SATR-L-2001

September 10, 2017 | Author: Fayyaz Ahmed | Category: Nut (Hardware), Screw, Mechanical Engineering, Nature
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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008)

Rev 3 SATR NUMBER

SAUDI ARAMCO TEST REPORT Flange Joint Tightening Inspection Report

SATR-L-2001

PROJECT TITLE

WBS / BI / JO NUMBER

EQUIPMENT ID NUMBER(S) or LINE NUMBER

FLANGE JOINT NUMBER/S

LAYOUT DRAWING NUMBER

REV. NO.

SCHEDULED TEST DATE & TIME

ACTUAL TEST DATE & TIME

15-Dec-09

SYSTEM ID.

PURCHASE ORDER NUMBER

MH's SPENT

TRAVEL TIME

SAUDI ARAMCO USE ONLY

SAUDI ARAMCO INSPECTION LEVEL

CONTRACTOR INSPECTION LEVEL

REFERENCE

A

General Requirements

A1

Tools for bolt tightening have been identified and resolved between Contractor, SAPMT, Proponent and Inspection prior to commencing the erection of the piping.

SAEP-351, Para. 6.1

A2

Bolt tightening procedure in lieu of SAEP-351 is approved by the Proponent, SAPMT, Inspection & Piping Stds Committee Chairman or his rep. (Includes tensioning procedures such as "Hydratight", etc) Note: ASME PCC-1 can be used as a guideline to establish such procedures. Use of SAEP-351 is recommended and pre-approved. Note 2: When SAEP-351 is followed, attention shall be given to selection of approved lubricants (Certs needed) & friction factors.

SAES-L-350, Para. 3.2.1

A3

SAEP-351 is not pre-approved. SAEP-351 option is chosen: A) Submit a procedure to Company, a "cut and paste" of SAEP-351 B) Submit Certs/MSDS/Data Sheets on selected lubricant(s). C) Submit a personnel roster attesting to crew training and skills. Note: Gasket Installation Procedure required will account for every single type of gasket on a major project (color coding). Critical is that differing gasket metallurgies are not mixed (controls) and that the procedure is checked against the Piping Line Class Tables

SAEP-351, Para. 3.2.2

A4

Contractor personnel crews executing flange assembly work have proper training & skills to work per SAEP-351. Note: Verification is by submission of a roster to COMPANY. Roster shall attest to the fact that personnel have been trained & certified (by QA/QC Mgr responsible) to work per SAEP-351 reqmts & that they possess experience or skills to follow the procedure. SA recommends a short field course covering step by step the following elements: A) Lubricant use, thread cleaning, cleanliness, rust removal B) Preservation/protection of lubricated threads (Good Practice) C) Calibrated Equipment care & handling, use of buckets

SAEP-351, Para. 3.2.2

A5

Not more than one gasket is used between flange mating surfaces. Note: Equipment flanges and various piping line class flanges are to be designed with "compatible" (RF to RF, FF to FF, etc) flanges and gaskets. Do not allow incompatible flange joining without specific approval (includes gasket type/torque values) from CSD.

B

Torque Wrench Method per SAEP-351

B2

The specific required torque value is identified and conforms with in Table-SAEP-351-02 9applies to all gaskets listed in SAES-L-109, except for insulating gaskets) and Table-SAEP-351-03 (applies to isolating gaskets (e.g., PIKOTEK), based on a friction factor of 0.16) (Refer to Attachment 1 & 2)

B3

Torque wrench calibrated. (Date of Calib:__________ / Due date for Calibration __________)

SAEP-351, Para. 6.3

B4

Lubricant applied to stud threads an face of nut contacting the flange.

SAEP-351, Sec. 7, Step 2

B5

All studs and nuts installed hand tight and pass freely through the flange holes.

SAEP-351, Sec. 7, Step 3

Page 1 of 12

PLANT NO.

EC / PMCC / MCC NO. QUANTITY INSP.

SAUDI ARAMCO ACTIVITY NUMBER

TEST PROCEDURE ACCEPTANCE CRITERIA

MECH-

CONTRACTOR / SUBCONTRACTOR

Test Pack No.

SAUDI ARAMCO TIP NUMBER

ITEM No.

30-Dec-08 DATE APPROVED QR NUMBER

SAES-L-109, Para. 11.1

SAEP-351, Para. 5.2, 3, 4

WORK PERMIT REQUIRED?

PASS

FAIL

N/A

RE-TEST DATE

B6

Each stud is numbered as shown in Attachment 1.

SAEP-351, Sec. 7, Step 4

B7

For insulting gaskets like PIKOTEK, enough gap (½" of gap is recommended) should be available between flange faces to avoid any damage to seals during inserting the gaskets,

SAEP-351, Sec. 7, Step 5

B8

Matting flange faces and the gaskets should be dry and free from grease, oil or water.

SAEP-351, Sec. 7, Step 6

B9

Stud are tightened, as numbered, with air impact wrench or equivalent following the bolt tightening sequence.

SAEP-351, Sec. 7, Step 7

Page 2 of 12

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008)

Rev 3

SAUDI ARAMCO TEST REPORT

SATR NUMBER

Flange Joint Tightening Inspection Report

SATR-L-2001

PROJECT TITLE

ITEM No.

WBS / BI / JO NUMBER

TEST PROCEDURE ACCEPTANCE CRITERIA

REFERENCE

30-Dec-08 DATE APPROVED QR NUMBER

15-Dec-09

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

1st stage tightening @ 30% of required Torque (maximum) B10

Note:Required Torque Value and actual attained torque values are entered in Bolt Tightening Report, Attachment 2 of checklist.

SAEP-351, Sec. 7, Step 9

B11

Final Tightening to + 5% of Torque Required (Actual Torque _____ )

SAEP-351, Sec. 7, Step 9

B12

After tightening, all bolts have full thread engagement with the nut. Note: Complete engagement (less 1 full thread) is acceptable. (ASME B31.3, Para. 335.2.3)

SAES-L-109, Sec. 3

C

Bolt Tensioning Method when approved. (i.e.: HYDRATIGHT - 50% Tensioning Method) NOTE: Items listed below shall be verified against the project approved bolt tensioning procedure for conformance.

C1

Pressure gages in the tensioning machine are calibrated.

C2

Mark bolts in 2 Sets, Set 'A' & Set 'B', alternatively.

HYDRATIGHT Procedure or Equivalent

C3

Tensioners are fitted to every other bolt of Set 'A'.

HYDRATIGHT Procedure or Equivalent

C4

Pressurize the tensioners to pre-determined "Pressure A" per the approved procedure. (This is repeated 2 more times.)

HYDRATIGHT Procedure or Equivalent

C5

Transfer tensioners to Set 'B' bolts and pressurize to pre-determined "Pressure B" and tighten nuts. This is repeated 2 more times. (NOTE: Pressure B is lower in value than Pressure 'A')

HYDRATIGHT Procedure or Equivalent

C6

After tensioning, Break Loose Pressure (BLP) is verified to be greater than or equal to Pressure B by the following steps: a) Fit tensioner to one of the tensioned bolts in Set 'A'. b) Pressurize slowly until the nut is loosened using a Tommy Bar and socket. c) Once the nut moves, stop pressurizing and record the achieved pressure. This is the Break Loose Pressure. (NOTE: If BLP < Pressure B, Tensioning is a Fail. )

HYDRATIGHT Procedure or Equivalent

D

Bolt Tensioning Method (i.e.: HYDRATIGHT-100% Tensioning Method) NOTE:Items listed below shall be verified against the project approved bolt tensioning procedure for conformance.

D1

Pressure gages in the tensioning machine are calibrated.

D2

Tensioners are fitted to ALL bolts.

HYDRATIGHT Procedure or Equivalent

D3

Pressurize the tensioners to pre-determined "Pressure A" per the approved procedure. (This is repeated 2 more times.)

HYDRATIGHT Procedure or Equivalent

D4

After tensioning, Break Loose Pressure (BLP) is verified to be greater than or equal to Pressure A by the following steps: a) Fit tensioner to one of the tensioned bolts in Set 'A'. b) Pressurize slowly until the nut is loosened using a Tommy Bar and socket. c) Once the nut moves, stop pressurizing and record the achieved pressure. This is the Break Loose Pressure. (NOTE: If BLP < Pressure A, Tensioning is a Fail. )

HYDRATIGHT Procedure or Equivalent

Page 3 of 12

Sch. Q, Att. IV

Sch. Q, Att. IV

MECH-

N/A

RE-TEST DATE

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008)

Rev 3

SAUDI ARAMCO TEST REPORT

SATR NUMBER

Flange Joint Tightening Inspection Report

SATR-L-2001

PROJECT TITLE

ITEM No. E

WBS / BI / JO NUMBER

TEST PROCEDURE ACCEPTANCE CRITERIA

Findings are recorded in Bolt Tightening Report Form SATR-L-2001, Attachment 4.

REFERENCE DOCUMENTS: 1. 2. 3. 4. 5. 6.

REFERENCE

SAES-L-350 - Construction of Plant Piping, (30 September, 2003) SAES-L-109 - Selection of Flanges, Stud Bolts and Gaskets, (9 March 2008) SAEP-351, Bolted Flange Joints Assembly, (7 November 2006) ASME B31.3, Process Piping, (2004 Edition) Schedule Q, Contractor's Quality Requirements Recommended Tensioning Procedure-By HYDRATIGHT

Page 4 of 12

30-Dec-08 DATE APPROVED QR NUMBER

15-Dec-09

MECH-

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-TEST DATE

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008)

Rev 3

SAUDI ARAMCO TEST REPORT

SATR NUMBER

Flange Joint Tightening Inspection Report

SATR-L-2001

PROJECT TITLE

WBS / BI / JO NUMBER

ITEM No.

TEST PROCEDURE ACCEPTANCE CRITERIA

REFERENCE

Contractor / Third-Party

15-Dec-09

MECH-

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-TEST DATE

Saudi Aramco

Technician Performing Test* Name, Title, Department, Company, Initials and Date:

30-Dec-08 DATE APPROVED QR NUMBER

PMT Representative

Test Performed Successfully and Results are Acceptable:

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

Name, Initials and Date:

QC Inspector

PID Representative Witnessed Test

Work / Rework May Proceed

Name, Initials and Date:

Name, Initials and Date:

QC Supervisor

Proponent and Others Quality Record Approved:

Name, Sign and Date:

Name, Organization, Initials and Date:

*Person Responsible for Implementation of Test and Analysis of Results

Y = YES

Page 5 of 12

N = NO F = FAILED

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008)

SAUDI ARAMCO INSPECTION CHECKLIST Review Procedure - Flange Joint Assembly & Gasket Installation

Rev 3 SAIC NUMBER

SAIC-L-2002

30-Dec-08 DATE APPROVED QR NUMBER

15-Dec-09

ATTACHMENT 1 - SAEP-351 TABLES (FLANGE JOINT ASSY)

MECH-

"SPEC CHECK" GUIDE FOR BOLT TORQUE VALUES STOP LEAKS "BEFORE" THEY HAPPEN (TORQUE IT RIGHT ONE TIME)

Figure SAEP-351-01 – Stud Bolt Tightening Sequence (STAR PATTERN)

SAES-L-109, Tables 1 & 2 (SASDs for Flanges & Blinds)

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008)

Rev 3

SAUDI ARAMCO TEST REPORT

SATR NUMBER

Flange Joint Assembly & Gasket Installation Report

SATR-L-2001

EQUIPMENT ID NUMBER(S) or LINE NUMBER

FLANGE JOINT NUMBER/S

LAYOUT DRAWING NUMBER

REV. NO.

SCHEDULED TEST DATE & TIME

ACTUAL TEST DATE & TIME

30-Dec-08 DATE APPROVED QR NUMBER

15-Dec-09 Test Pack No.

MECHSYSTEM ID.

PURCHASE ORDER NUMBER

PLANT NO.

EC / PMCC / MCC NO. QUANTITY INSP.

MH's SPENT

TRAVEL TIME

SAUDI ARAMCO USE ONLY

SAUDI ARAMCO TIP NUMBER

SAUDI ARAMCO ACTIVITY NUMBER

SAUDI ARAMCO INSPECTION LEVEL

CONTRACTOR INSPECTION LEVEL

WORK PERMIT REQUIRED?

Attachment 2 - FLANGE JOINT INSPECTION & TIGHTENING REPORT Pre-Inspection of Flange Joint Assembly Completed and Checklist, SAIC-L-2014, signed:

YES NO

QR # ______ YES NO

Did the crew follow the Approved Procedure

FLANGE JOINT INFORMATION: Flange

Size:

Gasket

Type:

Size:

Rating:

Type: __________________________ (Indicate number for Ring Gasket)

Bolt

Size:

Type:

Lubricant:

Material : Outer Guide Ring: __________ Inner Guide Ring: __________ Material : Ring Joint Gasket: __________ Others: __________

Material : Required Torque or Tension Values: _______________

Tightening Method:

Residual Bolt Load / Stress Required: TORQUE METHOD No. of Pass

BOLT TENSIONING METHOD

Torque Value

Tensioning Stage

1

30% of Reqd. Torque

Pressure A

2

+ 5% of Reqd. Torque

Pressure B

Pressure Reading

Break Loose Pressure RESULT:

REMARKS:

Contractor / Third-Party

Saudi Aramco

Technician Performing Test* Name, Title, Department, Company, Initials and Date:

PMT Representative

Test Performed Successfully and Results are Acceptable:

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

Name, Initials and Date:

QC Inspector

PID Representative Witnessed Test

Work / Rework May Proceed

Name, Initials and Date:

Name, Initials and Date:

QC Supervisor

Proponent and Others Quality Record Approved:

Name, Sign and Date:

Name, Organization, Initials and Date:

*Person Responsible for Implementation of Test and Analysis of Results

Y = YES

Page 11 of 12

N = NO F = FAILED

Page 12 of 12

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