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Zakum Development Company (ZADCO)

UZ750 Project
Record No: UZ750-P7512-Q-SR-xxxx
Title: Piping Flange Management
Page 1 of 4

Project Scope:
AUP ECW EPC-1 EPC-2

Date: Contractor: Petrofac Emirates


Sub-Contractor:
Performed By: Discipline: Quality
Location: Possible Actual
> 80%
Attended By: Overall Assessment
60 – 79%
Score:
< 59%

Compliant Y/N
Level of
Item Checkpoints Or
Compliance
Comment

Is the Flange management procedure approved by


1. Yes, No, N/A
Company available for reference.
Are flanged joints uniquely identified on isometric
2. Yes, No, N/A
drawings.
Is Flange Management Database being maintained and
3. up to date. - (Please refer flange management Yes, No, N/A
procedure P7512-PB-2000-G-0106 for details.)
Are following records completed.
 Sample Joint Integrity record.
4. Yes, No, N/A
 Joint Completion Certificate (JCC)
 Witness Joint Register
Do construction and/or commissioning functions provide
5. broken flange notice if flange joints are broken for any Yes, No, N/A
reason.
Are flange tags adequate (material used, legibility of
6. markings.) Yes, No, N/A

Is classroom and practical training provided for personnel


7. (supervisor, inspectors and workers) performing flange Yes, No, N/A
management.
Is a register of trained operators maintained and available
8. Yes, No, N/A
Are only trained personnel with Valid I/D Cards
performing flange management activity. Verify inclusion
in register.

I. Operator #1 – Name…………………………….

9. II. Operator #2 – Name……………………………. Yes, No, N/A


III. Operator #3 – Name…………………………….

IV. Operator #4 – Name…………………………….

V. Operator #5 – Name…………………………….

Level of Compliance. 5 - Excellent; 4 – Good; 3 - Acceptable; 2 - Insufficient; 1 - Deficiency Exists


* Delete not applicable

Distribution: UZ750-PM; UZ750-Q; CONTRACTOR PM & Q; SUB-CONTRACTOR PM & Q

Form Number UZ750-QM-PL-CK-0075 Rev A


Record No: UZ750-P7512-Q-SR-XXXX
Piping Flange Management
Page 2 of 4
Compliant Y/N
Level of
Item Checkpoints Or
Compliance
Comment

Is calibration of manual torque wrench, hydraulic torque


wrench and tensioning machine valid . Record serial
number & certificate number
10. I. Serial number…………….…………Certificate number………………………... Yes, No, N/A
II. Serial number…………….…………Certificate number…………………….…..

III. Serial number……………….………Certificate number………………….……..

Are permanent gaskets colour coded as per ASME 16.20


11. and Specification For Marking And Colour Coding Yes, No, N/A
P7512-TS-2000-P-0011
Are fasteners (studs and nuts) Colour coded as per
12. Specification For Marking And Colour Coding Yes, No, N/A
P7512-TS-2000-P-0011
Are temporary fastens and gaskets clearly
13. Yes, No, N/A
identified as temporary by means of Colour coding.
Is a register is maintained to ensure that all Temporary
14. Yes, No, N/A
gaskets are removed
The following checks are to be conducted on sample 10 flanged joint. Samples to include a mix of configurations –
pipe-pipe; pipe-valve; pipe- equipment. Record drawing / joint numbers checked on Attachment #1
Is it safe to conduct inspection – consider;
 Access & egress
15.  Scaffolding Yes, No, N/A
 Lighting
 Other nearby activities affecting inspection
Is flange sealing face's finish compliant with the flange
16. material's specification or the manufacturer's Yes, No, N/A
recommendations. Record inspections;
Are flange faces protected at all times and free from
17. damage, grease and protective coatings – sample Yes, No, N/A
inspection
Are spiral wound gaskets for use with raised face flanges
18. Yes, No, N/A
provided with both inner and outer guide rings
Are gaskets re used
19. Yes, No, N/A
Are insulating gaskets used as per recommendation and the
20. applicable torque values followed as per vendor Yes, No, N/A
recommendations at dissimilar flange connections
Are pipe spool / valve / instrument internals free from debris
21. Yes, No, N/A
and foreign materials before box up. Bolt holes are cleaned

22. Are identification markings of stud & nut visible Yes, No, N/A

Are Sealing faces flat, parallel, aligned and in good condition


23. Yes, No, N/A
and free of defects.
24. Is gasket of the correct type – material & pressure rating Yes, No, N/A
25. Is gasket correctly seated – centralized between faces.
Is stud and nut material correct; is correct stud length. Are
26. Yes, No, N/A
identification markings of stud & nut visible
Are studs and nuts free-running , in good condition, free
27. Yes, No, N/A
from corrosion and thread damage.
28. Is preservation applied to threads. Yes, No, N/A

Level of Compliance. 5 - Excellent; 4 – Good; 3 - Acceptable; 2 - Insufficient; 1 - Deficiency Exists


* Delete not applicable
Form Number UZ750-QM-PL-CK-0075 Rev A
Record No: UZ750-P7512-Q-SR-XXXX
Piping Flange Management
Page 3 of 4
Compliant Y/N
Level of
Item Checkpoints Or
Compliance
Comment

Are flange management tags in place.


29. Check of details on the tag are filled correctly – verify same Yes, No, N/A
in flange joint register
Check that correct tightening method (Manual Torque Wrench, Hydraulic torque wrench , hydraulic tensioning ) is
used as per stud bolt size in accordance with project flange management procedure.
Torqueing
30. Is approved lubricant, suitable for service being used Yes, No, N/A
Is the approved tightening sequence being used utilizing
the cross-bolt tightening method.

 1st Pass: 30 % of specified torque value

 2nd Pass: 60 % of specified torque value


31. Yes, No, N/A
 3rd Pass; 100 % of the specified torque
value,

 Final Pass: This will be a repeat pass


followed by clockwise direction at 100% of specified
torque value.
32. Are flanges checked for square-ness after each pass. Yes, No, N/A
Tensioning
33. Is specific procedure approved and available Yes, No, N/A
Are operators trained & qualified to use tensioning
34. Yes, No, N/A
equipment.
Are sufficient “tensioners” being used for the number of
35. stud bolts to be tightened – min 50% i.e. 12 studs require Yes, No, N/A
6 tensioning tools operating at the same time.
Are manufacturer’s / sub-contractor specific
36. Yes, No, N/A
recommendations being followed
Flanges checked for square-ness after each
37. Yes, No, N/A
tensioning phase.
COMMENTS:
Act. Finding Action CAR/PAR/NCR No
Issue CAR; Issue PAR
Issue NCR; Issue Observation
No Action Required
Issue CAR; Issue PAR
Issue NCR; Issue Observation
No Action Required
Issue CAR; Issue PAR
Issue NCR; Issue Observation
No Action Required
Issue CAR; Issue PAR
Issue NCR; Issue Observation
No Action Required
Issue CAR; Issue PAR
Issue NCR; Issue Observation
No Action Required
Issue CAR; Issue PAR
Issue NCR; Issue Observation
No Action Required

Level of Compliance. 5 - Excellent; 4 – Good; 3 - Acceptable; 2 - Insufficient; 1 - Deficiency Exists


* Delete not applicable
Form Number UZ750-QM-PL-CK-0075 Rev A

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