SATR-L-2001
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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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