Project: Mansourah-Massarah Ma’aden Gold

Client: Larsen & Toubro Limited

Project (GRE Option)
Contract No: MMGP/190485/IK/026 Location: Mansourah, Saudi Arabia

Method Statement for Installation of

Flanges for GRE Pipe System
(Doc. No. ISECC-MS-0004)

Revision History

ABDUL WASAY MOHD.

GENARO DE LEON
KHAN SHAFIUDDIN
00 24.08.2020
Project Installation
Initial Issue for Approval Site Manager L&T
Supervisor Manager
Rev No. Rev. Date Description of Revision Prepared By Checked By Approved By Approved By

Doc. No. ISECC-MS-0004 Rev.00

 Revision Index

Rev. No Rev. Date Description

00 24.08.2020 Initial Issue for Approval

Doc. No. ISECC-MS-0004 Rev.00

 INDEX

No. of Clause Name of Clause

1.0 INTRODUCTION

1.1 TOOLS FOR FLANGED JOINT

1.2 GRE FLANGED JOINT DESCRIPTION

1.3 GASKET

1.4 BOLTS

1.5 TROUBLESHOOTING

Doc. No. ISECC-MS-0004 Rev.00

 1.0 Introduction
AMIPOX flanges are normally used for joining GRE/RTRP to existing steel pipes,
valves or pumps; rubber gaskets are used for hydrostatic sealing. AMIPOX flanges
meet the dimensional requirements. Drilling patterns of all common standards such
as ANSI, API, and ISO etc.

Before assembling flanged joints, all safety precautions need to be checked. Ensure
that all necessary tools and materials are available.

1.1 Tools for Flanged Joints

Tools necessary for assembly of flanges:

 Ring spanner with required bolt head size

 Torque wrench with required socket size
 Oil to lubricate bolts, washers and nuts

1.2 GRE Flanged Joint Description

 AMIPOX flanges are flat faced. These flanges must be accurately
aligned and not subject to any stress.
 The bolts and nuts must have washers to avoid exceeding the
permitted surface pressure. As an alternative, a stub-end type flange
with steel backing ring centre can be installed.

Table 1.2-1: ACCEPTABLE TOLERANCE FOR MISALIGNMENT OF FLANGES

DURING INSTALLATION

Tolerances

Diameter range
Misalignment
300 to 1200 mm
50 to 300 mm ND
ND

Flange misalignment ± 1.6 mm ± 3.2 mm

Separation between spools ±0 ± 1 mm

Angular misalignment ± 0.17° ± 0.17°

Doc. No. ISECC-MS-0004 Rev.00 Page 4 of 10

  Pipe must not be pulled together by tightening the bolts. If a GRE
pipeline is connected to a metal pipe, this metal pipe must be
anchored to prevent any movement or loads being transmitted to the
GRE line.

Figure 1.2-1: GRE Flange assembly using full face elastomeric gasket
For GRE DN25 to DN1000 for up to 16 bar design
& DN25 to DN300 for up to 40 bar design

Figure 1.2-2: GRE Flange assembly using o-ring elastomeric gasket

For GRE DN1050 to DN1200 for up to 16 bar design
& DN350 to DN600 for 20 to 40 bar design

 First, finger tighten all nuts. Bolt threads must be clean and
lubricated to attain proper torque. Use lubricated washers under both
nuts and bolt heads to protect flange back faces.
 Tighten all nuts following the sequences shown in Figure 1.2-3 below.
 Do not exceed the torque increments given in Table 1.2-1 and Table
1.2-2 below.

Doc. No. ISECC-MS-0004 Rev.00 Page 5 of 10

  After all bolts have been tightened to the recommended torque,
recheck the torque on each bolt in the same sequence, as previously
tightened bolts may have relaxed.

 Note: Excess torque can prevent sealing and can damage flanges.

Figure 1.2-1: Flange Assembly

Figure 1.2-3: Bolts tightening sequence

Doc. No. ISECC-MS-0004 Rev.00 Page 6 of 10

 Table 1.2-1: GRE Flange assembly using full face elastomeric gasket for GRE
DN25 to DN1200 for up to 16 bar design & DN25 to
DN300 for up to 40 bar design

Torque
Nominal Pipe Size Final Torque
Increments
inch mm (N-m) (N-m)
1 25 10 30
1.5 40 10 30
2 50 10 40
3 80 15 56
4 100 15 56
6 150 20 82
8 200 20 82
10 250 30 150
12 300 30 150
14 350 30 150
16 400 50 250
18 450 80 400
20 500 80 400
24 600 100 500
28 700 100 500
30 750 100 500
32 800 100 500
36 900 100 500
40 1000 100 500

Important Note:
 Above recommended bolt torques is applicable to GRE to GRE
flange, GRE flange to GRE spacer and steel flange connection
and etc. using full-face gasket of an elastomeric suitable for the
service pressure and temperature and fluids in the system, and
where GRE flange material rigidity is lesser or equal to the
mating flange.

Doc. No. ISECC-MS-0004 Rev.00 Page 7 of 10

 Table 1.2-2: GRE Flange assembly using o-ring elastomeric gasket for
GRE DN1050 to DN1200 for up to 16 bar design &
DN350 to DN600 for 20 to 40 bar design

Nominal Pipe Size Torque Increments Final Torque

inch Mm (N-m) (N-m)

14 350 50 150
16 400 50 150
18 450 50 150
20 500 50 150
24 600 50 150
28 700 50 150
30 750 50 150
32 800 50 150
36 900 50 150
40 1000 50 150
42 1050 50 150
44 1100 50 150
48 1200 50 150

Important Note:
 Above recommended bolt torques is applicable to GRE to GRE
flange, GRE flange to GRE Spacer & steel flange connection &
etc. using o-ring gasket of an elastomeric suitable for the service
pressure and temperature and fluids in the system, and where
GRE flange material rigidity is lesser or equal to the mating
flange.
 For GRE groove flanges: when connecting two GRE flanges, one
flange shall be flat face and the other flange shall have O-ring
groove in the face.

Doc. No. ISECC-MS-0004 Rev.00 Page 8 of 10

 1.3 Gaskets
For AMIPOX GRE fiberglass flanges assembly, use full-face gaskets of an
elastomeric suitable for the service pressure and temperature and fluids
in the system. Gaskets should be 1/8 inch (3mm) thick with shore
durometer hardness between 60 and 75. Refer to ASTM D1330
specification for sheet rubber gaskets, grade 1 or 2, to establish minimum
physical property requirements for use with water, Rubber gasket with
steel inlay or compressed fiber is used for high pressure AMIPOX flanges
and Rubber “O Ring” sealing is also used for higher pressure and
diameters.

1.4 Bolts
AMIPOX GRE flanges are thicker than metal flanges and require washers.
This should be taken into account when calculating the bolt length. For
flange thickness see the appropriate AMIPOX product datasheet for
dimension data.

1.5 Troubleshooting
If the assembled joint leaks:

 Loosen it and remove all bolts, nuts, washers and gaskets

 Check for alignment of assembly. Rebuild to correct alignment as

required.

 Check the gasket for damage. If damaged, discard and replace it with
new, undamaged gasket.

 Check flanges for seal ring damage. In particular, check the condition
of the inner seal rings. Flanges with damaged inner seal rings must be
removed and new, undamaged flanges installed.

 If leaks occur as a result of deficiencies in non-fiberglass components

of the piping system, consult the manufacturer of the defective
components for recommended corrective procedures.

Doc. No. ISECC-MS-0004 Rev.00 Page 9 of 10

  Clean and re-lubricate old threads and washers before re-joining.

 Repeat the joining procedure outlined above.

 After corrective action has been taken, retest the joint to make sure
proper sealing is achieved.

Doc. No. ISECC-MS-0004 Rev.00 Page 10 of 10