
1.
5
SCOPE AND PURPOSE 1.1.
2.
5
GENERAL
5
REFERENCE DOCUMENTATION 2.1.
5
DEFINITIONS
3.
SCOPE
5
4.
RESPONSIBILITY
5
5.
PERSONNEL QUALIFICATION
6
6.
MATERIAL
6
7.
ASSEMBLING EXECUTION
6
7.1. 7.2. 7.3. 7.4. 8.
6 6 8 8
GENERAL CHECKLIST BEFORE ERECTION ASSEMBLY CHECKLIST AFTER ASSEMBLY
9
TIGHTENING 8.1. 8.2.
9.
9 9
CHOICE OF THE METHOD MANUAL TIGHTENING
9
BOLT TORQUING 9.1. 9.2. 9.3.
10.
12 12 12
CORRESPONDENCES CHECK OF FINAL BOLT STRESS
13
ASSEMBLY PROCEDURE QUALIFICATION
12.1. 12.2. 13.
10 10
GENERAL BOLT TENSIONING PROCEDURE
MAXIMUM BOLT STRESS
11.1. 11.2. 12.
10
BOLT TENSIONING
10.1. 10.2. 11.
9 9 10
GENERAL PREPARATION TORQUE TIGHTENING SEQUENCE
13 13
MOCK-UP QUALIFICATION PROCEDURE BOLT ELONGATION PROCEDURE
14
BOLT TENSIONING CALCULATION NOTE
13.1. 13.2. 13.3.
14 14 15
DETERMINING THE LTF(LOAD TRANSFER FACTOR) DETERMINING THE TOOL PRESSURE DESIGN CHECK
14.
DISASSEMBLING
16
15.
IDENTIFICATION AND FOLLOW UP
16
15.1. 15.2.
16 17
COLOR CODE LABEL
18
APPENDIX A: TIGHTENING SEQUENCE: «CRISS-CROSS» METHOD “This document is the property of TEPNG. It must not be reproduced or transmitted to others without written authorization from the Company”.
NG22-280-CST-SPD-002101-011.doc
Document Number :
OML 58 Upgrade Phase 1
NG22-280-CST-SPD-002101
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Revision : 01 Rev. Date :
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APPENDIX B: ANOMALY REPORT CARD
19
APPENDIX C: SECURITY INSTRUCTION C.90
20
APPENDIX D: SECURITY INSTRUCTION C.91 A & APPENDIX E: SECURITY INSTRUCTION C.91 B
21
APPENDIX F: SECURITY INSTRUCTION C.39
23
APPENDIX G: RECOMMEND TORQUES AND TENSIONS FOR FLANGE BOLTING
24
APPENDIX H: FLANGE ASSEMBLY CHECK LIST
28
APPENDIX I: BOLT MARKING FOR BOLT TENSIONING
30
APPENDIX J: BOLT TENSIONING CHECKLIST
31
APPENDIX K: BOLT TENSIONING TOOLS
33
“This document is the property of TEPNG. It must not be reproduced or transmitted to others without written authorization from the Company”. NG22-280-CST-SPD-002101-011.doc
Document Number :
OML 58 Upgrade Phase 1
NG22-280-CST-SPD-002101
ASSEMBLING FLANGED JOINTS PROCEDURE Document Type :
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Zone :
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Revision : 01 Rev. Date :
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1. SCOPE AND PURPOSE 1.1. General OML58 Block, operated by TOTAL E&P Nigeria Ltd, is located in Nigeria, at some 75km North-West from Port Harcourt, close to the villages of OBITE and OGBOGU. The project is composed of five main parts: •
OGBOGU FS (Flow Station), which is an existing oil treatment plant,
•
OBITE TC Treatment Center which is an existing gas treatment plant
•
OGBOGU CLUSTER (Production Center), which is an existing gas production cluster,
•
IPP-GSU (Gas Supply Unit for the Independent Power Plant), which is a new unit (grass root) dedicated to the future IPP (not in current Contractor SOW),
•
Interconnecting pipelines and cables.
TOTAL E&P Nigeria Ltd, intend to upgrade the OML 58 facilities and mainly increase the gas export capacity from 9.5 to 15.65 MMSCMD (Million Metric Standard Cubic Meter per Day) of marketable gas.
2. REFERENCE DOCUMENTATION • • • •
TOTAL General specification GS PVV 171 Contract UPG-D100 Exhibit A Appendix 10 Specific pre-commissioning / commissioning requirements and explain the chapter on this document. GS EP COR 350 & 354 painting requirements. ANSI B31
2.1. Definitions The following terms are used in this Procedure: COMPANY
TOTAL E&P NIGERIA LIMITED
CONTRACTOR
The Consortium made of SAIPON SNC, SCNL, PNL & DESICON Engineering
PROJECT
OML 58 UPGRADE PHASE 1
PNL
PONTICELLI Nigeria Limited
3. SCOPE This procedure is applicable for all lines on the OML58 Upgrade Phase1 Project.
4. RESPONSIBILITY . This procedure is managed by the CONTRACTOR QUALITY MANAGER and he is responsible for the approval and issue of all revisions to this document. “This document is the property of TEPNG. It must not be reproduced or transmitted to others without written authorization from the Company”. NG22-280-CST-SPD-002101-011.doc
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OML 58 Upgrade Phase 1
NG22-280-CST-SPD-002101
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Revision : 01 Rev. Date :
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In accordance with project Codes and Standards, CONTRACTOR is responsible on applying correct bolt up procedure on all piping and equipment assembly. He will perform the bolt-up activity of: - Piping assembly as per CONTRACTOR procedure and if necessary API6A / ISO 10423 recommended torques or tensions, - Equipment assembly as per Vendor procedure Vendor is responsible for correct bolt up procedure of “Package Equipment” critical flanges. Flange assembling is carried out under responsibility of the Pipe Fitter Foreman. He is responsible to monitor staff competence in term of Quality and Safety for the assembling work achievement. The Pipe Fitter FOREMAN is, consequently, responsible for applying this procedure.
5. PERSONNEL QUALIFICATION The personnel carrying out assembling operations shall be qualified. This qualification is obtained through internal CONTRACTOR training or from a training given by an external company.
6. MATERIAL The Pipe Fitter FOREMAN must check that the material is adapted for the work: - Individual and collective adapted tools (bronze tools on high explosive risks zone, anti-deflagrant material…), - Adapted individual protections (gloves, screen, glasses, evacuation mask …), - Adapted security, insulation or test spades, - Insulation gasket in conformity with the specifications, - Adapted tightening tools.
7. ASSEMBLING EXECUTION 7.1. General The major factors for successfully sealing a bolted assembly and eliminating leakage are: - proper selection and design of the components, i.e. flanges, gaskets and bolts; - proper preparation, inspection and installation; - correct bolt-up procedure All gasket sealing surfaces shall be protected from damage (shock, stripe, corrosion, sanding…) by installation of hardwood blanks and shall be inspected after prefabrication, lifting, offshore transfer and final installation.
7.2. Checklist before erection 1. Review potential risks for damage from surround area or activities. 2. Confirm correct type, size and rating to be installed or dismantled. Check the location of the gasket to be erected or dismantled (refer to the assembling drawings and associated documents) 3. Inspect gasket sealing area and confirm it is free from defects or damage such as: o scores, o erosion/corrosion, o Deformation. 4. Flange faces with coarse tool marks or scratches that may cause the joint to leak should be rejected and where necessary remachined if required. “This document is the property of TEPNG. It must not be reproduced or transmitted to others without written authorization from the Company”. NG22-280-CST-SPD-002101-011.doc
Document Number :
OML 58 Upgrade Phase 1
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ASSEMBLING FLANGED JOINTS PROCEDURE Document Type :
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System / Subsystem :
hold
Zone :
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Revision : 01 Rev. Date :
Status : IFC 30-Aug-2011 Page 7 of 34
Approval Class : 2
5. Check that flange facing, dimensions and type of bolting are in accordance with the general specifications. 6. Use straight steel rule edge to check facing flatness. Flange shall have bearing surfaces for bolting that are parallel to the flange face within 1 degree. Damaged or badly corroded flanges should be repaired or replaced. 7. Flanges at rest should be parallel, in case of misalignment; corrective measure will defined will be defined with COMPANY and witnessed by COMPANY. Completed flanged connections shall be free of residual stresses during assembly, particularly in machinery piping and shall not be “force fit” to achieve fit-up. Guidelines of alignment allowance are given in figure n° 1 for pipe flanges. Any anomaly shall be filed and reported using the “Assembly anomaly report card” given in Appendix B which is then transmitted to COMPANY for decision.
Fig. 1: ALIGNMENT RAISED FACE ALLOWANCES FOR PIPING FLANGES
A = 1 mm / 200 mm MAXIMUM OUT OF PARALLEL ALIGNMENT OF FLANGES MEASURED ACROSS ANY DIAMETER B = 3 mm MAXIMUM TRANSLATION OF BRANCHES OR CONNECTIONS 8. All gaskets shall be new and unused whenever an opened assembly is to be closed again. Check conformity of the gasket (material, dimensions, series, thickness, type) to ensure that it is in compliance with the piping specification, class, pressure rating or the dismantled gasket. 9.
Check the general aspect of the gasket: • coating,
“This document is the property of TEPNG. It must not be reproduced or transmitted to others without written authorization from the Company”. NG22-280-CST-SPD-002101-011.doc
Document Number :
OML 58 Upgrade Phase 1
NG22-280-CST-SPD-002101
ASSEMBLING FLANGED JOINTS PROCEDURE Document Type :
PRC
System / Subsystem :
•
geometry,
•
crushing,
•
spiral windings,
hold
Zone :
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Status : IFC 30-Aug-2011 Page 8 of 34
Approval Class : 2
• traces of corrosion or erosion. All damaged gasket (including loose spiral winding) shall be rejected. 10. Check studs and nuts : • grade •
coating damage
•
threading,
•
bolts,
•
nut,
•
Dimensions.
If necessary, stud bolts shall be cleaned using wire brush to remove any dirt on the threads. Visually examine studs and nuts to ensure it is free from burrs. Nuts should turn freely on the studs for a distance equal to their in-service distance. In the case of existing stud bolts re-assembly, wires brush them before greasing. 11. Check the supporting quality of the line and report any anomaly.
7.3. Assembly 1.
The gasket is now under responsibility of pipe fitter foreman (final or temporary)
2.
If required, grease RTJ seating face and if necessary seal the gasket.
CAUTION: Some services such as Oxygen or Hydrogen are not compatible with the use of grease. 3.
Center the flange faces using appropriate tool (pin, centering device,). Align flange faces exactly, leaving just enough space to insert a gasket. Once flanges have been aligned up, visually examine them to assure that an acceptable fit has been obtained.
4.
Install the first stud bolts.
Note: For a gasket in vertical plane, it is necessary to start the assembly by placing the lower stud bolts which will be used as support for the gasket before tightening, 5.
Install the gasket.
6.
Center the gasket.
7.
Insert all remaining studs and nuts on hand-tight. Do not pull up studs in a manner that reaches uneven compression of the gasket.
8.
Ensure all bolts are tensioned evenly and in sequence with at least two threads protrusion through the nuts at both sides. Otherwise, distribute protrusion equally from the sealing facing
Note: If bolt tensioner is to be used, over length bolt are required (protrusion shall be at least one bolt diameter on one of the two sides). Attention is to be paid for allowance for tensioning equipment access. 9.
Tighten the stud bolts with manual wrench to obtain the parallelism of the flange faces.
7.4. Checklist after assembly The PIPE FITTER FOREMAN (or a person whom he designates), checks by surveying: “This document is the property of TEPNG. It must not be reproduced or transmitted to others without written authorization from the Company”. NG22-280-CST-SPD-002101-011.doc
Document Number :
OML 58 Upgrade Phase 1
NG22-280-CST-SPD-002101
ASSEMBLING FLANGED JOINTS PROCEDURE Document Type :
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1.
The parallelism of the flanges
2.
The remaining length of stud bolt
3.
The correct torque values have been applied and recorded.
Revision : 01 Rev. Date :
Status : IFC 30-Aug-2011 Page 9 of 34
Approval Class : 2
8. TIGHTENING Bolts shall be of sufficient length to leave minimum of three threads at the end of tightening activity.
8.1. Choice of the method The method of tightening commonly used is the manual tightening method. The use of bolt torquing or pre-tensioning (bolt tensioning) is determined by COMPANY piping specifications.
8.2. Manual Tightening 1.
Tighten with "CRISS-CROSS" method (sketch in Appendix A) with the suitable wrench keys while controlling parallelism.
2.
Ensure the tightening of all the bolts is sufficient. (interaction between various tightening)
See NOTE section from paragraph 10. 2 for RTJ flanges.
9. BOLT TORQUING 9.1. General Hydraulic, pneumatic or beam type torque wrenches are commonly used in bolt torquing. The hydraulic wrenches are normally preferred. Reference to the tensioning equipment manufactures hydraulic pressure/tensioning values shall be used for guidance. The pressure to be applied is indicated in the equipment pressure / torque conversion specific chart.
9.2. Preparation 1. Using Appendix G table, determine the torque values necessary to achieve the desired bolt stress. 2. Bring all nuts up snug-tight with a short wrench using the "CRISS-CROSS" pattern shown in Appendix A. Do not tighten the bolts using impact force. 3. All torque wrenches shall be of adequate capacity and recently calibrated. Certificates of torque wrenches calibration shall be available. 4. In the event that seizure of the nut being torqued is encountered, back the nut off until seizure is eliminated and torque again. Apply lubricant if necessary and replace the nut and/or bolt if seizure reoccurs.
“This document is the property of TEPNG. It must not be reproduced or transmitted to others without written authorization from the Company”. NG22-280-CST-SPD-002101-011.doc
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OML 58 Upgrade Phase 1
NG22-280-CST-SPD-002101
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9.3. Torque tightening sequence 1. Torque bolts and nuts in a "CRISS-CROSS" pattern as shown in Appendix A using a minimum of three torquing stages and recommended final torque as defined in Appendix G. • STAGE 1 Torque to a maximum of 50% of the final torque value and in accordance with the “CRISSCROSS” sequence. Check that the flange is bearing uniformly on the gasket. Then tighten with 40% of the final torque value in clockwise circular sequence. • STAGE 2 Torque to the final torque value with the “CRISS-CROSS” method. 1. After these three basic torque stages completed, repeat torquing the nuts at least once using the final torque in a "CRISS-CROSS" sequence until no further rotation of the nut is observed. 2. Continue torquing with the final torque in a circular sequence to ensure no further rotation. 3. All torque readings and sequences of tightening shall be filed and recorded for future reference using the form given in Appendix H.
10. BOLT TENSIONING 10.1.
General
The advantage of this method lies mainly in the homogeneity of tightening. It requires stud bolts over lengths are equals to one bolt diameter. However, its implementation shall be carried out strictly in accordance with the equipment manufacturer’s recommendations. The hydraulic pressure to be applied is function of the bolt diameter and the type of tool; it is indicated in the equipment specific tables as shown in table 5 in paragraph 13.3. The tensioning of bolts shall be performed by trained personnel with appropriate equipment (bridges, pullers, hydraulic pumps, connection pipes, manometers, etc.). Tools are shown in Appendix L. Ideally all bolts should be tensioned in one operation to ensure even loading on the bolts and gaskets. It may not be practical to tension all bolts in one operation, but at least 2 bolts diametrically opposed should be tightened in one operation to ensure an acceptable degree of uniformity in loading. CAUTION: Bolt tensioning should not be carried out on equipment or systems which are in service. The trained personnel selected to perform the controlled bolt tensioning shall develop in the preliminary operation a diagram correlating the required pressure to be reached in the hydraulic circuit connected to the tensioners and the required load in each bolt.
10.2.
Bolt tensioning procedure
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The following procedure provides an example of 20" - 900# flange and 4 bolts tightened at the same time. In case the quantity of tensioner is different, each group below will have the same quantity as quantity of tensioner. 1. Group the 20 bolts into five groups (quantity of tensionners is the quantity of each group, 4 A's, 4 B's, 4 C's, 4 D's and 4 E's) as shown in Appendix I and then mark them accordingly on the flange. 2. Mount the 4 hydraulic tensionners on the first 4 bolts A's group of bolts. 3. Check the hydraulic system if there is any pressure problem. 4. Check that the specified hydraulic pressure is applied to the tensioner before running the nut down on each stud. 5. Apply equivalent hydraulic pressure by operating the hydraulic pump to give a bolt load equal to 40% of the maximum bolt stress (see paragraph 11). Note: It is often advisable to continuously re-apply the bolt stress, especially with Ring Type Joints, until no further movement of the flange nuts can be obtained. Also, it may be beneficial to allow a few minutes between each pressurization to allow the gasket to bed in. 6. Shift the tensionners to the next group and repeat the steps 3 to 5 until all group are 40% tightened. 7. Repeat the steps 2 to 5 with 70% of the maximum bolt stress 8. Shift the tensionners to the next group and repeat the steps 3 to 5, but applying a bolt load equal to 70% of the maximum bolt stress. 9. Repeat the steps 2 to 5 with 100% of the maximum bolt stress 10. Shift the tensionners to the next group and repeat the steps 3 to 5, but applying a bolt load equal to 100% of the maximum bolt stress. 11. Repeat steps 3 to 5 on all group of bolts to check if the hydraulic pressure required is enough to obtain the required bolt stress. Note: As a check to see if an excessive load has been lost in the initial groups, assemble two tensioning tools to randomly select but diametrically opposite group bolts. Apply 100% final hydraulic pressure and attempt to further tighten the flange nuts. If the nuts cannot be further tightened, then tensioning is complete and the tensioners may be removed. If the flange nuts can be further tightened, then repeat steps 2 to 5 by increasing the hydraulic pressure to 100% of final hydraulic pressure, on the bolts of each group. 12. The bolt tensioners may now be removed. 13. As a final check, use a hammer and ‘ring’ each bolt to ensure no loose bolts remain 14. The PIPE FITTER FOREMAN and the trained personnel selected to perform the bolt tensioning shall fill the forms given in Appendix J, K stating the procedures adopted during the operations and the parameters adopted (pressure in the hydraulic circuit, temperature of flanged joints, etc). The form shows also the original length of bolts (unstressed conditions) and the final length of bolts (stressed conditions). As the hydraulic operating pressure varies according to the type and size of tools used, reference shall be made to the equipment's manufacturer specifications. CAUTION: Never exceed the tensioner maximum working pressure “This document is the property of TEPNG. It must not be reproduced or transmitted to others without written authorization from the Company”. NG22-280-CST-SPD-002101-011.doc
Document Number :
OML 58 Upgrade Phase 1
NG22-280-CST-SPD-002101
ASSEMBLING FLANGED JOINTS PROCEDURE Document Type :
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hold
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Revision : 01 Rev. Date :
Status : IFC 30-Aug-2011 Page 12 of 34
Approval Class : 2
Never exceed the tensioner maximum piston/ram stroke
11. MAXIMUM BOLT STRESS
11.1.
Correspondences
The bolt-up procedure with torque wrench method is based, as an example, on the bolt stress of A-193 Grade B7 or A-320 Grade L7 in making up the flange, while the bolt tensioning method is referred to a generic maximum bolt stress. Table n° 3 indicates the maximum bolt stress values recommended, it is important to notice that there are some flanges where lower bolt stress values are appropriate depending on the flange rating, and/or type bolting. In case of the Ring Joint Flanges, lower maximum bolt stress values are recommended for the higher flange ratings to avoid excessive bolt loads which can lead to undesiderable deformations to ring gasket and flange groove seating surfaces. Unlike raised face flanges, there is a little difference in gasket seating area with ring joint flanges as flange ratings increase so bolting loads are more concentrated in narrow zones of the ring groove. The remaining situations are all governed by the material strength of the specific bolt indicated. See Appendix G for correspondence between bolt load and bolt diameter depending on flange class and face type.
11.2.
Check of final bolt stress
The check of final bolt stress shall be performed for critical flange by means of the bolt elongation method described at the paragraph 12.2. The check will be spot, 10% of flanged joint (for piping) and at least 4 bolts of every joint for equipment tightened by each crew, and it shall be performed as follows: 1. measure with caliper the bolt elongation of the four bolts diametrically opposite; 2. check the correspondence of the specified bolt stress in the range of ± 10% of the bolt elongation measured; 3. if the above tolerance is not achieved in one bolt, then all the bolting of the joint will be checked and, in case of no compliance, retensioned; in case of no compliance of all 4 bolts for more than two joints in the same sampling, all the flanged joint tensioned by the crew who performed the bolt-up during that working day, will be completely checked.
MAXIMUM BOLT STRESS
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BOLT MATERIAL MAX. BOLT STRESS, σ A-193 Grade B7 A-193 Grade B8 A-193 Grade B8M A-193 Grade B16 A-320 Grade L7 A-453 Grade 660
max
Status : IFC 30-Aug-2011 Page 13 of 34
Approval Class : 2
(Mpa)
360 360 360 360 360 360
Table n° 3
12. ASSEMBLY PROCEDURE QUALIFICATION Each size of bolts for flange shall be submitted to a qualification procedure. The qualification shall be carried out on mock-up flange and elongation of each bolt shall be measured to ensure uniform bolt tension. For the finished joint, bolt elongation should correspond to maximum bolt stress value determined as per Appendix G ± 10%.
12.1.
Mock-up qualification procedure 1. Prepare the stud bolt ends to improve accuracy of stretch measurement. The stretch measurement will be tenths of millimeters accurate. 2. Using Appendix J form, number each bolt 3. Measure and record the initial length of each bolt. 4. Tighten the bolts, measure and record the final length of each bolt. 5. Record the desired stretch and also the recommended tool setting (torque value). 6. The crew is considered "qualified" after having assembling two sets of bolted flanges with the maximum bolt stress ± 10%.
12.2.
Bolt elongation procedure A suitable device for measuring bolt elongation is the use of a caliper. The formula derived from the basic stress-strain relationship is:
Where L is the effective bolt length measured from center of nuts (as shown in Appendix J). And A is the elongation coefficient. “This document is the property of TEPNG. It must not be reproduced or transmitted to others without written authorization from the Company”. NG22-280-CST-SPD-002101-011.doc
Document Number :
OML 58 Upgrade Phase 1
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hold
Zone :
Bolt Material A-193 Grade B7 A-193 Grade B8 A-193 Grade B8M A-193 Grade B16 A-320 Grade L7 A-453 Grade 660
00
E (Gpa) 205 205 205 205 205 195
Revision : 01 Rev. Date :
Status : IFC 30-Aug-2011 Page 14 of 34
Approval Class : 2
A (no unit) 0.001756 0.001756 0.001756 0.001756 0.001756 0.001846
Table n° 4
13. BOLT TENSIONING CALCULATION NOTE Before any bolt tensioning, it is necessary to calculate the correlation between required pressure to be reached in the hydraulic circuit connected to the tensioners and the required stress in each bolt.
Load Transfer Factor = 1.01 + (Bolt Dia / Clamp Length) Tool Pressure = (Reqd Bolt Load x LTF) / Tool Hydraulic Pressure Area
13.1.
Determining the LTF(Load Transfer Factor)
Any stretch Bolt Tensioner regardless of make, exhibits a Load Transfer Loss as the bolt load is transferred from the Tensioner to the joints hexagon or round nuts. The Bolt load loss is a direct loss of stud elongation, this is due to many different factors, such as thread deflections, radial expansion of the nut and ‘bedding in’ of the nut into the joint reaction surface. Because of this phenomenon it is essential that a load allowance is made when calculating the required operating pressure of a Tensioner, to achieve a known residual bolt load, extra load must be applied so the bolt will relax down to the required load on transfer. The load transfer factor can be accurately calculated and is a direct function of joint clamp length and the nominal diameter of the stud :
Load Transfer Factor = 1.01 + (Bolt Dia / Clamp Length) Units: D = Nominal Thread Diameter (mm or In) C = Bolt Clamp Length (mm or In) Note: If the calculated LTF is less than 1.1, then use a 1.1 LTF CAUTION: Applying the Load Transfer Factor to the required bolt Stress will Increase the % of yield being generated on the bolt this value must be checked again
13.2. Determining the Tool Pressure Tool Pressure = (Required Bolt Load x Load Transfer Factor) / Tool Hydraulic Pressure Area Units: “This document is the property of TEPNG. It must not be reproduced or transmitted to others without written authorization from the Company”. NG22-280-CST-SPD-002101-011.doc
Document Number :
OML 58 Upgrade Phase 1
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ASSEMBLING FLANGED JOINTS PROCEDURE Document Type :
PRC
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Zone :
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Revision : 01 Rev. Date :
Status : IFC 30-Aug-2011 Page 15 of 34
Approval Class : 2
Tool Pressure = (N/mm2 or Ton/In2) Required Bolt Load = (N or Ton) LTF = (No Units) Tool Hydraulic Pressure Area = (mm2 or In2) *To convert N/mm2 to bar: Multiply by 10 * To Convert Ton/In2 to psi: Multiply by 2240 CAUTION: Check that the calculated tool pressure does not exceed the Maximum Working Pressure of the tool. This value is hard stamped on all tools and is documented on the tool technical data sheet which came with the tools.
13.3. Design Check It is always good practice to determine the % of bolt yield applied, if the final bolt stress exceeds 75% of the bolt yield strength, then it may be necessary to consider the fatigue characteristics of the bolt and joint. CAUTION: NEVER EXCEED 95% OF THE BOLT YIELD STRENGH
% of Yield = (Bolt Stress Required / Yield Strength of bolt) x 100 Units: Bolt Stress Required = (N/mm2 or Ton/In2) Yield Strength of Bolt = (N/mm2 or Ton/In2) Step 2: Example: Bolt Clamp Length = 144mm Bolt Diameter M36 x 4 Bolt Yield Strength = 720 N/mm2 Tool Hydraulic Pressure Area = 2955mm2 (Tool data) Required Bolt Load = 299kN LTF= 1.01 + (Bolt Dia / Clamp Length) = 1.01 + (36/144) = 1.26 % Yield Check = (Reqd Bolt Stress / Bolt Yield Strength) x LTF x 100 = (365.8 / 720)x 1.26 x 100 = 64.01% Tool Pressure = (Reqd Bolt Load x LTF) / Tool Hydraulic Pressure Area = (298858 x 1.26) / 2955 = 127.43 N/mm2 = 1274.3 bar
Tools Pressure / Tension correspondance table : Step 4:
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Tool reference Pressure Area (mm²)
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Tool T22 2,884
Tool T23 5,271
Tool T24 8,445
Tool T25 12,197
Max Pressure (bar)
1500
1500
1500
1500
Max Load (kN)
433
791
1267
1830
Max Piston Stroke (mm)
15
15
15
12
Pressure (bar)
Pressure (bar)
Pressure (bar)
Pressure (bar)
Dia (in)
Dia (mm)
L (in)
L (mm)
LTF
Tension (kN)
1 1/2
M39
10 1/2
40%
70%
100%
40%
70%
100%
40%
70%
100%
40%
70%
100%
219
1,15
346
553
968
1383
303
530
757
189
331
472
131
229
1 1/2
M39
327
12 3/4
276
1,13
346
541
947
1353
296
518
740
185
323
462
128
224
2
320
M52
14 1/4
298
1,15
644
562
984
1405
351
614
877
243
425
607
2
M52
15 3/4
337
1,14
644
556
972
1389
347
607
867
240
420
600
2
M52
20 3/4
464
1,11
644
541
946
1352
337
591
844
234
409
584
2 1/2
M64
20 1/4
435
1,13
1032
554
970
1385
384
671
959
2 1/2
M64
20 1/4
435
1,13
1032
554
970
1385
384
671
959
2 1/2
M64
30 1/2
695
1,09
1032
534
934
1334
370
647
924
2 3/4
M70
22 1/4
478
1,13
1146
615
1077
1538
426
746
1065
Table n° 5
14. DISASSEMBLING 1.
Respect security instructions C.39 in Appendix F, and C90-C91A-C91B in Appendix C,D if asbestos or ceramic fibers are sealing the flanged assembly.
2.
Chock the flanged assembly to be dismantled with wood chocks and/or hoist and sling.
3.
Loosen the bolts without removing them,
4.
Use flange spreader instead of wedges. Space the flanges, facing the flanged assembly which will be in the direction of the wind (wind in the back),
5.
Clean the gasket seating facings (calamine, grease, products, varnish…),
6.
Inspect the supports, gaskets, stud bolts and line. In the event of an anomaly the PIPE FITTER FOREMAN fills the anomaly report card (Appendix B) which is then transmitted to COMPANY for decision,
7.
If necessary, grease the nuts, bolts, stud bolts.
15. IDENTIFICATION AND FOLLOW UP According to the Quality requirements required by COMPANY, the flanged assembly can be identified by a color code or/and a label. A register will be maintain by Quality Control Manager.
15.1. Color code A color code can be used to identify: -
provisional gaskets : none
-
tested final gaskets : RED painting on one bolt on one flange only
-
After this RED marking, no gasket replacement will be possible without approval of COMPANY.
-
in the case of systems for which the leak test is not required, the flange edge is directly painted in red after tightening.
-
If COMPANY found no anomalies after inspection, COMPANY will mark in green the closest bolt (next to the RED marked one) with a GREEN paint.
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The colors being specific to each production site, PIPE FITTER FOREMAN will take care of giving information to the assembling affected personnel on each working site.
15.2. Label The label ensures the traceability of the executants for each assembly. Labels shall include specific valve / equipment tag numbers, where necessary. It is fixed by a wire to one of the stud bolts and at least includes the following indications: • • •
PONTICELLI NIGERIA LTD Executant’s name Execution date
The figure 2 shows CONTRACTOR label:
PNL Name : ……….. Dat
Fig.2
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APPENDIX A: TIGHTENING SEQUENCE: «CRISS-CROSS» METHOD
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APPENDIX B: ANOMALY REPORT CARD
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APPENDIX C: SECURITY INSTRUCTION C.90
C.90 03/02/98
MEASURES TO BE TAKEN FOR HANDLING MATERIAL CONTAINING «FIREPROOF CERAMIC FIBERS»
1°)
FIELDS OF APPLICATION:
The refractory ceramic fibers (RCF), just as the glass, rock fibers, etc… belong to the group of vitreous artificial mineral fibers. They are used for the insulation at high temperature in the following fields: - Industrial furnaces and boilers, - Heat shields, - Expansion gaskets, - Anti fire protection systems and fire wall.
2°)
INCURRED RISKS:
The exposure to ceramic fibers can cause momentary irritations of the eyes, skin and respiratory tracts. To date, no other significant effect was observed. Nevertheless, the International Research Cancer Center has classified ceramic fibers as being possible carcinogens on the man after studies undertaken on the animal.
3°)
RECOMMENDED METHOD TO LIMIT EXPOSURE:
- Always maintain the level of dust contamination at minimum level, - Use personal protection equipments, - Wear integral safety goggles - Wear mask or standard half-mask P3 type. - Wear clothing with long sleeves or better a disposable combination. - Do not clean personal clothing by blowing on it, - Do not eat or drink at the working station.
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APPENDIX D: SECURITY INSTRUCTION C.91 A & APPENDIX E: SECURITY INSTRUCTION C.91 B
C.91 A REV.1 APRIL 17, 1997
MEASURES TO BE TAKEN DURING INTERVENTIONS (EXCEPT CAPACITES) ON GASKETS, CORDS OR BRAIDS CONTAINING ASBESTOS.
1°)
INCURRED RISKS:
The inhalation of asbestos dust can cause affections of the respiratory tracts of which most serious are: - Asbestose, noncancerous lung disease, - Bronchopulmonary cancer, - Mesothelioma, pleura, pericardium or peritoneum severe tumour.
2°)
EQUIPMENT FOR THE PERSONNEL: - Mask or half-mask with P3 filter, - Elastomer Gloves, - Disposable Combination.
3°)
PROCESS :
•
Pulverization of a fixing product - for the braids and cords, - for the gaskets (requiring a scraping by manual tools).
•
Manual removal of the gasket, braids or cord
•
Installation of the element (joined, braid, cord) in an identified plastic bag.
•
Deposit of the bag in an identified dustbin (in charge of client). FOOT-NOTE: Gaskets, cords or braids not identified are to be treated as containing asbestos.
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C.91 B REV.1 APRIL 17, 1997
MEASURES TO BE TAKEN DURING INTERVENTIONS IN CAPACITES ON CORDS OR BRAIDS CONTAINING OF ASBESTOS. 1°)
INCURRED RISKS:
The inhalation of asbestos dust can cause affections of the respiratory tracts of which most serious are: - - Asbestose, noncancerous lung disease, - Bronchopulmonary cancer, - Mesothelioma, pleura, pericardium or peritoneum severe tumour.
2°)
EQUIPMENT OF THE INTERVENING PERSONNEL: - Mask or half-mask with P3 filter, - Elastomer Gloves, - Disposable combination, - Washable safety boots.
3°)
EQUIPMENT OF SUPERVISING PERSONNEL: - Identical to the intervening personnel.
4°)
METHOD UTILISEE:
•
Ground protection by a polyane film,
•
Pulverization of a fixing product on the braid or cord,
•
Manual removal of the braid or cord,
•
Deposit of the element (braid or cord) in an identified plastic bag,
•
During every exit from the capacity, removal of the combination in the protected zone by polyane film and put in a plastic bag,
•
Dispose the polyane film in a plastic bag, Plastic deposit of the bags in an identified dustbin (in charge of the client).
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APPENDIX F: SECURITY INSTRUCTION C.39
C.39 JANUARY 92
DISASSEMBLING OF THE VALVE BONNETS DISASSEMBLING FLANGED VALVES, FLANGES, OR BLIND SPADES ON FLANGES
1) Ask the authorization to your FOREMAN in order to disassemble or receive the order. 2) Before any work begin, a task pack corresponding to the work is required. Start only when this you are authorized to work. 3) Wear the necessary safety material planned for the work, as detailed hereafter: Masks with cartridge, breathing insulating apparatuses, protect faces, glasses, gloves, boots, special clothing, etc. 4) Check that the working station ensures your safety: ground continuity and handrail. If the working environment do not have this continuity, systematically use your tether and your harness of which you must attach your tether. 5) Open the cover of the valve completely so that it is free of air. THEN CARRY OUT DISASSEMBLING 6) Think of what will arrive when the bonnet will be unbolted and fix it to the environment or use lifting equipment if necessary. 7) Choose 2 bolts diametrically opposite fixing the bonnet to the body of valve and unbolt them only partially. 8) Unbolt the other bolts completely. 9) Make oscillate the valve from the body of valve to break the gasket. 10) The gasket being broken and the bonnet dismantled from the body of the valve, you will be able to unbolt the last 2 bolts completely and lift the bonnet with precautions due to its weight. For valve disassembling, apply all the rules above to remove the valve of its FLANGE instead of removing the bonnet from the body of the valve. 11) Place yourself on the wind each time it is possible so that possible emanations move away from you, carried by the wind. “This document is the property of TEPNG. It must not be reproduced or transmitted to others without written authorization from the Company”. NG22-280-CST-SPD-002101-011.doc
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APPENDIX G: RECOMMEND TORQUES AND TENSIONS FOR FLANGE BOLTING
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APPENDIX H: FLANGE ASSEMBLY CHECK LIST
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FLANGE ASSEMBLY CHECK LIST Piping Area : Test Pack Number : Torquing Device ref. :
Project : OML58 Upg Ph 1 ‐ OBAGI Site Piping Class : Report Number : Flange Number
Isometric Number
BOLT Diam Torque Value Tightening Complete (inches) (N.m)
SEQUENCE CONFORM SHORT WRENCH TIGHTENING STAGE 1 : 50% FINAL TORQUE VALUE STAGE 2 : FINAL TORQUE VALUE BLOCKING (no further rotation) TIGHTENING COMPLETE Others
COMMENTS
Reference Acceptable Table DIA BOLT (inches)
DIA BOLT ISO
NUT SIZE (mm)
Tension F kN
Torque value f = 0.07 N.m
Torque value f = 0.13 N.m
0,5 0,625 0,75 0,875 1 1,125 1,25 1,375 1,5 1,625 1,875 2 2,5
M14 M16 M20 M24 M27 M30 M33 M36 M39 M42 M48 M52 M64
21 24 30 36 41 46 50 55 60 65 75 80 95
33 52 78 107 141 184 232 288 346 412 561 644 1 032
48 92 160 253 376 540 745 996 1 297 1 653 2 549 3 097 6 068
80 155 270 429 639 925 1 285 1 727 2 261 2 894 4 493 5 476 10 828
SPD CST
SPD QAQC
CLIENT
Name : Date : Signature :
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APPENDIX I: BOLT MARKING FOR BOLT TENSIONING
The 5 groups are marked respecting criss cross method from Appendix A: for 4 tensionners, group A is number 1 to 4, B is 5 to 8, …
12 BOLTS FLANGE 2 TENSIONNERS
. The 6 groups are marked respecting criss cross method from Appendix A: for 2 tensionners, group A is number 1 and 2, B is 3 and 4, ...
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APPENDIX J: BOLT TENSIONING CHECKLIST
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APPENDIX K: BOLT TENSIONING TOOLS
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