Pearl GTL

Project
Shell Project No: HP-3000-QAT
Project Document Number: T- 4.250.955

Purchase Order Number:

2MH127

Tag/Item Number(s):

N/A

Unit(s):

ASU

PCWBS:

LINDE ENGINEERING

Contractor Project No:

Project Rev.: A

Page 2 of 21

5887

QATAR SHELL GTL PROJECT (PEARL)

C2 AIR SEPARATION UNITS CONSTRUCTION

30.06.08

Ready for Constructions

BS

EO

AG

RFC

19.06.08

Ready for Constructions

FB

EO

AG

RFC

15.04. 08

Issued for Company comments

BR

UA

ZG

ICC

08.04.08

Issued for Review

BR

UA

ZG

IFR

06.04.08

Issued for Internal Review

BR

UA

ZG

IIR

Date

Description

GAMA
Rev.
No.

Project
Rev
No.

Prepared Checked Approved

By
By
By
ORIGINATOR

Status

Document Title:

LINDE ENGINEERING AG

METHOD STATEMENT FOR BOLT TIGHTENING

(PIPING & EQUIPMENTS)
Document No.

Contractor

LOC470
Gama Qatar Co. W. L. L.

GAM

MTS

MEC

GTL

014

Org.
Code

Doc.
Type

Disc.
Code

Geogr.
Area

Seq.
No

Rev.
No

Project Document Number: T- 4.250.955

Vendor Code

Rev No: A

Q A T A R

Doc. Title

Date

GAM-MTS-MEC-GTL-014
METHOD STATEMENT FOR BOLT TIGHTENING (PIPING & EQUIPMENTS)

30.06.2008 Rev-E

TABLE OF CONTENTS
1.
2.
3.
4.
5.
6.
7.
8.

PURPOSE _____________________________________________________________________ 5
SCOPE ________________________________________________________________________ 5
HSSE _________________________________________________________________________ 5
REFERENCES _________________________________________________________________ 5
DEFINITIONS _________________________________________________________________ 6
EQUIPMENTS _________________________________________________________________ 6
MANPOWER ___________________________________________________________________ 6
RESPONSIBILITY ______________________________________________________________ 7
8.1.
8.2.
8.3.
8.4.
8.5.
8.6.
8.7.
8.8.
8.9.
8.10.
8.11.
8.12.

9.

SITE MANAGER __________________________________________________________________7

CONSTRUCTION MANAGER ______________________________________________________7
EQUIPMENT MANAGER __________________________________________________________7
SITE ENGINEER __________________________________________________________________7
SITE SUPERVISOR _______________________________________________________________7
CREW LEADER/FOREMAN _______________________________________________________7
STEEL ERECTOR_________________________________________________________________7
QC ENGINEER ___________________________________________________________________7
QC INSPECTOR __________________________________________________________________7
HSSE MANAGER _______________________________________________________________8
HSSE OFFICER_________________________________________________________________8
BOLT TIGHTENER_____________________________________________________________8

PROJECT REQUIREMENTS _____________________________________________________ 8

9.1.

10.

MATERIAL: ______________________________________________________________________8

PROCEDURE ________________________________________________________________ 8

10.1.
10.2.
10.3.

11.
12.
13.
14.
15.
16.
17.

PRE ASSEMBLY INSPECTION ___________________________________________________8

TORQUE WRENCHES __________________________________________________________9
PIPE ERECTION _______________________________________________________________9

JOINT TIGHTENING PROCEDURE ____________________________________________ 10

METHOD OF TIGHTENING OF BOLTS ________________________________________ 10
TORQUE VALUES ___________________________________________________________ 12
DISASSEMBLY AND REASSEMBLY ___________________________________________ 12
SUMMARY OF BOLTING TORQUES ___________________________________________ 13
QUALITY ASSURANCE _______________________________________________________ 16
ATTACHMENTS _____________________________________________________________ 16

17.1.
17.2.
17.3.

BOLT TIGHTENING INSPECTION REPORT ______________________________________16

FLANGE ALIGNMENT INSPECTION REPORT ____________________________________16
JSA___________________________________________________________________________16

T-4.250.955 REV-A

Page 4 of 21

Q A T A R

Doc. Title

Date

GAM-MTS-MEC-GTL-014
METHOD STATEMENT FOR BOLT TIGHTENING (PIPING & EQUIPMENTS)

30.06.2008 Rev-E

1. PURPOSE
The purpose of this method statement is to clarify the tightening & torque of high, ordinary
strength bolts and inspection works at the Qatar Shell GTL Pearl Project by GAMA Qatar
located inside the Ras Laffan Industrial City in Qatar.

2. SCOPE
This method statement identifies the basic structure of the Tightening & torque of high, ordinary
strength bolts works used for the successful completion of the Piping & Equipments works, by
using the FSI Procedure stage by stages will be followed.

3. HSSE
All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan
Industrial City and International standards, codes, LINDE ENGINEERING AG and QSGTL
and/or its PMC requirements and instructions.
In addition all employees and GAMA subcontractor employees on site will have thorough
QSGTL site safety induction, LINDE ENGINEERING AG Site Safety Induction and GAMA
Qatar Safety induction for site safety, health, environmental and security prior to work
activities. Other training courses will be attended as required by LINDE ENGINEERING AG
or QSGTL and/or its PMC as required.
Risk Assessment will have been prepared by the Risk Assessment Team (RAT) ranking the
hazards associated with project works and control measures to be taken to mitigate the
hazards to an acceptable level.
Each work scope or task will have a completed and approved Job Safety Analysis (JSA)
identifying the potential hazards and control measures that will be implemented to protect
people and environment. Supervisor as the basis of conducting his daily Total Safety Task
Instructions (TSTI) and his weekly Tool Box Talk (TBT) will use the JSA.
In addition to the above, employees conducting bolt tightening works will wear required
PPE and highly visible vest where traffic or other hazards may exist. For additional safety
requirements for a particular or specific task please refer to the JSA prepared for that task.

4. REFERENCES
T-4.234.542

Project Quality Plan

T.13.377.360E

Flawless Startup Initiative (FSI)

T.13.377.453E

T.13.377.539G

T.13.377.578G

Specification For Flange Joint Integrity and Tightness

Project specification PART III Contractor Services Chapter
9 - Flawless Start-up
Project specification PART IV Procedures and
Requirements Chapter 10 - Flawless Start-Up

T-4.250.955 REV-A

Page 5 of 21

Q A T A R

Doc. Title

Date

GAM-MTS-MEC-GTL-014
METHOD STATEMENT FOR BOLT TIGHTENING (PIPING & EQUIPMENTS)

30.06.2008 Rev-E

DEP 31.38.01.11

T.4.096.689

Piping General Requirements (AmendmentsT.13.376.815E)

Flange Tightening

T-13.377.454

Preservation of Old & New Equipment Standing Idle

T-4.250.930

QA/QC Procedure for Cleanliness

T-4.250.906

MS for Piping Cleanliness

5. DEFINITIONS
Company

: QSGTL/or its PMC

Contractor

: LINDE ENGINEERING AG

Sub Contractor

: GAMA QATAR

Contract

: QSGTL Pearl Plant - C2 ASU Project

ITP

: Inspection and Test Plan

QCP

: Quality Control Procedure

QCE

: Quality Control Engineer

QCI

: Quality Control Inspector

QA/QC

: Quality Assurance / Quality Control

TPI

: Third Party Inspection

6. EQUIPMENTS
Various Torque wrenches + Normal Spanners of all sizes
Feeler gage
Hammer

7. MANPOWER
Supervisor Engineer
QA/QC Engineer
Site Supervisor/Foreman
HSSE officer
Crew Leader
Steel Erector
Bolt Tightener.
T-4.250.955 REV-A

Page 6 of 21

Q A T A R

Doc. Title

Date

GAM-MTS-MEC-GTL-014
METHOD STATEMENT FOR BOLT TIGHTENING (PIPING & EQUIPMENTS)

30.06.2008 Rev-E

8. RESPONSIBILITY
8.1.

SITE MANAGER

The site manager will provide inputs to the project execution plan to ensure that job
strategies & philosophy are addressed.

8.2.

CONSTRUCTION MANAGER

The construction manager is responsible for the overall management of the project
construction team to ensure that safe and effective operations are conducted and
properly documented.

8.3.

EQUIPMENT MANAGER

The equipment manager will be responsible for the transporting equipments availability
and good order.

8.4.

SITE ENGINEER

Shall report to Construction Manager

Shall be responsible for planning, execution and implementation of all site activities
related to this procedure
Shall train the Bolt Tightening persons & assign them a unique number with a similar
manner to the welder numbers, Bolt tightener certificates shall be issued and
certificates will bear this number.

8.5.

SITE SUPERVISOR

Shall report to Site Engineer

Shall be responsible for execution of construction activity
Shall also prepare daily site construction records

8.6.

CREW LEADER/FOREMAN

Shall supervise the group of erectors and lead them as per site requirements.
Shall makes reports and keeps records of work accomplished and materials used.
Shall perform related work and will be reporting to the Site supervisor.

8.7.

STEEL ERECTOR

Shall erect steels structures as per site requirements and approved drawings in
coordination with the Crew leader/Foreman.

8.8.

QC ENGINEER

Shall report to Manager (QA/QC) and shall be responsible for overall implementation,
monitoring and control of QC activities with releated to the Flawless start-up Initiative
(FSI)

8.9.

QC INSPECTOR

Shall report to QC Engineer

Shall be responsible for attending all Inspection Stages as required by ITP &FSI
Shall be responsible of performing all checks and shall prepare necessary Inspection
Reports.
T-4.250.955 REV-A

Page 7 of 21

Q A T A R

Doc. Title

Date

GAM-MTS-MEC-GTL-014
METHOD STATEMENT FOR BOLT TIGHTENING (PIPING & EQUIPMENTS)

30.06.2008 Rev-E

8.10. HSSE MANAGER

Shall report to Project Manager and shall be responsible for over all control and
Inspection of HSSE issues.

8.11. HSSE OFFICER

Shall report to HSSE Manager
Shall be responsible for monitoring all safety aspects for this procedure.

8.12. BOLT TIGHTENER

All the bolt tightening persons are to be trained and certified. They should have
Knowledge about FSI.

9. PROJECT REQUIREMENTS
This method statements deals with tightening of bolt for various type of bolts used in
Flanges of vessel
Piping and piping connection to rotary/static equipments
Flanges of Equipment
Piping & Flange connection

9.1.

MATERIAL:
ASTM A 193 GRADE B7
ASTM A 193 GRADE B8
ASTM A 320 GRADE L7

10. PROCEDURE
10.1. PRE ASSEMBLY INSPECTION
Bolt holes of mating flanges shall be aligned using a spud wrench or similar tool.
Lateral alignment shall be checked by ensuring that bolts and studs can be inserted
without force and that the alignment tool is not required to impart a significant force to
achieve alignment.
Two bolts shall be installed diametrically opposite each other, one bolt half way
between the previously installed bolts, then the washer and nuts engaged
For flanges installed on horizontal lines, in order to retain the gasket the lower bolts
should be installed first. (eg bolts 2, 3, 4 shown in Figure 1)
Parallelism of the flanges shall then be checked to confirm they are within the
tolerances specified in Appendix 12 of DEP 31.38.01.11.

T-4.250.955 REV-A

Page 8 of 21

Q A T A R

Doc. Title

Date

GAM-MTS-MEC-GTL-014
METHOD STATEMENT FOR BOLT TIGHTENING (PIPING & EQUIPMENTS)

30.06.2008 Rev-E

The gaskets are then to be centred between the flanges. Nuts shall be hand tightened
to hold the gasket in place. When flanged joints are in horizontal lines gaskets without
centring devices such as ring joints, shall be lowered to the bolts for retention and
then raised into position.
The remaining bolts and nuts shall be installed and hand tightened with the flange
faces parallel. Care should be taken to assure proper seating and centring of the
gasket within the allowable tolerances.
Bolts shall be tightened by wrench and inspected for tightness in accordance with Sec
11. Stud bolts should have an equal protrusion through the nuts on both sides of the
flanges of between 1 and 3 threads.

10.2. TORQUE WRENCHES

Torque wrenches shall be calibrated as per calibration schedule and have a valid
certificate that must be revalidated after the wrench has been inspected and
recalibrated on a monthly basis. A validation sticker confirming inspection and last
date of calibration shall be attached to the torque wrench at all times.
There are various types of tools available to achieve the proper torque value. The
manufacturer's instructions shall be followed for the operation and maintenance of all
Torque wrenches used to perform tightening procedure.
Hydraulic tensioning tools shall be supplied in accordance with DEP 31.38.01.11,
Appendix 4

10.3. PIPE ERECTION

During erection of piping, each flange joint that will be disturbed during subsequent
testing or commissioning activities shall be installed and checked by a qualified pipe
fitter to confirm the following:
Flange face is clean and has been inspected to confirm there are no scratches, burrs,
rust or any other defect on the gasket seating surface.
The alignment of the flange is in accordance with Appendix 12 of DEP 31.38.01.11
Piping- General Requirements and that the gasket is properly aligned with the
flange seating surface.
Bolts are the correct length, diameter and material (including confirming color coding,
if required), are undamaged, free of any burrs and are coated only with project
approved lubricant
Bolts are installed in one direction with thread on one side. Stud grade punch to be
visible.
The thread projection on each end of the stud bolt is between 1 and 3 threads and is
uniform.
T-4.250.955 REV-A

Page 9 of 21

Q A T A R

Doc. Title

Date

GAM-MTS-MEC-GTL-014
METHOD STATEMENT FOR BOLT TIGHTENING (PIPING & EQUIPMENTS)

30.06.2008 Rev-E

Where applicable, any spectacle blind in the joint has been inspected to confirm that
it is undamaged (no burrs or scratches on the gasket contact surface), and that the
closed portion is coated with approved preservation material and a physical means of
protection such as a timber cover.
Temporary gaskets have been installed correctly rated to meet the expected test
pressures.

11. JOINT TIGHTENING PROCEDURE

The assembly drawings will indicate the bolt length, diameter and material type plus
the gasket type and rating.
Flange faces shall be thoroughly cleaned using a SHELL or its PMC approved
solvent to remove preservatives and the gasket surfaces shall be inspected for
defects. Any rust or burrs shall be removed using a hand wire brush and/or a hand
file. Particular attention shall be paid to seating surfaces for ring type joints.
(Appendix 1 includes acceptance criteria for flange imperfections)
Bolts shall be checked for correct length, diameter and conformance with material
specification. Except for those is oxygen service, all bolts will be coated with a SHELL
or its PMC approved lubricant that shall be suitable for the expected temperatures
and materials. NOTE: Once approved, a single lubricant type for each material (if
necessary) shall be specified by LINDE for use by GAMA.
Gaskets shall be checked for size, rating, material specification and cleanliness.
Remove any grease, burrs and rust from the gasket and trial fit it against the flange
gasket seating surface.
Confirm the tightening method to be used to determine if it is to be tightened by:
a) Purpose made hand wrench/spanner (bolts < diameter)
b) Torque wrench (bolts diameter)
c) Hydraulic tensioning tools (as specified in DEP 31.38.01.11) See also 14 below
Check the service to confirm the level of QC recording required.

12. METHOD OF TIGHTENING OF BOLTS

The following procedure shall be used for each successive step when wrench tightening
bolts:
Two diametrically opposite bolts shall be tightened either simultaneously or in direct
sequence. For flanges that do not require torque tightening, the bolts are to be
tightened to a point where initial resistance is felt (nipped-up).
Where torque
tightening is specified then the bolts shall be tightened to the initial wrench torque
value that applies 50% of the required bolt stress (See 13 below), either
simultaneously in pairs by two tradesmen working in tandem or in direct sequence.
T-4.250.955 REV-A

Page 10 of 21

Q A T A R

Doc. Title

Date

GAM-MTS-MEC-GTL-014
METHOD STATEMENT FOR BOLT TIGHTENING (PIPING & EQUIPMENTS)

30.06.2008 Rev-E

Care shall be taken to prevent over-tightening one side of the flange and result in
gasket crushing or flange distortion.
Uniform Gap between flanges to be maintained before tightening begins.
Thereafter, two diametrically opposite bolts located 90 further round the
circumference shall be tightened, again being careful not to distort the flanges. This
procedure shall be repeated until all bolts have been tightened once. This sequence
of tightening pairs of bolts is to be applied irrespective of whether the tightening is by
torque or hand wrench/spanner.
Once all the bolts in the flange have been initially tightened, the diametric tightening
process shall be repeated starting at the first bolt pair. For flanges that are tightened
with hand wrenches/spanners, the subsequent tightening should take them to a
tightness where the bolts are uniformly tight and the gasket evenly compressed with
the flange faces parallel.
For torque wrench tightening, the bolts shall be tightened in wrench torque
value steps that tighten the bolts to 80% then 100% of the bolt stress. When
performing the last two tightening sequences of all flange diameters, the pipe surface
temperature is to be less that 40C. This is to minimize stress relaxation in the bolts
due to the high temperature gradients.
As an example, the tightening sequence is shown in Figure-1 for a bolt flanges.
Similar sequence shall be used for flanges having different numbers of bolts.

After the flanged connection has been tightened, the joint shall be inspected for uniform
bolt loading by wrench testing each bolt in the same sequence specified above until all
bolts are judged to have the same level of tightness.
T-4.250.955 REV-A

Page 11 of 21

Q A T A R

Doc. Title

Date

GAM-MTS-MEC-GTL-014
METHOD STATEMENT FOR BOLT TIGHTENING (PIPING & EQUIPMENTS)

30.06.2008 Rev-E

13. TORQUE VALUES

GAMA shall develop a table for each type of bolt specified for the project that
indicates for every bolt size, the required torque value for each of the tightening
steps. A typical torque table is shown below.
When completed the tables shall be reduced to pocket-size and issued to all
pipe fitters, foremen and inspectors in a laminated format.
WRENCH TORQUE VALUES (Sample Table)

TARGET TORQUE (N-m)

Bolt Size (mm)

Initial Step (50%

bolt stress)

Intermediate Step
(80% bolt stress)

Final Step (100% bolt

stress)

14. DISASSEMBLY AND REASSEMBLY

When disassembly of a joint is required, the bolts shall be loosened in the
same sequence specified in Sec 12 for tightening. Each nut shall be loosened
one-twelfth turn in the proper sequence, and the loosening sequence repeated
at least once before any bolt is completely loosened. The retightening of bolts
on reassembly shall follow the original procedure for tightening and inspection.
In addition, the bolts, nuts, and bolt and nut bearing surfaces shall be relubricated as specified.
The retightening of bolts on reassembly shall follow the original procedure for
tightening and inspection. In addition, the bolts, nuts, and bolt and nut bearing
surfaces shall be re-lubricated as specified in Sec 11 above.
Gaskets shall be replaced, reuse is not permitted.

T-4.250.955 REV-A

Page 12 of 21

Q A T A R

Doc. Title

Date

GAM-MTS-MEC-GTL-014
METHOD STATEMENT FOR BOLT TIGHTENING (PIPING & EQUIPMENTS)

30.06.2008 Rev-E

15. SUMMARY OF BOLTING TORQUES

Table 1
B8M BOLTS (CLASS 1)

Bolt
Diameter Bolt
Size
(mm)
Load
(Inch)
(KN)

12.7
12

Lubrd Bolts( u =
0.1)
Torque
Torque
(N-m)
(ft-lb)

Dry Bolts (u =
0.2)
Torque Torque
(N-m)
(ft-lb)

35

25

44

Yield
(Mpa)

%Yield

32

Bolt
Stress
(Mpa)
166

205

81%

5/8

15.9

21

70

50

90

66

159

205

77%

19.1

32

125

90

164

121

159

205

77%

7/8

22.2

42

185

135

249

183

146

205

71%

25.4

58

280

205

381

281

146

205

71%

1-1/8

28.6

76

410

300

562

414

148

205

72%

1-1/4

31.8

98

580

425

800

590

151

205

74%

1-3/8

35.0

120

770

565

1069

789

149

205

73%

1-1/2

38.1

145

1005

740

1406

1037

150

205

73%

1-5/8

41.3

176

1300

960

1831

1351

152

205

74%

1-3/4

44.5

205

1630

1200

2296

1694

152

205

74%

1-7/8

47.6

241

2040

1500

2878

2123

154

205

75%

50.8

275

2470

1820

3501

2582

153

205

75%

T-4.250.955 REV-A

Page 13 of 21

Q A T A R

Doc. Title

Date

GAM-MTS-MEC-GTL-014
METHOD STATEMENT FOR BOLT TIGHTENING (PIPING & EQUIPMENTS)

30.06.2008 Rev-E

Table 2
B8
B8M Bolts (Class 2)
B8T Bolts (Class 2)
Lubrd Bolts (u=
0.1)

Dry Bolts (u=

0.2)

Bolt
Diameter Bolt
Size
(mm)
Load
(Inch)
(KN)

12.7
30

Torque
(N-m)

Torque
(ft-lb)

Torque
(N-m)

60

44

5/8

15.9

54

130

19.1

72

7/8

22.2

Yield
(Mpa)

%Yield

105

Torque Bolt
(ft-lb)
Stress
(Mpa)
77
398

690

58%

96

233

172

412

550

75%

200

148

364

258

353

550

64%

110

350

258

644

475

379

550

69%

25.4

146

520

384

966

713

370

550

67%

1-1/8

28.6

162

640

472

1198

883

316

450

70%

1-1/4

31.8

199

860

634

1619

1194

306

450

68%

1-3/8

35.0

212

1000

738

1893

1396

264

345

77%

1-1/2

38.1

236

1200

885

2281

1682

244

345

71%

1-5/8

41.3

274

1500

1106

2861

2110

238

205

116%

1-3/4

44.5

316

1850

1364

3540

2611

234

205

114%

1-7/8

47.6

369

2300

1696

4413

3255

236

205

115%

50.8

423

2800

2065

5386

3972

236

205

115%

Bolt yield stress in this area is based on B8T Class 1 properties.

T-4.250.955 REV-A

Page 14 of 21

Q A T A R

Doc. Title

Date

GAM-MTS-MEC-GTL-014
METHOD STATEMENT FOR BOLT TIGHTENING (PIPING & EQUIPMENTS)

30.06.2008 Rev-E

Table 3
B7 & L7 Bolts

Bolt
Diameter Bolt
Size
(mm)
Load
(Inch)
(KN)

12.7
39

Lubrd Bolts (u =
0.1)
Torque
Torque
(N-m)
(ft-lb)

Dry Bolts (u=

0.2)
Torque Torque
(N-m)
(ft-lb)

80

59

140

Yield
(Mpa)

%
Yield

103

Bolt
Stress
(Mpa)
530

720

74%

5/8

15.9

58

140

103

251

185

444

720

62%

19.1

107

300

221

546

403

529

720

73%

7/8

22.2

138

440

325

810

597

476

720

66%

25.4

177

630

465

1270

863

448

720

62%

1-1/8

28.6

218

860

634

1610

1187

424

720

59%

1-1/4

31.8

278

1200

885

2260

1667

427

720

59%

1-3/8

35.0

318

1500

1106

2839

2094

396

720

55%

1-1/2

38.1

374

1900

1401

3611

2663

386

720

54%

1-5/8

41.3

439

2400

1770

4578

3376

381

720

53%

1-3/4

44.5

513

3000

2213

5741

4234

380

720

53%

1-7/8

47.6

610

3800

2803

7292

5378

390

720

54%

50.8

726

4800

3540

9233

6810

404

720

56%

ASTM A/193/A183M does not address mechanical requirements for

B8T Class 2, B8M Class 1 or B8 bolts greater then 1-1/2 dia.

T-4.250.955 REV-A

Page 15 of 21

Q A T A R

Doc. Title

Date

GAM-MTS-MEC-GTL-014
METHOD STATEMENT FOR BOLT TIGHTENING (PIPING & EQUIPMENTS)

30.06.2008 Rev-E

16. QUALITY ASSURANCE

The QA/QC management system for controlling the integrity of the joint shall be
developed in detail during the activities, but shall include the following elements:
ALL joints shall be signed off by a qualified pipe fitter and checked by
Inspectors.
Bolt torque tightening shall be applied to all bolts diameter.
Recording of joint inspections and tightening will be kept for selected critical
Services (oxygen, hydrogen, severe cyclic conditions, cryogenic, vacuum,
Very toxic substances, high temperature [>350C], high pressure),
A helium test to be carried out for super-critical services, i.e. critical and can
cause harm to people or the plant, eg very toxic service.
A Quality Assurance System shall be operated conforming to related standards.
Controls and checks shall be established and documented through relevant GAMQCR-QAC-GTL-041.

17. ATTACHMENTS
17.1. BOLT TIGHTENING INSPECTION REPORT
17.2. FLANGE ALIGNMENT INSPECTION REPORT
17.3. JSA

T-4.250.955 REV-A

Page 16 of 21

C2 ASU PEARL GTL PROJECT

RASLAFFAN INDUSTRIAL CITY
BOLT TIGHTENING INSPECTION
REPORT

Subcontract Ref.:

Report No.:

Item Description:

Inspection Date:

Item Location /
Area:

Test Code No.:

Subsystem:

ITP No.:

Ref. DWG / Docs:

Used Measuring and test equipment ref. (if applicable):
INSPECTIONS
Item No/Spool
No

Mark No./Joint No

Accepted By

ORGANIZATIONS
THIRD PARTY REP.
GAMA REP.
LINDE REP.
QSGTL OR its PMC REP.

GAM-QCR-QAC-GTL-041

Bolting
Grade

DATE

Size

NAME

Bolt Tightening
(Torque Value)

Inspectors
Signature

SIGNATURE

C2 ASU PEARL GTL PROJECT

RASLAFFAN INDUSTRIAL CITY
FLANGE ALIGNMENT INSPECTION
REPORT

Subcontract Ref.:

Report No.:

Item Description:

Inspection Date:

Item Location /
Area:

Test Code No.:

Subsystem:

ITP No.:

Ref. DWG / Docs:

Used Measuring and test equipment ref. (if applicable):
INSPECTIONS
Item No/Spool
No

Mark No./Joint No

Accepted By

ORGANIZATIONS
THIRD PARTY REP.
GAMA REP.
LINDE REP.
QSGTL OR its PMC REP.

GAM-QCR-QAC-GTL-058

Face Distance

DATE

Face parallelism

NAME

Centreline offset

Inspectors
Signature

SIGNATURE

Q A T A R

JOB SAFETY ANALYSIS / RISK ASSESSMENT

JSA Number: T.4.250.955

NEW

Page No: 1 of 3

REVISED

Job being analysed: METHOD STATEMENT FOR BOLT TIGHTENING (PIPING&EQUIPMENTS)

Department/Section doing JSA:HSSE & Mechanical Works
JSA Members:Mr. Syd Osborne, Mr. Ali E. TURKER
Job Performers:Mr. Ali E. TURKER
General job requirements / Common
Normal Approvals:
Name
Signature
Date
Personnal Protective Equipment.
JSA by:
Mr. Atila Gtn,
18.03.08
Job Supervisor:

Muslim Topalogu

18.03.08

Additional Approvals (Determined by Job Supervisor in correlation with LINDE HSSE Manager).
Name
Signature
Discipline Superindent (LINDE)
HSSE Representative (LINDE)
OTHERS(List Below):

Date

1. The following Personal Protective

Equipment shall be worn while tightening &
torqueing bolts in structural steel members:
Approved coveralls, safety glasses, safety
helmet, safety shoes, safety gloves & safety
harness.
2.Permit To Work.

Approval required for hazardous work detailed in the LINDE work permit procedure.
Changing conditions and emergency procedures
Stop work. Switch of equipment.Supervisor directs personnel to nearest and safest muster point considering wind direction. Supervisor counts all employees. Missing
employees are reported to LINDE HSSE Dept. When all clear is given check with LINDE HSSE before returning to work.
LINDE EMERGENCY TELEPHONE NO.

HSSE MANAGER
PEARL HOT LINE:

506 41 20
474 88 88

Note: 1) If any of the tasks involves biological, physical or chemical hazards, then The LINDE Industrial Hygienist must also approve the work.
2) Use additional sheets as necessary.
3) Details on safety (PPE,Hazard etc) and environmental requirements can be found in LINDE and SHELL Safety and Environment Procedures.

JOB SAFETY ANALYSIS / RISK ASSESSMENT

T.4.250.955

Q A T A R

SCOPE : METHOD STATEMENT FOR BOLT

TIGHTENING(PIPING & EQUIPMENTS)

Initial Risk
ITEM

ACTIVITY

Bolts tightening for

Piping and Flanges

HAZARD / POTENTIAL
CONSEQUENCES
1.1

Residual Risk

CURRENT
CONTROLS

RISK
RANK

Hand and finger injury.

1.1.1
B

LOW

1.1.2
1.1.3

1.2

Pinch point.

1.2.1
1.2.2
B

LOW
1.2.3
1.2.4

1.3

Improper use of tool.

1.3.1

1.3.2
1.3.3
B

LOW 1.3.4
1.3.5
1.3.6

Bolts torqueing final 2.1

tightening after
erection of structural
steel members and
Flanges

Falls of materials &

tools.

2.1.1

2.1.2
B

3
LOW

2.1.3
2.1.4

Do not use wrenches if the jaws

are sprung.
Do not use tools with loose,
cracked, splintered.
Ensure all bolt holes shall be
aligned during insertion of bolts.
Ensure that all hand tools are in
good condition.
Ensure qualified/ competent
employee to carry out the task.
Use the right tools for the job.
Keep away hand & finger from any
pinch point hazard.
All tools shall be inspected &
colour coded with the approved by
LINDE.
Use the right tool for the job.
Operate tools according to
manufacturers instruction.
Use appropriate personnel
protective equipment.
Perform maintenance on tools
regularly.
Cheater bar are not allowed use
as an extension for tightening
bolts.
Install barricades "exclusion zone" 2.1.1.1
and secure the area with sign
boards to prevent unauthorized
entry.
All materials shall be safety
lowered from one level to the next
either by hand-to-hand or by
securily attaching a rope and
hauling.
Tools shall be tied by a retaining
rope attached to the harness.
Provide adequate working
platforms

ADDITIONAL
CONTROLS

Ensure to provide safety

nets,toe boards.

LOW

SCOPE : METHOD STATEMENT FOR BOLT

TIGHTENING(PIPING & EQUIPMENTS)

JOB SAFETY ANALYSIS / RISK ASSESSMENT

T.4.250.955

Q A T A R

Initial Risk
ITEM

ACTIVITY

HAZARD / POTENTIAL
CONSEQUENCES
2.2

Residual Risk

CURRENT
CONTROLS

RISK
RANK

Fall of working
personnel at height.

2.2.1

2.2.2

2.2.3
B

MED

2.2.4

2.2.5

2.3

Wind hazards.

2.3.1

LOW
2.3.2

Ensure all materials, tools,and

equipment are kept secure at all
times.
Install lifting apparatuses such as
gin wheel and hoisting rope for
lifting pieces of materials.
Full body harness and lanyards
shall be inspected.
All employees shall wear
inspected full body harness fitted
with twin lanyards with shock
absorbers, each lanyard shall be
fitted with dual action self-locking
safety hook to allow for 100% Tieoff.
Ensure housekeeping is done
regularly to maintain walkway free
of hazards.
Monitor wind speed using
Anemometer. Crane operations
should be stopped if wind speed
exceeds 25 knots or as stipulated
by crane manufacturer, which ever
is lower.
Employees should be aware of the
affect of weather conditions on the
operation.

ADDITIONAL
CONTROLS
2.2.1.1
2.2.1.2
2.2.1.3

LOW

Ensure 100% fall protection.

Ensure that all employees
working at height are properly
trained.
Discuss working at height
hazards at daily TSTI.