bolted flanges generic

8/13/2019 Bolted Flanges Generic

1/46


2/46

Purpose

To provide work and process controls to achieve

high level of leak tightness integrity to properly

designed Bolted Flange Joint Assemblies

Uniform use of this procedure by and other

Contractor personnel is expected to result in aero incidence rate of flange leaks


3/46

SCOPEThis process is applicable to flanged !oint assemblies for"

#iping

$alves

%eactors

$essels

&rums

'xchangers

Boilers

Coalescers

and other e(uipment using flanged !oints administered at

all !obsites


4/46

SCOPE

This process is to be implemented in con!unction

with the approved design standards)

This process is applicable to the field offices thatpurchase* receive* field fabricate* inventory*

install* erect* and inspect piping and piping

related components)


5/46

SCOPE

&eficiencies identified during in+process monitoring andfinal inspections* shall be documented and tracked in

accordance with the individual site practices for Control

of Deficient Items.

Any aboveground piping within the !urisdiction of A,-'

,ection . #ower Boilers* and A,-' ,ection B/0)0

#ower #iping* and any work related to A,-' ,ection

$... $essels* shall be executed in accordance with the

A,-' -anual for A,-' Code Construction andadditional re(uirements stated in the Bolt Flange Joint

Assembly procedure)


6/46

Definitions

Fasteners 1 all bolting* studs* nuts* and washersused in the assembly of flanged !oints)

Flange Maps are isometrics drawings* sketches*

e(uipment drawings* and2or #3.&4s that 5map6

flange locations and identifies each flange

connection with uni(ue numbers)


7/46


8/46

DefinitionsInspection and Test Plan (ITP) is a document that

outlines examination* inspection* and2or hold points* and

witness points activities)

Flange Tightening Method is used to tighten flanged

connections as pre+determined and specified on the

flange maps) The method used can be indicated on

flange tags so that the relevant information is

communicated to persons directly responsible for the

assembly of flanged connections)


9/46

Training

.n general* all personnel with duties associatedwith the bolted flanged !oint assembly program

are to receive training) All training is to be

documented)

The BFJ Progra! "ualit# Training Matri$ lists

all affected personnel and their corresponding

level of needed training)


10/46

%esponsibilitiesSite Manager 8,-9 ensures that the re(uirements of this :ork

#rocess are properly implemented)

Superintendents are responsible for the overall (uality of work

performed by maintenance and construction personnel for

their assigned area8s9)

Site "ualit# Control Manager 87C-9 manages the 7uality

Control functions for the pro!ect* provide oversight* and direct

the work of the site 7C.4s)

The 7C- addresses any deficiencies in the BFJA program

with appropriate personnel to assure continued compliance

with the program)


11/46


12/46

%esponsibilities

Piping Fore!an ( PF ) is responsible for"

Understanding the work scope and re(uirements of this

process

Adhering to pro!ect drawings and specifications

-aintaining good workmanship and fulfilling all (uality

re(uirements of the work and targeting punch+list itemsassociated with completed work activities

Assigning trained personnel to assemble flanged !oint

connections

Arranging all re(uired work permits* tools* e(uipment*scaffolding* and consumable material for the work activities

Coordinating and scheduling work activities based on pro!ect

schedule re(uirements

'xamining and verifying BFJA4s in accordance with the .T#4s


13/46

%e(uirements'or Process

All materials and workmanship shall fully comply with the designdrawings* Client specifications* and applicable Codes and

,tandards)

Field changes to design documents shall not be performed without

prior written approval from the Client)

All measuring and test e(uipment used during the installation*

testing* and verification of piping systems shall meet the

re(uirements of T.; procedure -T'+0* Control of -easuring and

Test '(uipment)

All material specifications and applied tightening method information

must be disseminated to personnel assigned to flange mapping)


14/46

Preplanning ctiities

#re+activity construction meetings should be held to

finalie the scope of activities prior to the

commencement of work or unit blinding)

A review of the .nspection and Test #lan for BFJA4s

and referenced documents shall be performed by the

7C-) The re(uired 7C and Client


15/46

#replanning Activities

#iping ,upervision8#,9 shall maintain a full

understanding of the work scope and installation criteria)

The #,* working with the 7uality Control personnel* shall

develop the leak test program as per the procedure to

ensure that all piping is tested is in accordance with the

pro!ect specifications)


16/46

'or Preparation*Initiation

Assigned personnel will have the responsibility of providing a blind

list and of hanging of blind tags at all blind locations) This will bedone prior to the hanging of flange tightening tags by craft

personnel)

Applicable personnel will have the responsibility for generating

flange tightening tag lists for all flanges to be disturbed during

each2any activity 8i)e)* Turn+Around* %outine -aintenance* Capital#ro!ect* etc)9) This list will be maintained and appended should the

scope of the activity be advanced)

All disturbed flanges will be identified using a uni(ue numbering

system) This system numbering will be e(uipment* unit outage*

and2or pro!ect specific) The determination of the tightening methods to be employed shall

be indicated on the Flange Tags)


17/46

Flange Tag Preparation and +anging At initial execution of work* the company will issue and hang initial

Flange Tightening Tags on all flanges2line breaks to be loosenedand then tightened)

Flange Tightening Tags are to be filled out and installed on all

flange2line breaks and when blinds are installed)

'ach flange will have an individual tag 5Uni(uely numbered6)

Flange tags shall be initiated and attached to affected BFJA4s in

accordance with the flange maps)

Flange Tightening Tags are to be filled out and hung as each flange

connection is made up and completed) These tags will be attached

to the flange connection using electrical tie wraps or bailing wire)


18/46

The same process is to be followed throughout the final removal

and final assembly of the connection)

The Flange Tightening Tags will be removed only by 7C after the

final removal of the blinds and2or final flange make up)

All revisions or additional of work are to be treated as Field Changes

and will be added only as additional work once approved by

appropriate management personnel) =nce approved and planned*

7A27C &epartment shall be notified of the work* prior to execution*and prepare Flange Tightening Tags and update the flange logs for

the flanges2line break affected)

Flange Tag #reparation and


19/46

Material +andling and Storage


20/46

-echanical Joints

Flanged valves shall be checked for thefollowing" Check* globe* and control valves are installed with

indicated flow in the correct direction as indicated on

the #3.& -anufacturer4s name tag description agrees with

stock code number 8if used9* description* and trim)

&o not rely on warehouse tag)


21/46

'or Process Flo, and

Docu!entation All BFJA4s shall be tightened using the method assigned)

As flanges are tightened* the responsible craftsmen will completethe re(uired entries on the tag* sign and date* and inform his

appropriate foreman or supervisor of the connection completion)

The foreman or his designee will then check the flange for proper

gasket* proper type of bolting 8i)e)* nuts and studs9* proper flange

alignment* and bolt tightness) .f all is correct* the foreman ordesignee will sign the flange tag and notify the 7C representative

that the flange is ready for inspection)

7C will verify the flange installation is in accordance with the .T#)

:hen .T#4s re(uire witness or holds by the Client* the 7C inspector

shall make those notifications to Client) Upon final acceptance* the 7C .nspector will remove the Flange

Tightening Tag8s9 and turn them into the ,ite 7C -anager)


22/46

Blinds All blinds installed on towers* drums* reactors* piping* etc) shallreceive Flange Tightening Tags) The installation of the Blinds shall

be documented in the designated area for Blind installation located

on the back side of the Flange Tightening Tag)

Flange Tightening Tags are not to be removed until the blinds have

been removed* the final flange is made up* and the actions

documented on the front of the tag as per the procedure)

Flange Tightening Tag tracking is to be kept by 7C in the masterelectronic >ine Break Tracking ,ystem) -anways are to be

included)


Docu!entation


23/46

?@0

System requires Bolt/Nut Replacement ___Yes___No

#3.& Do)

FLANGE TIGHTENING TAG

F%=DT

UD.T"

'7U.#2.&"

&AT'"

C%AFT,-AD"

PRINT NAME

SIGNATURE/DATE

Foreman

PRINT NAME _____________________

,ignature

SIGNATURE/DATE

7uality Control

PRINT NAME

SIGNATURE/DATE

Final Flane !a"e up #ata

continue# $rom $ront si#e

B=>T ,#'C.F.CAT.=D"

B=>T, %'#>AC'&" E', D=

;A,'T ,#'C.F.CAT.=D"

.D,#'CT F>AD;' FAC'

E', D=

STENCIL/COMPANY

SIGNATURE/DATE

D': ;A,'T .D,TA>>'&

E', D= =$A> %.D; .D,#'CT'&

E', D=

STENCIL/COMPANY

SIGNATURE/DATEBelow is to be used only for blind installation

CRAFTSMAN ________________________

PRINT NAME

_______________________________ STENCIL/COMPANY

_______________________________

SIGNATURE/DATE

C=-#'T'DT #'%,=D

PRINT NAME ________________________________

STENCIL/COMPANY

________________________________

-A.DT'DADC' SIGNATURE/DATE

F=%-AD2,U#$)

PRINT NAME ________________________________ SIGNATURE/DATE


24/46

At times Flange Tightening Tags become misplaced* the foreman or

,upervisor over this work will obtain a new tag from the 7C

&epartment) The new tag number will replace the missing tag

number and the new number added to the Flange -ap) This new

tag is to be attached to flanged connection) All (uality checks* suchas proper gasket* bolts* nuts* tor(ue tightness* etc) will following the

same work process as a new connection)


Docu!entation


25/46

Flange Assembly #ractices

Preparation Bolts shall be checked for proper sie* length* and grade as per the

information provided on the flange tag) Bolts shall be clean and free

of damage)

'xisting bolts to be reused shall be clean* in good condition* and

undamaged 8nuts should run free on the bolt9) They shall beprepared for short+term storage using a rust preventing lubricant

and can only be re+used as per the Bolt .nspection and %e+Use

procedure)

Just prior to installation* bolt threads and bearing surface of nuts for

all bolting shall be coated with an anti+seie compound) ;askets shall be checked for sie* conformance to specifications*

damage* and cleanliness) All gaskets shall be compared with the

flange face to insure that the gasket seal area properly mates to the

flange face)


26/46

Flange faces shall be thoroughly cleaned and the gasket surface

inspected for any defects) Burrs and rust shall be removed)

#articular attention shall be paid to the sealing surfaces for metal

gaskets such as the grooves in ring !oint flanges and to the 0GH

AA%< finished flanges) Any (uestionable flange faces shall bebrought to the attention of 7C in accordance with the BFJA .T#)

Alignment measurements shall be taken prior to flange assembly

8e)g) installing stud bolts9) Alignment tolerances of mating flanges

for #ipe to $essels or ,tationary '(uipment Doles* #ipe to #ipe*

and #ipe to .nline &evices shall be in accordance with thetolerances outlined in the Table --0)

Flange Assembly #ractices


27/46

-aximum -isalignment Table --0

-I./ME/T DETI- M0IM1M PE%MISSIB-EMIS-I./ME/T OF F-/.ED JOI/TS2

I/3

D#, I 0G 0GI D#, I

GG

D#, G

$ertical bolt hole offset 02K 020L 020L


28/46

sse!&l#

Bolt holes of mating flanges may be brought into initial alignment

using a spud wrench or other tool) The alignment tolerances

provided in Table --0 shall be recognied)

Flange 5makeup6 shall be done without the use of gasket sealing

compounds) The gasket shall be inserted* and centered between the flanges and

nuts hand tightened to hold the gasket in place) Assure the color

coding of spiral would gaskets) 8attachment J9 :hen flanged !oints

are in horiontal lines* gaskets without centering devices such as

ring !oint gaskets shall be lowered to the bolts for retention and thenraised into position)


29/46

The remaining bolts and nuts shall be installed and hand tightenedwith the flange faces parallel) Care shall be taken to assure proper

seating and centering of the gasket within the allowable tolerances)

,nug tightening with a combination wrench prior to tensioning is

permitted on large flanges)

Bolts should be installed so that only one to three threads show pastthe nut on either side)

sse!&l#


30/46


31/46

F.;U%' 0 1 B=>T T.;


32/46

sse!&l#

Two diametrically opposite bolts shall betightened either simultaneously or in direct

se(uence)

Care shall be taken to prevent over+tightening

one side of the flange to prevent gasket crushing

or flange distortion* especially when tightening

flanges containing ring !oint* spiral wound* orsimilar type gaskets)


33/46

.n the case of flanged !oints that re(uire controlled tor(uing* it isrecommended that initially two diametrically opposite bolts shall be

initially loaded utiliing tor(ue wrench tightened to GHN of the tor(ue

load value listed in the procedure* either simultaneously or in direct

se(uence)


34/46

sse!&l#

:hen flanged !oints are assembled with hand wrenchesO the

se(uence in in the procedure shall be used with an effort to

approximate the tor(ue values)

.f flange !oints re(uire hydraulic tensioning* this work will be

performed by a subcontractor that specialies in controlled bolting

and with experience in hydraulic tensioning methods) ,pecific

re(uirements regarding the basic (ualifications of this contractor

and their work practices are detailed in the procedure)

After the flanged connection has been fully tightened with hand

wrenches* the !oint shall be inspected for uniform bolt loading by

wrench testing each bolt in the same se(uence listed until all bolts

are !udged to have the same level of tightness)


35/46

=nce the flange !oint is assembled* the craftsman shall initial the

applicable examination entries on the flange tag and alert his

foreman or designee for verification of the BF>A) The foreman or

designee will verify the BFJA* initial the flange tag for acceptance*

and notify 7C for inspection All flange connections that re(uire controlled tor(uing or hydraulic

tensioning must be documented by the craftsperson) At a minimum

this documentation shall include the Control >oaded Flange

Connection &ata ,heet as seen in the procedure)

sse!&l#


36/46

Final Co!pletion and Turnoer

Final Co!pletion and Turnoer

The ,ite 7C -anager or his designee will accumulate flange tagsand update the flange tags logs) Flange tags* flange tag maps* and

flange tag logs will become an integral component of document

turnover)


37/46

Good Poor

Rotational

Skewed

Excessive Gap

Non Parallel

Flane Fit !p " Alin#ent

Flane Face

$nspected %or Cleanliness

Pipe &ore

St!ds and N!ts

Gasket

'es No

Proper FlaneMaterials and Ratin

Con%ir#ation o% Material and

$nspect General Condition

St!ds and N!t Material

St!d and N!t Condition

'es No

Condition o% Flane Face(A)rasions* rooves* r!st+

Gasket Material

Gasket Condition

(Cr!s,ed or )ent-+

A!dit o% Flane Asse#)l. Process

/ork Practice

Proper Se0!encin

/orker Trained

Proper Tools

Sa%e /ork Practices

'es No

Proper Tor0!in E0!ip#ent

Proper Ti,tness o% St!d

Co#pleted Asse#)l.Marked and $nitialed

Proper 1andlin and

Place#ent o% Gasket

E0!ip#ent 2 Spool $3 Contractor 2 Cra% ts#en4 A!ditor(s+4

Bolt Inspection and %euse


38/46


Procedure

The #urpose of this procedure is to assure proper inspection of boltstargeted for reuse in systems re(uiring bolt replacement) This

program is to assist in providing a 5leak free6 startup after

turnaround)

,ystems re(uiring bolt replacement will be identified on the FlangeTightening Tag) The bolts will be replaced with new and2or

inspected bolts of the re(uired type and sie)

B l I i d %


39/46

The implementation of a 5Bolt Cleaning and .nspection ,tation6 will be

mandatory)

This station will be e(uipped with"

A bench grinder e(uipped with ade(uate safetyguards* utiliing a buffing wheel to expedite and provide

thorough cleaning for inspection on bolts larger than P6 &ia)

A


40/46


Procedure

All bolts to be reused in systems that re(uire replacement will beremoved and sent to the 5Bolt Cleaning and .nspection ,tation6)

The Bolt Cleaning station will inspect all received bolts for"

Bolt 5Type6 markings* re!ecting those without markings

=bvious defects* re!ecting those that are damaged)

All bolts that are re!ected are to be laid on an .nspection

bench for final inspection and accountability



41/46

.f no obvious defects are found"

The bolts will be thoroughly cleaned

>ubricated* with a light lubricant 8i)e)* :& @9)

Dote" Dever+seie is not to be put on the bolts at the

5Bolt Cleaning and .nspection ,tation6)

A new nut will be run by hand from one end of the bolt off

the other end

5 .f the nut does not run freely* the bolt will beconsidered to have been yielded 8i)e)* over tor(ued*

etc)9 therefore re!ected and segregated for further

inspection)


Procedure



42/46


Procedure

All bolts that are deemed acceptable by the 5Bolt Cleaning and

.nspection ,tation6 shall be placed on an .nspection bench"

,orted by sie and type

Facing in the same direction) All ends with the bolt type

stamped on them are to be faced on the same side) =nce the bolts are inspected and accepted they shall be

color coded by applying a #urple paint on the opposite

end from the stamped markings)



43/46

All accepted bolts will be stored in designated storage bins

segregated by the sies and types of the boltso These bolts shall be issued when the newly ordered bolting

materials are depleted)

All bolts that are re!ected by the 7C &epartment shall be

documented to show the (uantities of sies and types of the

re!ected bolts to be replaced with new ones)

o This report shall be submitted to the ,ite ,uperintendent

assuring a prompt reordering of replacement bolts asneeded)


Procedure


44/46

MI/IM1M %E"1I%EME/TS FO% BO-T

TE/SIO/I/. CO/T%CTO%S

7ualifications of a contractor specialiing in controlled bolt tensioningshall be addressed in the re(uest for in(uiry phase) The following

deliverables shall be reviewed and subse(uently agreed upon by

the Client* 7C -anager* and the Contractor 7uality -anager prior

to award of a contract"

7ualifications of personnel assigned to the pro!ect Dumber of craftsmen and supervision per field crew and

roles

7uality Control27uality Assurance plan

Utilities and2or e(uipment re(uirements

Tensioning Contractor approved !oint assembly anddisassembly procedures

#roposal for bolt loading when there is not enough clearance

for tensioning device


45/46


46/46

Docu!entation %e4uire!ents 1

The Tensioning ,ubcontractor 7uality #lan shall re(uire

inspection reports2records on all tension or !oints for the

pro!ect) The .T# shall outline responsibilities for monitoring

all tensioning activities by the ,ubcontractor) .nspection reports2records should contain* as a minimum* the

designated Control >oaded Flanged Connection &ata ,heet

for each flange pair)

MI/IM1M %E"1I%EME/TS FO% BO-T

TE/SIO/I/. CO/T%CTO%S

bolted flanges generic

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