Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
(GUPCO)
Origin
Code
GU
Location
0000
Disc
Code
PM
Doc
Type
PRO
Sequential
Number
0047
Rev.
C2
Rev.
Issue Date
Prepared By
Checked By
Approved By
A1
C1
18/11/08
10/12/08
REVIEW
Approved for use
H. HELMY
S. WRIGHT
S.TANTAWY
H. HELMY
S. WRIGHT
S.TANTAWY
C2
08/09/09
Revised in Italics to
include Hydratight
Comments
H. HELMY
S. WRIGHT
S.TANTAWY
TABLE OF CONTENTS
1.0 INTRODUCTION............................................................................................................ 3
1.1
Scope.............................................................................................................. 3
2.2
3.0 Bolting........................................................................................................................... 3
4.0 Quality Records
APPENDIX A
APPENDIX B
APPENDIX C
APPENDIX D
APPENDIX E
APPENDIX F
Page 2 of 12
INTRODUCTION
Scope
This Specification defines the minimum requirements for the management of bolted joint
integrity at both Onshore and Offshore facilities operated by GUPCO during the delivery of
GUPCO Projects.
Contractors or Sub-Contractors performing works on behalf of GUPCO Projects shall adhere to
these guidelines. Any deviation by the Contractor or Sub-Contractor is to be approved in writing
by the authorised GUPCO representative prior to performing the work.
2.0
2.1
2.2
Process Piping
Pipeline Transportation Systems for Liquid Hydrocarbons and
Other Liquids
Gas Transportation and Distribution Piping Systems
Design and Installation of Offshore production Platform Piping
Systems
Recommended Practice for Design and Installation of Pressure
Relieving Systems.
Sulphide Stress Cracking Resistant Metallic Materials for
Oilfield Equipment
Installation of Ductile Iron Water Mains and their Appurtances
PVC Design & Installation
Project Specifications
GU-0000-PM-PRO-0031
GU-0000-PM-PRO-0035
GU-0000-PM-PRO-0036
GU-0000-PM-PRO-0038
GU-0000-PM-PRO-0039
GU-0000-PM-PRO-0041
GU-0000-PM-PRO-0043
GU-0000-PM-PRO-0044
3.0
Hydrotest Procedure
Handover and Completion Certificates
As-Built Dossier Index
Dimensional Control Procedure for Piping
Works
Dimensional Control Procedure for Piping
Works
Inspection, measuring & test Equipment
Calibration & Control Procedure
Inspection & Test Plan Control Procedure
Construction Procedure
BOLTING
All flange bolting shall be checked for correct grade and any damage to coatings and threads
prior to fitting.
All flanges bolting shall be free to move through mating flanges holes in a plane at right angles
to the flange face and parallel to the pipe run (misalignment of flange holes resulting in knurling
of nut on the flange will be rejected)
All flange machine bolts shall extend fully through their nuts and shall have bolt heads all one
side of the joint.
Page 3 of 12
Each stud bolt shall be assembled with a minimum of one full thread beyond the nut at each
end but preferably 2 to 3 threads at each end.
Each stud bolt 11/8 diameter and larger shall be assembled as above but with 1 1/2 bolt
diameters beyond the nut at one end but in no case less than a minimum of one bolt diameter
beyond the nut at one end to facilitate installation using a hydraulic bolt tensioning device.
Stud bolts shall not be cut from lengths of studding and grade and manufacturer markings shall
be clearly visible for checking after installation.
All nut bearing faces and threads of bolts and stud bolts shall be lubricated with API 5A2 or
equal lubricant prior to fitting. BP standard bolting lubricant is Dow Corning Molycote 1000
which has a coefficient of friction of 0.11 and is to be used in preference to other bolting
lubricants when available.
Bolt torque/tension shall be applied in three stages using the diametrical sequence, 1st stage
30%, 2nd stage 60%, 3rd stage 100% Refer to appendix B.
Prior to pressure testing all flanged joints shall be tightened in accordance with this procedure
and the Joint Integrity certificate (appendix F) completed by the contractor and witnessed by
GUPCO. This record shall form part of the final documentation handover package
4.0
QUALITY RECORDS
Records of all flanges subjected to Joint Integrity Management shall be maintained.
These records shall form part of the final handover documentation.
A sample Joint Integrity certificate is shown in appendix F.
Page 4 of 12
Page 5 of 12
Page 6 of 12
Page 7 of 12
APPENDIX D
Bolt Stress The table below gives torque values required to achieve an average bolt stress equivalent
to 50 % of the bolt yield stress.
(Care should be taken to select the correct coefficient of friction)
Lubricant / (Coefficient of friction )
HTL654
HTL655
Copper
Nickel /
Molycote 1000
(=0.10)
(=0.11)
Torque required lbf.ft(Nm)
79 (107)
85 (115)
139 (188)
151 (205)
223 (302)
242 (328)
333 ( 451)
362 (491)
508 (689)
553 (750)
Bolt
Size
(in)
Bolt
Tension
(lbs)
Min
Yield
(psi)
HTL653
MOLY
(=0.06)
5/8
7/8
1
1
1/8
1
1
3/8
1
1
5/8
1
1
7/8
2
2
2
2
3
3
3
10305
15466
21525
28323
38902
105000
105000
105000
105000
105000
52 (71)
92 (125)
146 (198)
219 (297)
331 (449)
49560
61530
105000
105000
459 (622)
616 (835)
710 (963)
959 (1300)
773 (1048)
1044 (1415)
1338 (1814)
1816 (2462)
74760
89250
105000
105000
804 (1090)
1027 (1392)
1258 (1706)
1614 (2188)
1372 (1860)
1761 (2388)
2393 (3245)
3081 (4177)
105000
122325
105000
105000
1288 (1746)
1592 (2158)
2031 (2754)
2519 (3415)
2216 (3004)
2751 (3730)
3888 (5217)
4836 (6557)
140700
181125
226800
251750
302100
357675
418000
105000
105000
105000
95000
95000
95000
95000
1937 (2626)
2766 (3750)
3805 (5159)
4602 (6239)
5976 (8102)
7613 (10322)
9526 (12915)
3074 (4168)
4411 (5980)
6091 (8258)
7392 (10022)
9627 (13052)
12294 (16668)
15414 (20898)
3358 (4553)
4822 (6538)
6663 (9034)
8089 (10967)
10540 (14290)
13464 (18254)
16887 (22895)
5914 (8018)
8521 (11553)
11806 (16007)
14367 (19479)
18753 (25425)
23995 (32532)
30137 (40860)
Dry
(=0.20)
146 (198)
258 (350)
415 (563)
620 (841)
953 (1292)
Page 8 of 12
BOLT
SIZE
INS
5/8
7/8
1
1 1/8
1
1 3/8
1
Up to &
incl 3
RATING
900# & ABOVE
NA
NA
MW
MW
MW
HT
HT
HT
HT
HT
RATING
600#
MW
MW
MW
MW
OR NM
OR NM
OR NM
OR NM
MW
HT
HT
HT
HT
HT
RATING
150#-300#
MW
MW
MW
MW
OR NM
OR NM
OR NM
OR NM
MW
HT
HT
HT
HT
HT
HT
Hydraulic Tensioning
MW
NM
NA
AT HYDROTEST
BOUNDARIES ALL
RATINGS
MW
MW
MW
MW
MW
HT
HT
HT
HT
HT
Page 9 of 12
Project Title:
Maintenance No:
Work Pack No:
* YES/NO/NA
SIGN:
FORM JI1
* YES/NO
SIGN:
SITE:
* YES/NO
SIGN:
4.1.2
* YES/NO/NA
SIGN:
* YES/NO
SIGN:
MC1 No:
LOCATION :
SYSTEM :
4.2
Com
missioning
Installation Phase
PRE MC1 ACCEPTANCE
Tag
Number
Location
(P&ID and
Description)
Joint
Assembled by
(Print)
Signature to
Confirm
Compliance
with Assembly
Procedure
1
2
3
4
F4
F6
F9
F8
m.ebrahem
m.ebrahem
m.ebrahem
PMS
riggers
Torque Tightening
Required
Torque
Value+
(Nm or ftlb)
Hydraulic
Tool Model
Required
Hydraulic
Tool
Pressure+
(barg or psig)
Actual (Hand)
Torque
Value+ (Nm
or ft-lb) or
Hydraulic
Tool
Pressure+
(barg or psig)
1816 ft
(2462)
HTWP3140P-A
1816ft
(2462)
HTWP3140P-A
1816ft
(2462)
HTWP3140P-A
8500psi
N\A
N\A
N\A
N\A
8500psi
8500psi
F7
PMS
riggers
N\A
N\A
Required
Residual Bolt
Stress+
(N/mm2 or
lbs/in2 )
Reqd Tool
Pressure
1st Pass+
(barg or
psig)
Actual Tool
Pressure
1st Pass+
(barg or
psig)
Hydraulic
Tool Model
Reqd Tool
Pressure
2nd Pass+
(barg or
psig)
Actual Tool
Pressure
2nd Pass+
(barg or
psig)
-------
-------
-------
-------
-------
-------
-------
-------
-------
-------
-------
-------
-------
-------
Joint Tightened
by (Print)
Date
Tightened
Signature to
Confirm
Compliance with
Tightening
Procedure
A.omara
05/07/
2010
A.omara
05/07/
2010
-------
A.omara
06/07/
2010
-------
-------
PMS
riggers
24/08/
2010
-------
-------
-------
N\A
-------
-------
-------
PMS
riggers
24/08/
2010
N\A
-------
-------
-------
PMS
riggers
24/08/
2010
-------
-------
-------
-------
-------
-------
PMS
riggers
24/08/
2010
-------
-------
-------
-------
-------
-------
PMS
riggers
24/08/
2010
------N\A
N\A
N\A
5
SHT of
Leak
Tested by
SL1 Leak
Test
Number
Operational Phase
POST SH1 ACCEPTANCE
Service
Test
after
start up
Service
Test
after
warm
up
Service
Test
Period
Service
Test
Period
Service
Test
Period
Service
Test
Period
Temporary
Tag
Removal
Date
N\A
6
F12
PMS
riggers
N\A
N\A
N\A
F10
PMS
riggers
N\A
N\A
N\A
N\A
8
F11-F16
PMS
riggers
N\A
N\A
N\A
N\A
------------------4.4
Parts A & B to be completed before the SH1 can be signed and the equipment safely operated
+
4.5
Please state units
4.6
Bolt Lubricant To Be Used for Torque Tightening:
COMPLETED
APPROVED BY
REMARKS (include any procedural non-compliances);
BY
FLANGES FACE INSPECTED BY - CIC -ONLY
COMPANY
GUPCO.ENG
PMS
ONE BOLT IN F6 WAS SHORT AND2 BOLTS SHORT IN F15
SIGNATURE
INSTALL BOLTS ASTEM193-B8 IN FLANG F4
DATE
Tag
Number
Location
(P&ID and
Description)
Joint
Assembled by
(Print)
Signature to
Confirm
Compliance
with Assembly
Procedure
Torque Tightening
Required
Torque
Value+
(Nm or ftlb)
Hydraulic
Tool Model
Reqd Tool
Pressure+
(barg or psig)
Actual (Hand)
Torque Value
(Nm or ft-lb)
or Hydraulic
Tool
Pressure+
(barg or psig)
Part B
Hydraulic Bolt Tensioning
Required
Residual Bolt
Stress+
(N/mm2 or
lbs/in2 )
Reqd Tool
Pressure
1st Pass+
(barg or
psig)
Actual Tool
Pressure
1st Pass+
(barg or
psig)
Hydraulic
Tool Model
Reqd Tool
Pressure
2nd Pass+
(barg or
psig)
Actual Tool
Pressure
2nd Pass+
(barg or
psig)
Joint Tightened
by
(Print)
Signature to
Confirm
Compliance with
Tightening
Procedure
Date
Tightened
Leak
Tested by
SL1 Leak
Test
Number
Part C
Service
Test
after
start up
Service
Test
after
warm
up
Service
Test
Period
Service
Test
Period
Service
Test
Period
Service
Test
Period
Temporary
Tag
Removal
Date