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HAZARD ASSESSMENT:
1. Improper use of tools or 1. Worker could suffer 1. Use proper PPE and
using faulty tools. personal injury if not using follow procedures on use
tools properly. of tools.
2. Physical strain.
2. Back or muscle strain 2. Use lifting equipment
as a result of improper or use buddy system for
lifting technique. two man lifts.
SAFETY EQUIPMENT:
Safety Glasses with side shields, hard hat, steel toe boots, FR Clothing, gloves, personal gas
monitor and torque wrench.
SAFETY NOTE:
Hydrocarbon products are very susceptible to leaking through improperly fastened joints.
Personnel shall adhere to the following instructions to determine all connections are properly
fastened and free of leaks. These instructions are intended for all replacement work as well
as new additions or constructions.
PROCEDURE:
1 . Flanges: all flanges shall be inspected for imperfections and damage such as lateral
scores and dents across the gramophone finish. If any flanges are found to be damaged;
they must be replaced, especially during new construction or additions.
2. Gaskets: shall be inspected for flattened area, tears, breaks and other imperfections that
could cause leaking joints. Any gasket found damaged shall be rejected and a
replacement provided.
3. Bolts, studs and nuts: Those require replacing or for any additions or new construction
shall be as per the grade stipulated on drawings. All bolt and stud threads shall be
inspected for imperfections such as flattened threads, broken threads, cross threads, etc.
Nuts shall be similarly checked for thread damage. Ensure that the nuts run down the bolt
or stud freely; replace any damaged or unfit pieces.
5. Threaded fittings, nipples and valves: shall have all threads inspected for imperfections
and damage such as scoring, flats, broken or cross threading, etc. Reject or replace all
damaged fittings. Apply one wrap of Teflon tape to all male ends of any threaded
connections (Loctite Teflon Thread Sealant #59231 or #59241 or equivalent is
recommended). This is followed by applying SWAK or equivalent thread dope on top on
the wrap of Teflon tape to the leading threads of the fittings prior to fastening the item in its
intended location. Where certain valves are supplied with stainless steel bodies and
threads, take due care and attention to ensure that threads or any adjoining carbon steel
threaded connections are not damaged or scored by the stainless steel threads. The stainless
steel connection does not require as much torque applied to make a tight leak free connection
as the equivalent carbon steel threaded connection.
6. Assembly of flanged connections shall use the following sequence to make a tight leak
free joint:
. Ensure all flanges, gaskets, bolts, studs and nuts are free of dirt, mud, grit, etc.
. Bring flanges together ensuring there is sufficient gap to install the gasket. Flanges shall
be aligned so that there is not any hi-low between the mating flange faces.
. Ensure that the bolts, studs and nuts have been lubricated.
. Install two or three bolts near the bottom of the flange to receive and cradle the gasket.
. Install gasket between the flanges.
. Install remainder of the bolts and studs.
. Tighten all nuts to finger tightness. Center the studs between the nuts so that an equal
number of threads extend past the nut on each side of the connection.
. Tighten bolts or studs starting first at the 12 oclock position, 6 oclock position, 3 oclock
position, 9 oclock position. Then alternating out, remember when you tighten one bolt or
stud you then must tighten the one directly across from it.
Tighten bolts or studs in the 12, 6, 3 and 9 oclock positions using 25% of required torque.
Tighten the remaining bolts or studs in sequence to 50% of required torque.
Tighten all bolts or studs in sequence to 75% of required torque.
Tighten all bolts or studs in sequence to 100% of required torque.
Note: If the flanges are difficult to align and it becomes necessary to use the bolts or studs
to bring the flanges together, all bolts or studs and nuts shall be replaced with new ones
after the initial bolt-up has been made. Follow the same steps as previously detailed in this
procedure to fasten the connection the second time.
The following shows recommended bolt-up specifications and bolt or stud loadings.
7. Torque and Stretch Specifications for Flanged Joints
Requirement: 40% ofyield unless otherwise specified.
Stud/bolt material L.7 10500 psi yield strength.
1 1/2 .0028 36
2 5/8 .0036 74
1 5/8 .0036 74
2 5/8 .0036 74
10 1 .0066 318
16 1 .0090 656
18 1 .0100 656
20 1 .0100 656
1 5/8 .0036 74
6 1 .0066 318
10 1 .0090 656
12 1 .0100 656