tfa course for foremen & qc techn

8/9/2019 TFA Course for Foremen & QC Techn

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Total Flange Assurance (TFA)Trainin for C Technician &

2/28/2013

Foreman

20 March 2012


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1) Purpose & goal TFA2) Roles & Responsibilities3) TFA Specification and Procedure3) Bolt UT - Why Bolt UT?

- Principles of Bolt UT- Bolt UT machine

Topics covered

- o t step- y-step- GMAX SoftwareTheory Test

4) PracticalPractical Training SessionPractical Test


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SHELL: No leaks!No fire, no injury, no shutdowns, no pollution

Contractor: No rework!More incentivesNo injury

Why TFA? Purpose & Goals

ess sco ngMore time to do other things


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TFA Procedure

Procedure Work Process - Differences

Roles and Responsibilities:- Authorized ForemanQC Technician

SEPL TFA Inspector


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TFA Organisation

ZONE 1 ZONE 2 / 3 / 4

FITTER FITTER FITTER FITTER FITTER FITTER

TFA Authorized TFA Authorized TFA Authorized

FOREMAN

TFA

QC TECHNICIANTFA

Executing Engineer

TFAExecuting Engineer

SEAL

SEAL


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TFA v5 Scope - PipingDefinitionCritical Service

Bolt Joints in following operating condition to be identified as a critical bolt Joints Highly hazardous chemical service as defined in CFR 1910.119 (OSHA PSM rule), Lethal Service as defined in the ASME Section VIII Divisions 1 and 2 Codes Category M Fluid Service as defined in ASME B31.3. Hydrogen Service above 316 deg. C (600 F), class 600, size 10 and greater

Hy rocar on or Sour Service 316 eg. C 600 F , c ass 900, size 8 an greater Hydrocarbon or Sour Service 316 deg. C (600 F), class 1500, size 6 and greater Hydrocarbon or Sour Service 316 deg. C (600 F), class 2500, size 4 and greater Joints subjected to cyclic temperature


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Standard Flanges

Flanges that follow B16.5 (flanges 24)

Flanges that follow B16.47 (flanges >24) Series A or B Temperature at bolts 20% lower than process temperature unless flangeis insulated

Definition (cont.)

Non-standard Flanges

Flanges that DO NOT conform to B16.5 or B16.47

Temperature at bolts > 450C


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Selection of Bolt Tightening Method and QC ScopeFlange

Size150# 300# 600# 900# 1500# 2500#

1

1 12

3468

1012 2141618202426 428

303236 340424860


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Selection of Bolt Tightening Method and QC Scope(cont.)Zone Rating Service Method QC Scope Sealed by

1

1.1 Dn < 20, 150#

All Services Torquing Visual, ToqueSampling

AuthorizedForeman

Water,Compressed air ,

Steam,Nitrogen

Flogging Visual, SpannerSampling

1.2 Dn 4, 1500#

All Services Tensioning4.2 Dn > 3, 2500#


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TFA Zone 1Manual Tightening

Flange Size 150# 300# 600# 900# 1500# 2500#

1

1 12

3468

10

12 214

16182024

26 4283032

2 Fitters 2 Fitters 2 Fitters 2 Fitters 2 Fitters 2 Fitters 2 Fitters 2 Fitters 2 Fitters

Seal SealSeal

TFA Foremen

Seal SealSeal Seal SealSeal

TFA Foremen TFA Foremen

36

340424860


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TFA Zone 2

Tightening with Driven Wrenches

Flange Size 150# 300# 600# 900# 1500# 2500#

1

1 12

3468

10

12 214

16182024

26 4283032

2 Fitters

TFA Foremen Seal

2 Fitters 2 Fitters

QC Technician

Seal

Seal

Bolt-UTdatabase

36 340424860


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TFA Zone 3

Tightening with Driven Wrenches

Flange Size 150# 300# 600# 900# 1500# 2500#

1

1 12

3468

10

12 214

16182024

26 4283032

2 Fitters

TFA Foremen Seal

2 Fitters 2 Fitters

QC Technician

Seal

Seal

Bolt-UTdatabase

36 340424860


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TFA Zone 4Bolt Tensioning

Flange Size 150# 300# 600# 900# 1500# 2500#

1

1

123468

10

12 214

16182024

26 4283032

TFA Foremen Seal

Bolt-tensioning Crew

QC Technician

Special Services Provider

Bolt-UTdatabase

36 340424860


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FloggingOnly for Zone 1: Utilities Air, Water, N2, Steam

TorquingFor flanges in Zone 1 and Zone 2

Double Torquing (2 - Torque wrenches concurrently) -

Tightening Method

TensioningFor flanges in Zone 3: Critical and Zone 4 : All Service


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Visual, spanner (By Authorized FOREMAN) Visually check for F.L.A.N.G.E.Use spanner/hammer to test bolt tightnessOnly for Zone 1: Utilities Air, Water, N2, Steam

Torque wrench (By Authorized FOREMAN) Visually check for F.L.A.N.G.E.Use torque wrench (set at 90% of torque value) to check tightnessOnl for Zone 1 All service exce t Utilities

QC Method

Bolt UT, 3 samples (By QC Techinician) Visually check for F.L.A.N.G.E.Reference reading : 3 bolts; Final Reading : 3 bolts for QC check For Zone 2 Non-Critical services

Bolt UT, 6 Samples (By QC Techinician) Visually check for F.L.A.N.G.E.Reference reading : 6 bolts; Final Reading : 6 bolts for QC check For Zone 2 Critical services; Zone 3 & 4 : All Service


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TFATFA

11--seal approachseal approach

1 SealAuthorized TFA Foreman

TFA Tagging &1-seal ApproachZONEZONE

TFATFA

11--seal approachseal approach

Authorized TFA Foreman

execution under

# 1 # 2 / 3 / 4

-Execution-Responsible for the joint

SEPL TFA Inspector

sign-off EQCC to accept

1 SealQC Technician

has proper tech to check for properexecution

SEPL TFA Inspector

sign-off EQCC to accept


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Fitter (contractor)

Clean up the flange and prepare for inspectionSafely Break the Flange Joint

Works hand-in-hand with TFA Authorized Foreman

TFA Roles and Responsibilities

Execute Flange tightening as instructed by Authorized Foreman

,

Align Flange and hand tighten nuts

Prepare Bolts for Reference Reading


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Authorised TFA Foreman (AF) (contractor)

Inspect Flange Faces (report defects to QCT)

Works hand-in-hand with QC Technician & Fitter

TFA Roles and Responsibilities

Supervise safe breaking of Flange Joint

Execute Flange tightening as per given specZone 2, 3 and 4

Assist QCT for QC check of flanges for Zone 2 , 3 and 4

Check Lubrication of Nuts and Bolts

Ensure flange face checked

QC Check and Apply SEALforZone 1 Flanges- QC passed


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SEPL TFA inspector Project Engineer / Maintenance Engineer /Executing Engineer / Work Pack Leader

Maintain Log of Off-spec flanges

TFA Roles and Responsibilit ies

epor -spec anges o eer ng eamMaintenance Manager / Construction Manager Organize execution of Discovery works

Sign-offEQCCs following Equipment handover protocol


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1. Check flange faces2. Lubricate nuts and bolts

3. Check correct gasket install4. Install nuts and bolts hand tight (max 15% of studs to hold flange)

5. Tightening 1st pass

AF AF

AF AF

AF

Work Process : Zone 1

6. Tightening 2nd

pass7. Tightening 3rd pass8. Tightening Final pass9. QC Seal flange

AF AF AF AF


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5. Prepare bolt ends for Bolt UT sandpaper/ filing: 3 / 6 bolts

AF AF

AF AF

AF

Work Process : Zone 2 & Zone 3

6. QC Reference measurement (3 / 6 Bolts)7. Tightening 1st pass8. Tightening 2nd pass9. Tightening 3rd pass

10. Tightening Final pass11. QC Check applied load @ 3 / 6 bolts12. QC Seal flange

QCT AF AF AF

AFQCTQCT


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5. Prepare bolt ends for Bolt UT sandpaper/ filing: 6 bolts

AF AF

AF AF

AF

Work Process : Zone 4

6. QC Reference measurement (6 Bolts)7. Tightening for all Odd Studs8. Tightening for all EVEN Studs9. QC Check applied load @ 6 bolts

10. QC Seal flange

QCT AF AFQCT

QCT


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What is Ultrasonics?

Using ultrasound (sound above the range of human hearing) tomeasure distances

TFA Boltstress Ultrasonics

Ultrasonics: 1,000,000 - 5,000,000Hz (5Mhz)

Infrasound Sound Ultrasound

20Hz 20,000Hz


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What is Bolt Ultrasonics?

Using ultrasonics to measure the length of bolts in a very accurate way


Can measure a maximum distance of 1.5m


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Why do we use Bolt Ultrasonics?

By taking a reference value of the bolt length before the bolt istightened


tightened The two readings can be compared to determine elongation of

the bolt

elongationBolt before tighteningReference measurement

Bolt after tighteningFinal measurement


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Why do we use Bolt Ultrasonics?

A bolt is like a spring when you tighten the bolt, it stretches Like a spring how much the bolt stretches or elongates is


So, if we know the elongation, we will know the bolt load


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What is the relationship between bolt load and bolt stress?

Bolt Stress = Area of Bolt

Bolt Load A


=

Area of bolt is dependent on diameter of bolt

F A


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So, how do we use Bolt UT?

Measure reference (before tightening)

Measure final (after tightening)

Gives uselongation


Calculate Bolt Stress

Compare Bolt Stress with Required Bolt StressIs it within 10%, +15% of required bolt load?If yes passIf no retighten

Calculated by Bolt UT computer

Input Bolt Effective Area


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Why do we use bolt stress instead of bolt load?

Bolt Stress(MPa / psi)

Bolt Load

(N)

vs


size, so stress is the sameacross different bolt sizes

larger bolt = larger load

Failure point of bolts aredependent on materialgoverned by stress

Unable to directly correlatefailure point with loadneed to convert to stress first


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Bolt material

100% Yield Stress

psi(lbf/in2)

MPa(N/mm2)

TFA Procedure

B7, L7, B16 105,000 724B7M, L7M 80,000 551

B8 Class 1 29,000 200B8 Class 2 80,000 551


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Required Bolt Stress (MPa)Bolt material Standard

FlangesNon-standard

Flanges

TFA Procedure

, ,

Depends oncalculation

B7M, L7M 275

B8 Class 2 275

Based on 50% Yield Stress


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Why Bolt UT?

Bolt Tightening MethodsUncontrolled Semi-controlled Fully ControlledFlogging Torquing

Double TorquingBolt UT

ens on ng Accuracy 50-80% 20-40% 10%Method of Control None Torque Actual Load

Weakness Highly inaccurate,no way to

determining actualload or torque

Conversion of torque intoactual bolt load is

affected friction, torquingmethod and lack ofproper lubrication eg.E9901 26, E99

None directmeasurement of bolt

load/stress ensures thatbolt load is exactly correctas required.


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Can we do better?

The tightening of Flanges wererejectedrejecteddue toINSUFFICIENT LUBRICATIONINSUFFICIENT LUBRICATION

MAKE SURE !

What was not done well so far? What was not done well so far?

February 28, 2013 37

Stud/NutsTHREADSTHREADS are in good conditionLubricatorMOLYKOTE 1000MOLYKOTE 1000

Flange SurfaceFlange Surfaceis lubricated properly

Stud/NutsTHREADis lubricated

Nuts FACENuts FACEis lubricated


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February 28, 2013 38

Questions?


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tfa course for foremen & qc techn

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