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Title: Flange Bolting Standard

This document is protected by copyright. No part of this document may be reproduced, adapted, transmitted, or stored in any form byany process (electronic or otherwise) without the specific written consent of Woodside. All rights are reserved.Controlled Ref No: W1000SM3131997 Revision: 2DRIMS No:

3131997

Page 12 of 53Uncontrolled when printed. Refer to electronic version for most up to date information.

4 GUIDANCE ON MAKE UP OF SPECIAL FLANGE TYPES

4.1 Ameron GRE Flange Assemblies

Due to the nature of the fibreglass construction material, all GRE flanged joints should beassembled according to the manufacturers guidelines and recommended bolt torquevalues (see Appendix E).

4.2 DIN Flange Assemblies

Guidelines for the make up of DIN flanged joints are currently under review. Should anyassistance be required regarding DIN Flange Assemblies, contact Technical Services andIntegrity Group (Mechanical) OZE4.

4.3 Non-steel flanges

Only steel flange assemblies are covered by this document. Refer to the mechanicalintegrity custodian (OZE4) for make up of other material flanges (eg. cast iron, plastic).

Title: Flange Bolting Standard

This document is protected by copyright. No part of this document may be reproduced, adapted, transmitted, or stored in any form byany process (electronic or otherwise) without the specific written consent of Woodside. All rights are reserved.Controlled Ref No: W1000SM3131997 Revision: 2DRIMS No:

3131997

Page 13 of 53Uncontrolled when printed. Refer to electronic version for most up to date information.

5 PROCEDURE FOR HOT BOLTING

5.1 Hot Bolting to Replace Corroded Bolts

The practice of replacing corroded bolts one at a time on live systems is widespread inmany industries. The major concern is of a gas leak rather than bolt failure during hotbolting.To check the integrity of the flange is not compromised during this operation, the Taylor-Forge method from ASME was used to generate the calculations in A8000CM001.Based on these calculations hot bolting shall only be carried out on Class 150 and 300flanges that have 8 or more securing fasteners. Hot bolting on Class 600 and 900flanges that have 8 or more studs is also acceptable if the operating pressures are limitedto 8 MPa and 12 MPa respectively, due to inadequate bolting after allowance has beenmade for corrosion.On 4 bolt flanges it is feasible to hot bolt up to Class 900 based on the calculations,however, the possibility of a leak is quite high due to the large bolt spacing. It is thereforeallowable to hot bolt flanges with 4 securing fasteners only with the installation of twoexternal clamps. See Appendix K for guidelines on selection and placement. The flangeclamps that are readily available in the market (Lindapter) are only suitable for Class 150and 300 flanges. These clamps cannot be used on Class 600 or 900 flanges due tolimited space and/or inadequate capacity. Therefore, hot bolting of the flanges with 4securing fasteners is limited to Class 150 and 300.Hot bolting is not permitted on Class 1500 and 2500 flanges due to inadequate boltingstrength and the heightened consequences of a leak developing.A table summarising the hot bolting procedure is given below.

Summary of Hot Bolting Procedure to Replace Corroded BoltsClass 4 securing fasteners8 or more securingfasteners150

Yes (with clamps installed) Yes

300

Yes (with clamps installed) Yes

600

No Yes (limit pressure to 8 MPa)

900

NoYes (limit pressure to 12MPa)

1500

No No

2500

No NoHot bolting is considered to be a potentially hazardous practice and shall only beundertaken when all other options have been considered and there remains anoutstanding, fully justified operational advantage.

Title: Flange Bolting Standard

This document is protected by copyright. No part of this document may be reproduced, adapted, transmitted, or stored in any form byany process (electronic or otherwise) without the specific written consent of Woodside. All rights are reserved.Controlled Ref No: W1000SM3131997 Revision: 2DRIMS No:

3131997

Page 14 of 53Uncontrolled when printed. Refer to electronic version for most up to date information.

In all cases the tightening of joint fasteners shall be done by controlled means. Theflogging of fasteners is not permitted. The removal or existing studs should be donewithout applying excess strain, shocks or heat on the system.Hot bolting shall be controlled under the Permit to Work system. The possibility of a leakshould always be considered and such scenarios should be fully developed, withpersonnel protection and support services available on stand-by. If leaks develop then itis permissible to nip-up these joints whilst the system is pressurised in accordance withSection 5.0. It is preferred that every attempt be made to depressurise the line prior toattempting any tightening of leaking joints.

5.2 Hot Bolting to Replace Non-Corroded Bolts

Due to the extra capacity of the bolts when loss of bolt area to corrosion is not allowedfor, hot bolting of non-corroded bolts is allowed on Class 600 and Class 900 flanges withmore than 8 securing fasteners without limiting the pressures. This is the only change tothe above procedure.A summary of the hot bolting procedure to replace non-corroded bolts is given below.

Summary of Hot Bolting Procedure to Replace Non-Corroded BoltsClass 4 securing fasteners8 or more securingfasteners150

Yes (with clamps installed) Yes

300

Yes (with clamps installed) Yes

600

No Yes

900

No Yes

5B1500

No No

2500

No No

Title: Flange Bolting Standard

This document is protected by copyright. No part of this document may be reproduced, adapted, transmitted, or stored in any form byany process (electronic or otherwise) without the specific written consent of Woodside. All rights are reserved.Controlled Ref No: W1000SM3131997 Revision: 2DRIMS No:

3131997

Page 15 of 53Uncontrolled when printed. Refer to electronic version for most up to date information.

6 TIGHTENING OF LEAKING JOINTS UNDER PRESSURE

6.1 Instructions for Tightening Leaking Joints Under Pressure

Under controlled conditions it is acceptable to tighten a leaking ASME flange or ClampConnectors whilst under pressure. Leaking joints are mostly found during postmaintenance commissioning activities such as leak testing using either nitrogen orhydrocarbons. Experience has proven however, that if the Flanges and Clamps aretightened under controlled conditions using approved procedures such as that detailed onthe Check Lists then the number of leaking joints found will be significantly reduced tothe order of 1% of all joints tested.The results of trials undertaken by SIPM (see reference 12) support this view and provethat tightening leaking joints even under full test pressure can reduce down time withoutcompromising safety.Procedures for tightening leaking joints will vary from case to case depending on theoperational constraints affecting a particular activity. The following criteria should be useda) Bolts loads shall only be checked or tightened on a single bolt at a time.b) Tightening should be attempted with the system pressure at less than 4 MPa.c) Bolt loads shall only be applied using

controlled techniques and equipment suchas torque wrenches, torque guns and hydraulic tensioning gear.d) The recommended bolt loads detailed in this standard can be exceeded asfollows:For ASME Flanges- all sizes 10 %For Destec Clamps- up to size G2 20%,- size G3 to G8 25%,- size G10 and above 30%For Grayloc Clamps- all sizes 50%For Galperti Clamps- all sizes 25%

Note:

Working outside the above instructions should not be attempted without priorconsultation with the appropriate Technical Authority.

Title: Flange Bolting Standard

This document is protected by copyright. No part of this document may be reproduced, adapted, transmitted, or stored in any form byany process (electronic or otherwise) without the specific written consent of Woodside. All rights are reserved.

7 INSULATING FLANGES

The sketch below shows a flange type insulation joint using an insulating gasketassembly to provide electrical isolation between dissimilar piping materials. Insulating joints are designed to prevent galvanic corrosion and/or cathodic current cross flow.Flanges shall be free of pits, gouges, rust, debris, oil and grease. Surface finish shall beno greater than 250 RMS. Check and remove burrs from bolt holes and flanges.Ensure bolts and nuts are clean and nuts rotate freely along length of the stud.Minimise the possibility of steel washer distortion and subsequent damage to insulatingwasher. Nuts should be flat faced to maximise contact area with washer and minimisepossibility of deflection. Steel washers should be flat and extra thick for strength.Open the insulating kit and confirm components are as specified. Check the gasket ID.It should be no greater than the flange ID. The insulating washers shall have sealededges to prevent ingress of moisture.Insulating gaskets that lack history of successful application shall be tested to thesatisfaction of the Principal;

prior

to being considered for evaluation along with alreadyproven gaskets.Align flanges so they are concentric and parallel and insert gasket carefully.

No

lubricant, grease or adhesives shall be used on the gasket or flange faces. Do notdamage sealing element.Line up bolt holes with non-tapered drift pins using preferably three at 120 degreesseparation (large flanges) but at least two at 180 degrees separation. Insert boltsleeves. Do not force! If force is needed recheck / realign flanges.Apply non-conductive lubricant to threads and the nut face contacting the steel washer.This will help to reduce galling of the insulating washer on the flange.

WARNING

Do not use nickel based anti-seize. It is electrically conductive and will provide a path for current leakage across the flange.

Controlled Ref No: W1000SM3131997 Revision: 2DRIMS No:

3131997

Page 16 of 53Uncontrolled when printed. Refer to electronic version for most up to date information.

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