OEUP-InT1000-SOP-OPS-0031 PE Flange Assembly Bolt and Nut Tightening

PE Flange Assembly Bolt and Nut Tightening Standard operating procedure Level 1
OEUP-INT1000-SOP-OPS-003
PE Flange Assembly Bolt and Nut Tightening

Level 1 standard operating procedure
Review Record Rev 0 1 Date 23/04/12 19/09/12 Reason for Issue DRAFT Final Version Prepared CB CB Checked MH Approved
Next Review Date:
[23/04/2013]
*Please see Document Information and History section for more information. For internal Origin use and distribution only. Subject to employee confidentiality obligations. Once printed, this is an uncontrolled document unless issued and stamped Controlled Copy or issued under a transmittal.
Table of Contents
1. 2. 3. 4. Purpose/ Scope Responsibilities/Accountabilities Definitions/Acronyms Health Safety and Environment 4.1 4.2 4.3 5. 6. 7. 8. 9. Risk Identification Required Tools/Equipment Environmental Impact 3 3 3 Error! Bookmark not defined. Error! Bookmark not defined. Error! Bookmark not defined. Error! Bookmark not defined. 7 10 10 11 12
Operating Steps Troubleshooting Record Keeping References/Associated Documents Document Information and History
Table of Figures
Figure 1 - Bolt Tightening Sequence 13
List of Tables
Table 5.1: Operating procedure - step tracking table. Table 2 - Flange Bolt Torque Record 7 Error! Bookmark not defined.
List of Appendices
Appendix A Bolt Tightening Sequence Appendix B Torque record sheet B.1. 13 Error! Bookmark not defined. 15
Torque Chart for Flanges with Non-metallic Gaskets
Released on 11/03/2012 Revision 0 Status: Draft Process Owner is: Chief Mechanical Engineer Origin Energy Resources Limited: ABN 66 007 845 338 Once printed, this is an uncontrolled document unless issued and stamped Controlled Copy or issued under a transmittal.
Template: Operations Excellence Manager_Revision 2_11/10/2010_OEUP-1000-TMP-BUS-001
1.
Purpose/ Scope
This Standard Operating Procedure provides the steps to tighten bolts for PE piping connections. The procedure shall be followed whenever PE piping connections are bolted up except for hot bolting or for the tightening of leaking joints. This procedure applies to all Origin Energy operations however a more specific procedure i.e. a site or equipment specific procedure may be used in lieu of this procedure. Apply this procedure to assemble flanges at ambient temperature only, as torques will not be accurate if the flange(s) or stud(s) are at abnormal temperatures. This procedure does not apply to flanged joints which are integral to specific equipment items such as heat exchanger end covers where Original Equipment Manufacturer (OEM) recommendations shall be followed. Observance of this procedure will help ensure that gaskets provide an effective seal for all operating conditions.
2.
Responsibilities/Accountabilities
All personnel undertaking flange assembly must be assessed by a competent Supervisor to ensure necessary competency skills are met with to execute the job. It is the responsibility of Maintenance / Construction Supervisor to ensure bolts are tightened in accordance with this procedure. Roles Mechanical Engineer (Technical Function) Responsibilities / Accountabilities Responsible for the ongoing development of this document and its associated documents. Provides technical advice and guidance regarding flange bolting procedure Technical Authority Accountable to develop and maintain the Flange bolting procedure and Technical specifications Responsible for the approval of any deviations from this procedure or associated documents Project Manager/Engineer Responsible for ensuring this procedure is followed in its entirety to achieve flange integrity during new project commissioning Ensures that the responsible person and all members of the work party are deemed competent to undertake the task, have read and understood this procedure, and its referenced documents Correctly identify tasks covered in the scope of this document and ensures the procedure is distributed to the relevant personnel involved in the project Correctly identify tasks that are not covered in the scope of work and seek either approval from technical authority for deviation, if necessary or enforce the exclusions in the procedure as applicable Responsible for the implementation of safe work practices through the assessment and subsequent approval of NonRoutine tests as defined by this procedure HSE advisor Responsible for ensuring the worksite safety during the execution of flange management tasks Participate in JSA Construction Manager / Superintendant
Responsible for implementation of the site Safety Management Plan
Roles
Responsibilities / Accountabilities Visually verify all documentation (i.e. FIC) associated with the integrity of the assembly including pressure test reports prior to start up of the asset. C1-C6 documentation is a mandatory process to be followed.
Field/Site Construction Supervisor (Principal & Contractor)
Ensures that the responsible person and all members of the work party are deemed competent to undertake the task, have read and understood this procedure, and its referenced documents Ensures that the requirements of this procedure and the site Safety Management Plan are implemented prior to the activity taking place Acts as the Quality Assurance representative at site by the o Verification of adherence to this procedure and control/assurance checklists of all documents, checklists, and forms o Ensures all the documentation associated to the flange bolting task is attached in the FIC pack.
Site Maintenance Supervisor
Ensures that the responsible person and all members of the work party are deemed competent to undertake the task, have read and understood this procedure, and its referenced documents Ensures that the requirements of this procedure and the site Safety Management Plan are implemented prior to the execution of the activity Participates in the pre-start up meeting and ensures the approved lubricant is selected with the correct torque values identified for the application. Co-ordinates with Operations and Mechanical Engineers regarding any technical enquiries
Delegated Responsible Person at the work site
Responsible for the execution of the task in compliance with this procedure and its referenced documents Immediately reports any incidents, near misses, suspicious behaviour, or new hazards Stops the job immediately on identification of any new hazards not previously identified Ensures that all members of the work party are satisfied that all identified risks are adequately managed prior to the test commencing Responsible for installing information tags and/or completing the required information in the form in Appendix B (Torque record sheet).
Roles Work Party
Responsibilities / Accountabilities Ensures full understanding of this procedure and implements this procedure and its referenced documents to its entirety Participates in and acknowledges the requirements of prestart JSA Immediately reports any incidents, near misses, suspicious behaviour, or new hazards Stops the job immediately on identification of any new hazards not previously identified
Site Personnel
Complies with all exclusion zoning, flagging, barricading and signage Immediately reports any incidents, near misses, suspicious behaviour, or potential hazards Initial/Sign the required documentation as specified in this procedure
3.
ABS Bolt
Definitions/Acronyms
Definition/Expansion Acrylonitrile butadiene styrene Thermal plastic piping Bolt as used herein is an all inclusive term for any type of threaded fastener that can be used in a pressure boundary bolted flange joint assembly such as bolt, stud bolt, cap screw, etc A part of equipment which requires bolting which is not a flange connection (e.g. manways, inspection ports, end caps, etc) Environmental Management Plan Field Installation Checklist The potential for harm, such as injury, property damage or damage to the environment Is the sequential removal and replacement of bolts on flanged joints while under reduced operating pressure. It is carried out one bolt at a time in a predetermined cross pattern Refer to OEUP-1000-PRO-PIP-035 for procedure
Term/Acronym
Closure EMP FIC Hazard Hot Bolting
Insulating flange
A flange equipped with plastic pieces to separate its metal parts, thus preventing the flow of electric current. Insulating flanges are often used in cathodic protection systems to prevent electrolytic corrosion and are sometimes installed when a flow line is being attached to a wellhead Job Safety Analysis is a process used to identify and control hazards associated with a job or task or scope of work that may cause health, safety or environmental harm
JSA
PE PPE Proprietary PTW Risk Event SMP
Polyethylene Personal Protective Equipment Manufactured and sold only by the owner of the patent or brand name Permit to Work A function of both the likelihood and consequence of a specific hazard being realised Safety Management Plan
4.
Health Safety and Environment
Personnel performing any site work must wear approved protective clothing i.e. long sleeve shirt, trousers made of natural fibers, safety footwear and the approved PPE for the work being performed i.e. hearing protection, hard hats as required, eye protection and gloves. Gas detectors are mandatory to be worn, where applicable. All personnel must comply with the relevant site Safety and Environmental management plans.
4.1
Required Tools/Equipment
PPE Gas Detector Spanners, Shifters Pry bar Bolt torque wrench Bolt lubricant (approved for site use) Wire brush Hearing Protection Eye Protection
4.2
Environmental Impact
All works shall be carried out in accordance with Project/Site EMP. Fuel to be stored securely and in well ventilated areas. Notification of environmental incidents shall be made to the Site Supervisor and/or Site Environmental Officer.
5.
No. 1.
Operating Steps
Table 5.1: Operating procedure - step tracking table. Task Step Notes
Step Tracking 1, 2
Task Step Thoroughly clean all threads and bearing faces. Check threads for damage or excessive roughness. Check gasket type, specification, size, rating and condition.
2. 3.
Reject studs and nuts that show thread damage. Clean up excessive roughness. Reject gaskets not to specification, damaged gaskets and asbestos gaskets.
4.
Check nuts and studs for proper size, material spec and cleanliness.
5.
Check flange faces for corrosion, damage, cleanliness and dryness.
Rectify prior to assembly.
6.
Lubricate threads of non-coated bolts with a nickel-based lubricant paste or similar.
NOTE: do not contaminate the gasket or flange face with the anti-seize compound. Following Origin policy no bolt should be used unless lubricant paste or bolt coating is in use.
7.
Align flanges without using excessive force. A pry bar is generally required; manipulate the alignment by levering through mating flange bolt holes. Insert gasket and bolts ensuring full thread engagement.
Ensure the flanges are parallel and that the bolt holes line up. Avoid using the bottom holes for leverage because bottom studs will hold the gasket in place.
8.
Insert bottom bolts to help hold the gasket first. Ensure gasket is not pinched. Ensure there are a minimum of 2 threads protruding from each nut. The bolts are tightened in a criss-cross pattern. Numbers can be written beside the bolt on the flange with a paint pen.
9.
Number the bolts in the order they are to be tightened (as per Appendix A).
No. 10.
Task Step Determine the required torque.
Task Step Notes Manufacturer or suppliers recommended torques should be applied when known. or Appendix B.1 - Torque Chart for Flanges with Nonmetallic Gaskets or Appendix B.2 Torque Chart for Steel Flanges with Non-metallic Gaskets Please Note B.1 is for gaskets with 3mm thickness B.2 is for gaskets with 1.5mm thickness
Step Tracking 1, 2
11.
Tighten all nuts finger tight.
12.
Tighten nuts in order of the numbering used in appendix A to 30% of the final torque value. Continue the sequence until all nuts have been tightened to 30%.
Check that the gasket is centred in the flanges and bolts positioned with the head to the top. Throughout the tightening sequence, check the gap around the flange - if it is not consistent, make appropriate adjustments by selective bolt tightening before proceeding.
13.
After the nuts have been tightened to 30 % of their final torque value use some form of indication.
If the bolt size is adequate (approx > 5/8 inch) use a paint pen to add a stroke to the end of the stud Example first stroke:
if the bolt size is too small the mark will smudge (approx <5/8 inch) use form in Appendix B Torque Record sheet 14. Repeat step 12 to torque all nuts to 60% of the final torque value. Check that the gasket is centred in the flanges and bolts positioned with the head to the top. Throughout the tightening sequence, check the gap around the flange - if it is not consistent, make appropriate adjustments by selective bolt tightening before proceeding.
No. 15.
Task Step After the Nuts have been tightened to 60% of their final torque value use some form of indication.
Task Step Notes If the bolt size is adequate (approx > 5/8 inch) use a paint pen to add a stroke to the end of the stud Example second stroke:
Step Tracking 1, 2
If the bolt size is too small the mark will smudge (approx <5/8 inch) use form in Appendix B Torque Record sheet 16. Repeat step 12 to torque all nuts to 100% of the final torque value. If the gasket begins to deform, the 100% torque value is too high. In this case, use the highest non-gasketdeforming torque for the final torque value. Check that the gasket is centred in the flanges and bolts positioned with the head to the top. Throughout the tightening sequence, check the gap around the flange - if it is not consistent, make appropriate adjustments by selective bolt tightening before proceeding. 17. After nuts have been tightened to 100% of their final torque value use some form of indication. If the bolt size is adequate (approx > 5/8 inch) use a paint pen to add a stroke to the end of the stud Example third and final stroke:
If the bolt size is too small the mark will smudge (approx <5/8 inch) use form in Appendix B Torque Record sheet 18. Re-torque bolts to the final torque value: Start at bolt number 1 and proceed clockwise around the flange and double check that each bolt is fully torqued. 19. Re-torque bolts to the final torque value a minimum of 4 hours after completing step 18: Start at bolt number 1 and proceed clockwise around the flange and double check that each bolt is fully torqued. If no documentation, either via tagging or torque record sheet. Then it must be assumed that retorque has not been complete and step 19 must be completed prior to completing step 20
No. 20.
Task Step When all bolts have been tensioned to the correct torque after minimum of 4 hours, attach an information tag to each flange with the details: Flange Number Date Torque value Lubricant used Installers name Prior to the system being deisolated a FIC check must be completed post assembly Operator to check for the appropriate markings on nuts/studs and that the appropriate information is on the tags attached
Task Step Notes In some cases this will not be practical due to the time interval between completion of installation and commission. As well as other factors including weather, animals, etc. Please keep a copy of this information in Appendix B Torque Record sheet as backup information.
Step Tracking 1, 2
21.
Form A-1000-50-AQ-008 is to be used for the FIC stage. Example of completed symbol on stud if paint pen had been used:
If alternatives were used instead of visual markings the form in Appendix B Torque Record sheet should have been used to store information If no documentation exist to demonstrate retorque after a minimum of 4 hours then step 19 must be repeated prior to completion of FIC 22. After the System has been deisolated: Operations representative to remove tags and store in the Commissioning Pack.
6.
Troubleshooting
1. Check that the correct gasket type has been used 2. Check that the lubricant is suitable If both 1 and 2 are acceptable an alternative bolt coating may have been applied, reducing the friction such that torque values in Appendix C are too high. In this case use the highest non-gasket-deforming torque (check vendor torque requirements) as the final torque.
7.
Record Keeping
For critical steps procedural completion sign-off may be required. The supporting documentation that outlines the critical step is to be signed both by the Operations Technician and the relevant Supervisor as having been completed correctly. The Field Installation Checklist - Flange Bolt Testing (A-1000-50-AQ-008) is required to be completed by the Contractor and checked by the Origin Energy Construction Supervisor for all flanges post assembly and primarily used as a pre-commissioning check list.
During assembly information tags and/or Flange Bolt Torque Record form found in Appendix B are to be used. The decision to use either or a combination of both will depend on the practicality of the situation, i.e. the length between completion of the assembly and commissioning checks. Pre-start Toolbox meetings Job Safety Analysis (JSA) if required Field Installation Flange Bolt Testing (A-1000-50-AQ-008) Information tags and/or Flange Bolt Torque Record
8.
References/Associated Documents
ASME PCC-1-2010 Guidelines for pressure boundary bolted flange joint assembly ASME B31.3-2010 Process Piping A-10050-TS-1009 Technical Specification for Steel Pipe Flange Assembly ASME B16.5-2009 Pipe Flanges and Flange Fittings The Facilities Development Safety Management Plan The Site Operations Safety Management Plan Specific Development Safety Management Plan Specific Development Environmental Management Plan HSE-GDL-005 OEUP-1000-PRO-SAF-012 OEUP-1000-PRO-OPS-001 Origin Manual Handling Guideline Job Safety Analysis Performance of Permit To Work Procedure
9.
Document Information and History

PROCESS OWNER Position Upstream Engineering Manager DOCUMENT HISTORY Rev 0 Date Detailed Changes made in Document Prepared Checked Approved Name John Young
Page 12 of 16
Appendix A
Bolt Tightening Sequence
Figure 1 - Bolt Tightening Sequence
Page 13 of 16
OEUP-INT1000-SOP-OPS-003 Appendix B Sample of Flange Bolting Torque Record Sheet
Page 14 of 16
B.1.
Torque Chart for Flanges with Non-metallic Gaskets
Compressed Non-Asbestos Fibre (C.N.A.F.) gaskets are specified in Origins C150 piping spec rev 1 for class 150 piping. The following class 150 C.N.A.F gaskets can be used for class 150 piping under the listed service conditions:
Nominal PE pipe Size (mm) 125 160 200 225 250 315 355 400 450 500 560 630
Flange Size (mm) 100 150 200 200 250 300 300 400 450 500 600 600 (inch) 4 6 8 8 10 12 12 16 18 20 24 24
Bolt Diameter (inch) 5/8 3/4 3/4 3/4 7/8 7/8 7/8 1 1 1/8 1 1/8 1 1/4 1 1/4
Bolt Quantity (No.) 8 8 8 8 12 12 12 16 16 20 20 20
Target Torque (ft-Ib) 105 185 185 185 290 290 290 435 615 615 860 860 (N.m) 145 250 250 250 395 395 395 590 835 835 1165 1165
General Notes: (1) Installation at ambient temperature. (2) These specifications are for 3.0mm thick full faced gaskets. (3) Values based on coated bolts lubricated with anti seize paste or similar of friction factor 0.12, calculated using KLINGERexpert software. (4) Use of non-metallic gaskets outside of these specifications is allowable but must be supported by vendor advice including a recommended target bolt torque. Vendor advice on torque shall also be sought if coated bolts are used in conjunction with non-metallic gaskets.
Page 15 of 16
B.2.
Torque Chart for Steel flanges with Non-metallic Gaskets
Compressed Non-Asbestos Fibre (C.N.A.F.) gaskets are specified in Origins C150 piping spec rev 1 for class 150 piping. The following class 150 C.N.A.F gaskets can be used for class 150 piping under the listed service conditions:
Nominal Pipe Size (inch) (mm) Bolt Diam. (inch) Target Torque (ft-lb) (N.m) Recommended Gaskets (Klingersil or equivalent) Service Temperature (oC) Service Pressure (kPa)
15
60
80
KlingersilC4509, KlingersilC4509L KlingersilC4430, KlingersilC4409, KlingersilC4409L, KlingersilC4509, KlingersilC4509L KlingersilC4430, KlingersilC4409, KlingersilC4409L, KlingersilC4500, KlingersilC4509L, KlingersilC4509 KlingersilC4400, KlingersilC4400L, KlingersilC4300, KlingersilC6307 KlingersilC4400, KlingersilC4400L, KlingersilC4300, KlingersilC6307, KlingersilC8200, KlingersilC4808 KlingersilC4106 KlingersilC4324, Klingersiltop-chem2003, KlingersilC4300, KlingersilC6307 KlingersilC4324, KlingersilC4300 KlingersilC4106, KlingersilC4324, Klingersiltop-chem2005, Klingersiltop-chem2006
-29 to 38
101.3 to1960 101.3 to1960
20
60
80
-20 to 80
25
60
80
-20 to 80
101.3 to1960
Class 150 only
40
60
80
-20 to 80
101.3 to1960
50
5/8
120
165
-20 to 80
101.3 to1960
80
5/8
120
165
-20 to 80
101.3 to1960 101.3 to1960 101.3 to1960 101.3 to1960
100
5/8
120
165
-20 to 80
150
210
285
-20 to 80
200
210
285
-20 to 80
General Notes: (5) Installation at ambient temperature. (6) These specifications are for 1.5mm thick circular ring type gaskets, not full faced gaskets. (7) Values based on non-coated bolts lubricated with anti seize paste or similar, calculated using KLINGERexpert software. (8) Use of non-metallic gaskets outside of these specifications is allowable but must be supported by vendor advice including a recommended target bolt torque. Vendor advice on torque shall also be sought if coated bolts are used in conjunction with non-metallic gaskets.
Page 16 of 16

OEUP-InT1000-SOP-OPS-0031 PE Flange Assembly Bolt and Nut Tightening

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PE Flange Assembly Bolt and Nut Tightening Standard operating procedure Level 1

PE Flange Assembly Bolt and Nut Tightening

Next Review Date:

Torque Chart for Flanges with Non-metallic Gaskets

Responsible for implementation of the site Safety Management Plan

Field/Site Construction Supervisor (Principal & Contractor)

Site Maintenance Supervisor

Delegated Responsible Person at the work site

Roles Work Party

Closure EMP FIC Hazard Hot Bolting

PE PPE Proprietary PTW Risk Event SMP

Health Safety and Environment

Check flange faces for corrosion, damage, cleanliness and dryness.

Rectify prior to assembly.

Lubricate threads of non-coated bolts with a nickel-based lubricant paste or similar.

Task Step Determine the required torque.

Tighten all nuts finger tight.

Document Information and History

Bolt Tightening Sequence

Figure 1 - Bolt Tightening Sequence

OEUP-INT1000-SOP-OPS-003 Appendix B Sample of Flange Bolting Torque Record Sheet

Torque Chart for Flanges with Non-metallic Gaskets

Bolt Quantity (No.) 8 8 8 8 12 12 12 16 16 20 20 20

Torque Chart for Steel flanges with Non-metallic Gaskets

101.3 to1960 101.3 to1960

Class 150 only

101.3 to1960 101.3 to1960 101.3 to1960 101.3 to1960

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