Professional Documents
Culture Documents
To provide work and process controls to achieve high level of leak tightness integrity to properly designed Bolted Flange Joint Assemblies
Uniform use of this procedure by and other Contractor personnel is expected to result in a ero incidence rate of flange leaks
SCOPE
This process is applicable to flanged !oint assemblies for"
#iping $alves %eactors $essels &rums 'xchangers Boilers Coalescers and other e(uipment using flanged !oints administered at all !obsites
SCOPE
This process is to be implemented in con!unction with the approved design standards) This process is applicable to the field offices that purchase* receive* field fabricate* inventory* install* erect* and inspect piping and piping related components)
SCOPE
&eficiencies identified during in+process monitoring and final inspections* shall be documented and tracked in accordance with the individual site practices for Control of Deficient Items. Any aboveground piping within the !urisdiction of A,-' ,ection . #ower Boilers* and A,-' ,ection B/0)0 #ower #iping* and any work related to A,-' ,ection $... $essels* shall be executed in accordance with the A,-' -anual for A,-' Code Construction and additional re(uirements stated in the Bolt Flange Joint Assembly procedure)
Definitions
Fasteners 1 all bolting* studs* nuts* and washers used in the assembly of flanged !oints) Flange Maps are isometrics drawings* sketches* e(uipment drawings* and2or #3.&4s that 5map6 flange locations and identifies each flange connection with uni(ue numbers)
Definitions
Flange Tags are uni(uely numbered tags generated for each flanged !oint) The numbered tags correspond to the flange connections identified on corresponding flange maps) These tags contain all the pertinent information needed for the work scope* 7C inspections* and final checkout) Material Specifications provide information as to the material types* si es* and grades to be used* to include flanges* fasteners* and gaskets)
Definitions
Inspection and Test Plan (ITP) is a document that outlines examination* inspection* and2or hold points* and witness points activities) Flange Tightening Method is used to tighten flanged connections as pre+determined and specified on the flange maps) The method used can be indicated on flange tags so that the relevant information is communicated to persons directly responsible for the assembly of flanged connections)
Training
.n general* all personnel with duties associated with the bolted flanged !oint assembly program are to receive training) All training is to be documented) The BFJ Progra! "ualit# Training Matri$ lists all affected personnel and their corresponding level of needed training)
%esponsibilities
Site Manager 8,-9 ensures that the re(uirements of this :ork #rocess are properly implemented) Superintendents are responsible for the overall (uality of work performed by maintenance and construction personnel for their assigned area8s9) Site "ualit# Control Manager 87C-9 manages the 7uality Control functions for the pro!ect* provide oversight* and direct the work of the site 7C.4s) The 7C- addresses any deficiencies in the BFJA program with appropriate personnel to assure continued compliance with the program)
%esponsibilities
"ualit# Control Inspectors ("CI) are responsible for" #erforming inspections as per the .nspection and Test #lan) $erify and monitor the use of -aterial and Test '(uipment 8-3T'9 $erify bolt tor(uing re(uirements per the flange maps) %esponsi&le Person (%P) is the craft person responsible for" $isually verifying that the components and materials Assembling bolted flange !oint connections while maintaining safe work practices
%esponsibilities
Piping Fore!an ( PF ) is responsible for" Understanding the work scope and re(uirements of this process Adhering to pro!ect drawings and specifications -aintaining good workmanship and fulfilling all (uality re(uirements of the work and targeting punch+list items associated with completed work activities Assigning trained personnel to assemble flanged !oint connections Arranging all re(uired work permits* tools* e(uipment* scaffolding* and consumable material for the work activities Coordinating and scheduling work activities based on pro!ect schedule re(uirements 'xamining and verifying BFJA4s in accordance with the .T#4s
%e(uirements
'or( Process All materials and workmanship shall fully comply with the design drawings* Client specifications* and applicable Codes and ,tandards) Field changes to design documents shall not be performed without prior written approval from the Client) All measuring and test e(uipment used during the installation* testing* and verification of piping systems shall meet the re(uirements of T.; procedure -T'+0* Control of -easuring and Test '(uipment) All material specifications and applied tightening method information must be disseminated to personnel assigned to flange mapping)
Preplanning cti)ities
#re+activity construction meetings should be held to finali e the scope of activities prior to the commencement of work or unit blinding)
A review of the .nspection and Test #lan for BFJA4s and referenced documents shall be performed by the 7C-) The re(uired 7C and Client <old points shall be communicated to pertinent personnel at this time)
#replanning Activities
#iping ,upervision8#,9 shall maintain a full understanding of the work scope and installation criteria)
The #,* working with the 7uality Control personnel* shall develop the leak test program as per the procedure to ensure that all piping is tested is in accordance with the pro!ect specifications)
'or( Preparation*Initiation
Assigned personnel will have the responsibility of providing a blind list and of hanging of blind tags at all blind locations) This will be done prior to the hanging of flange tightening tags by craft personnel) Applicable personnel will have the responsibility for generating flange tightening tag lists for all flanges to be disturbed during each2any activity 8i)e)* Turn+Around* %outine -aintenance* Capital #ro!ect* etc)9) This list will be maintained and appended should the scope of the activity be advanced) All disturbed flanges will be identified using a uni(ue numbering system) This system numbering will be e(uipment* unit outage* and2or pro!ect specific) The determination of the tightening methods to be employed shall be indicated on the Flange Tags)
-echanical Joints
Flanged valves shall be checked for the following"
Check* globe* and control valves are installed with indicated flow in the correct direction as indicated on the #3.& -anufacturer4s name tag description agrees with stock code number 8if used9* description* and trim)
All BFJA4s shall be tightened using the method assigned) As flanges are tightened* the responsible craftsmen will complete the re(uired entries on the tag* sign and date* and inform his appropriate foreman or supervisor of the connection completion) The foreman or his designee will then check the flange for proper gasket* proper type of bolting 8i)e)* nuts and studs9* proper flange alignment* and bolt tightness) .f all is correct* the foreman or designee will sign the flange tag and notify the 7C representative that the flange is ready for inspection) 7C will verify the flange installation is in accordance with the .T#) :hen .T#4s re(uire witness or holds by the Client* the 7C inspector shall make those notifications to Client) Upon final acceptance* the 7C .nspector will remove the Flange Tightening Tag8s9 and turn them into the ,ite 7C -anager)
?@A0B
System requires Bolt/Nut Replacement ___Yes___No
CCCCCCCCCCCCCCCCCCCCCCCCCCCCC #3.& Do) FLANGE TIGHTENING TAG F%=DT UD.T"CCCCCCCCCCCCCCCCCCCCCCCCCCCCC '7U.#2.&"CCCCCCCCCCCCCCCCCCCCCCCCCC &AT'" CCCCCCCCCCCCCCCCCCCCCCCCCCCC C%AFT,-AD" CCCCCCCCCCCCCCCCCCCCC
PRINT NAME
B=>T ,#'C.F.CAT.=D" CCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCC B=>T, %'#>AC'&" CCCCE', CCCC D= ;A,F'T ,#'C.F.CAT.=D" CCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCC .D,#'CT F>AD;' FAC' CCCE', CCCCD= CCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCC
STENCIL/COMPANY
CCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCC
SIGNATURE/DATE
CCCCCCCCCCCCCCCCCCCCCCC CCCCCCCCCCCCCCCCCCCCCCC
SIGNATURE/DATE
D': ;A,F'T .D,TA>>'& CCCCE', CCCCD= =$A> %.D; .D,#'CT'& CCCCE', CCCCD= CCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCC
STENCIL/COMPANY
Foreman
CCCCCCCCCCCCCCCCCCCC
PRINT NAME
CCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCC
SIGNATURE/DATE Below is to be used only for blind installation
_____________________
,ignature CCCCCCCCCCCCCCCCCCCCCCCCC
SIGNATURE/DATE
CRAFTSMAN ________________________
PRINT NAME _______________________________ STENCIL/COMPANY _______________________________ SIGNATURE/DATE
7uality ControlCCCCCCCCCCCCCCCCCCCCCCCC
PRINT NAME
C=-#'T'DT #'%,=DCCCCCCCCCCCCCCCCC
PRINT NAME ________________________________ STENCIL/COMPANY ________________________________
CCCCCCCCCCCCCCCCCCCCCCCCC
SIGNATURE/DATE
0GI D#, I GG
020L 020L 020L 02LB M020L
D#, J GB
020L 020L 020L 02/G M020L
sse!&l#
Bolt holes of mating flanges may be brought into initial alignment using a spud wrench or other tool) The alignment tolerances provided in Table --0 shall be recogni ed) Flange 5makeup6 shall be done without the use of gasket sealing compounds) The gasket shall be inserted* and centered between the flanges and nuts hand tightened to hold the gasket in place) Assure the color coding of spiral would gaskets) 8attachment J9 :hen flanged !oints are in hori ontal lines* gaskets without centering devices such as ring !oint gaskets shall be lowered to the bolts for retention and then raised into position)
sse!&l#
The remaining bolts and nuts shall be installed and hand tightened with the flange faces parallel) Care shall be taken to assure proper seating and centering of the gasket within the allowable tolerances) ,nug tightening with a combination wrench prior to tensioning is permitted on large flanges) Bolts should be installed so that only one to three threads show past the nut on either side)
sse!&l#
#neumatic impact wrenches may only be used when controlled measures are taken to insure accurate tor(ue) The procedure provides re(uired tor(ue values based on bolt si e and flange rating) This specification will be applicable to standard flanges in accordance with A,-' B0L)H and A,-' B0L)B? ,eries 5A6 and ,eries 5B6 studs) 'xamples of the tightening se(uences for different flanges are shown in Figure 0) ,imilar se(uence patterns shall be used for flanges having different numbers of bolts)
20 8 14 4 10 18
13 21 3 11 19 7
24- BOL TS
18 10 2 23
15
sse!&l#
Two diametrically opposite bolts shall be tightened either simultaneously or in direct se(uence) Care shall be taken to prevent over+tightening one side of the flange to prevent gasket crushing or flange distortion* especially when tightening flanges containing ring !oint* spiral wound* or similar type gaskets)
sse!&l#
.n the case of flanged !oints that re(uire controlled tor(uing* it is recommended that initially two diametrically opposite bolts shall be initially loaded utili ing tor(ue wrench tightened to GHN of the tor(ue load value listed in the procedure* either simultaneously or in direct se(uence) <owever* in some cases lower initial tor(ue load values may be re(uired to prevent misalignment or distortion of the gasket) The tightening se(uence provided in the procedure should be followed until all bolts are tightened to the GHN tor(ue load value) The se(uence of tightening shall be repeated at H@N and then 0@@N of the tor(ue value) Bolts shall be tightened in three steps to obtain the tor(ue load values listed in the procedure) 'ach step must follow the se(uencing pattern prescribed)
sse!&l#
:hen flanged !oints are assembled with hand wrenchesO the se(uence in in the procedure shall be used with an effort to approximate the tor(ue values) .f flange !oints re(uire hydraulic tensioning* this work will be performed by a subcontractor that speciali es in controlled bolting and with experience in hydraulic tensioning methods) ,pecific re(uirements regarding the basic (ualifications of this contractor and their work practices are detailed in the procedure) After the flanged connection has been fully tightened with hand wrenches* the !oint shall be inspected for uniform bolt loading by wrench testing each bolt in the same se(uence listed until all bolts are !udged to have the same level of tightness)
sse!&l#
=nce the flange !oint is assembled* the craftsman shall initial the applicable examination entries on the flange tag and alert his foreman or designee for verification of the BF>A) The foreman or designee will verify the BFJA* initial the flange tag for acceptance* and notify 7C for inspection All flange connections that re(uire controlled tor(uing or hydraulic tensioning must be documented by the craftsperson) At a minimum this documentation shall include the Control >oaded Flange Connection &ata ,heet as seen in the procedure)
Proper Flan e Materials and Ratin Condition o% Flan e Face (A)rasions* rooves* r!st+ St!ds and N!t Material St!d and N!t Condition Gasket Material Gasket Condition (Cr!s,ed or )ent-+
/ork Practice
'es No
/orker Trained Proper Tools Sa%e /ork Practices Proper 1andlin and Place#ent o% Gasket Proper Se0!encin Proper Tor0!in E0!ip#ent Proper Ti ,tness o% St!d Co#pleted Asse#)l. Marked and $nitialed
Skewed
Excessive Gap
Non Parallel
A new nut will be run by hand from one end of the bolt off the other end 5 .f the nut does not run freely* the bolt will be considered to have been yielded 8i)e)* over tor(ued* etc)9 therefore re!ected and segregated for further inspection)