Revision

Rev Date Description Orig. Verif. Appr.

0 04/23/2018 Issued for Use DW DW KD
Revised for new document number (OLD # CORP-SPC-
1 08/08/2019 PB SH JPS
PRJ-002)

Page 2 of 13 | KURD-SPC-PRJ-002 Flange Joint Integrity Specification |

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 Content

1.0 Purpose.................................................................................................................................................. 4
2.0 Joint Integrity Policy ............................................................................................................................... 4
3.0 Scope ..................................................................................................................................................... 4
4.0 Reference documents ............................................................................................................................ 4
5.0 Responsibilities ...................................................................................................................................... 4
6.0 Definitions .............................................................................................................................................. 4
7.0 Qualifications and Training .................................................................................................................... 5
7.1 Qualification ....................................................................................................................................... 5
7.2 Training .............................................................................................................................................. 5
7.3 Special Training ................................................................................................................................. 5
8.0 QA/QC Management for Joint Integrity ................................................................................................. 5
General .................................................................................................................................................. 5
8.1 ................................................................................................................................................................... 5
8.2 QA/QC Requirements for Tools ......................................................................................................... 5
8.3 QA/QC Requirements for Joints ........................................................................................................ 6
8.3.1 Construction Phase ....................................................................................................................... 6
8.3.2 Pipe Spool Erection Phase ............................................................................................................ 6
8.3.3 Pressure Testing ............................................................................................................................ 6
8.3.4 Commissioning .............................................................................................................................. 7
9.0 Joint Tightening Procedure .................................................................................................................... 8
9.1 Preparation ........................................................................................................................................ 8
9.2 Method of Tightening of Bolts ............................................................................................................ 8
9.3 Disassembly and Reassembly .......................................................................................................... 8
9.4 Torque Values ................................................................................................................................... 9

Appendix A Flange Face Acceptance Criteria………………………………………………………………….10

Appendix B Bolt Tightening Sequence………………………………………………………………………….11

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 1.0 Purpose
This specification defines the requirements for mitigating actions to eliminate the possible causes of leaks due to
inadequate joint tightness in piping systems.

2.0 Joint Integrity Policy

To eliminate leaks, the following strategies shall be adopted:

• Qualify and uniquely identify all pipe fitters

• Apply an enhanced quality control process to joint fit-up and tightening
• Apply torque tightening to all bolts.

This specification will detail the processes that shall be applied in support of these objectives.

3.0 Scope
The specification will cover all flanged joints in piping systems including vendor package equipment assembled off-site and
includes pipe to pipe, pipe to valve, pipe to pipe specialty items, pipe to instrument and pipe to equipment connections.

The quality control requirements specified in this document are applicable to all joints to be made on Company projects,
with the exception of the following where the requirements for bolt tightening are detailed in the documents referenced
below.

• Manufacturers proprietary joints and closures, which shall be assembled in accordance with the manufacturers’
standards, in particular non-metallic materials.

• Insulated flanges and isolating flanges in cathodically protected pipe.

The requirements of this specification apply to all phases of Company projects, construction, including preassembly (if
applicable), pre-commissioning and commissioning.

4.0 Reference documents

ASME B31.3 Process Piping

ASME PCC-1 Guidelines for Pressure Boundary Bolted Flange Joint Assembly

5.0 Responsibilities
This specification is aimed at DNO Construction Personnel and Contractors performing works for DNO operated facilities.

The Custodian of this Specification is the Head of Projects.

6.0 Definitions
ITP Inspection and Test Plan

QA Quality Assurance

QC Quality Control

Page 4 of 13 | KURD-SPC-PRJ-002 Flange Joint Integrity Specification |

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 7.0 Qualifications and Training
7.1 Qualification
Contractor shall ensure that all pipe fitters mobilised to Company jobsites are suitably trained to perform the tasks identified
throughout this procedure in a professional and safe manner.

7.2 Training
Contractor must assess the competency of pipe fitters regularly and keep a log of training assessments.

Qualified Pipe fitters shall be assigned a unique number, in a similar manner to the issuance of welder numbers, and shall
be identifiable by an identification badge and by a label on their safety helmets.

7.3 Special Training

Flange alignment at rotating equipment requires special skills. Contractor shall arrange specialist training for a suitable
number of fitters to be qualified for rotating equipment alignments.

8.0 QA/QC Management for Joint Integrity

8.1 General
A QA/QC management system for controlling the integrity of the joint shall be developed by Contractor, and 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.

Contractor shall develop an Inspection and Test Plan (ITP) for these and other activities and include a QC form that
includes the check points listed in section 8.3.2 below, records the number of the pipe fitter carrying out the work and
where the witnessing parties’ signatures are recorded.

The ITP will require a series of HOLD inspections by Contractor’s Inspectors to confirm the condition of the flange
(undamaged, clean etc.) followed by a check of alignment and witness of torqueing at the tightening stage.

The ITP shall require a spot check and confirmation signature on 10% of flanges by Company’s own inspectors.

Each joint will be uniquely numbered to provide auditable QC traceability records.

8.2 QA/QC Requirements for Tools

Only purpose made hand torque wrenches are permitted on Company projects. Handmade tools, spanners and flogging
spanners are PROHIBITED.

Torque wrenches shall be calibrated and have a valid certificate that must be revalidated after the wrench has been
inspected and recalibrated monthly. A validation sticker confirming inspection and last date of calibration shall be attached
to the torque wrench at all times.

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 8.3 QA/QC Requirements for Joints
8.3.1 Construction Phase

Before pipe erection work starts on site, Contractor shall agree with Company which joints will be disturbed due to testing
or commissioning after the initial pipe spool erection phase.

Typically, joints at the following locations will be disturbed after initial installation due to pressure testing in accordance with
B31.3 and/or subsequent commissioning activities

• Connections at static and rotating equipment where test blinds will be installed.
• Flanges at control valves, pressure relief valves and other instrumentation that require isolation from the pressure
test.
• Flanged spools that must be rotated to allow installation of test equipment.
• Spectacle blinds that must be turned before start-up.
• Any other locations where commissioning procedures dictate joint disassembly to prove cleanliness.

8.3.2 Pipe Spool Erection Phase

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, with Contractor inspections 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 correct and that the gasket is properly aligned with the flange seating surface.
NOTE: A preliminary flange alignment at rotating equipment is necessary prior to hydrotesting and shall be carried
out by specially qualified pipe fitters, trained as required in section 7.3 above.

• Bolts are the correct length, diameter and material, are undamaged, free of any burrs and are coated only with
an approved lubricant

• The thread projection on each end of the stud bolt is between 1 and 3 threads.

• 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.

• The gasket is undamaged, unused and is the correct size and rating.

• The flange has been tightened in accordance with the procedure specified in section 9.0 below.

When he is satisfied that all the above is in accordance with specification, pipe fitter will “sign-off” the joint. The signature
shall take the form of marking the fitters own unique identification number on the pipe adjacent to the joint for which he is
responsible.

During erection of piping, with flange joints that will NOT be disturbed during subsequent testing or commissioning
activities, the pipe fitter shall carry out the same checks and shall indicate this by “signing-off” as above and painting the
exposed ends of the stud bolts yellow using paint suitable for the piping material (i.e. no zinc containing paints for stainless
bolts).

Contractor’s Inspection and Test Plan (ITP) for piping shall require a spot check and confirmation signature on 10% of
flanges for its own inspectors. The signature shall also take the form of a unique inspector identification number adjacent
to that of the fitter.

8.3.3 Pressure Testing

During inspection of piping systems prior to their release for pressure testing, Contractor shall confirm that every joint has
been signed off by a qualified pipe fitter and that 10% of the joints have been counter signed by the Contractor’s QC
Inspector. In addition, Contractor should check that each joint that will not be disturbed has been completed by confirming
the ends of the stud bolts are painted yellow. Any non-conformance shall be rectified prior to test release.

After the completion of the pressure testing, the joints that will not be disturbed shall be visually inspected to confirm they
are tight and the hydrotest sign off sheet shall include a confirmation signature from both the Contractor and Company’s
witnessing party that all such flanges are leak free.

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 Upon successful completion of the pressure test, a post test punch list shall be issued that identifies joints that can now be
reinstated to final completion status. The remainder will not be reinstated at this point because of subsequent planned
pre-commissioning or commissioning activities.

Where a joint is released for final completion on the post test punch list, it shall be made up by a qualified pipe fitter who
will replace the gasket and tighten the joint. When this is satisfactorily complete, the pipe fitter will sign the joint off by
writing his own unique identification number on the pipe adjacent to the joint next to the previous signature, and painting
the end of the stud bolts yellow. This second signature will confirm he has checked the following:

• The gasket is undamaged, unused and is the correct size and rating.
• The flange has been tightened in accordance with the procedure specified in section 9.0 below.

Contractor will only sign off the post test item as complete after confirming the signature has been applied. Contractor shall
apply a spot check audit by reopening and visually checking a percentage of the reinstatement joints.

8.3.4 Commissioning

At Mechanical Completion, ownership of a process system is transferred from the Contractor to the Company’s
Commissioning Group which will then become responsible for all joints that are unproven by pressure test within that
system.

When all pre-commissioning activities are complete on a system and affected joints are released for reinstatement, they
shall also be made up by a qualified pipe fitter who will sign it off following the same process as joints released after testing
per section 8.3.3 above.

In addition, if the Commissioning Group breaks any joints previously signed off through unforeseen breakouts for line
flushing/blowing etc. then they have responsibility for reinstating those joints using qualified pipe fitters who must sign them
off as acceptable.

Final flange alignment at rotating equipment shall be carried out by specially qualified pipe fitters.

Following completion of reinstatement of commissioning activities on a process system then a system leak test will be
performed (using air or nitrogen for systems in gaseous service).

All flange joints with the system under test will have the circumferential void between the flange faces taped with masking
tape and a single pinhole perforation in the tape.

During the leak test, each flange pinhole will be sprayed with soapy water to detect leaks by bubble formation.

If a leak is identified then the flange bolts will be re-tightened in accordance with section 9.0 below.

A target of “no leakage” is the ultimate objective. Any leaks observed shall be recorded and reported to Company.

9.0 Joint Tightening Procedure

9.1 Preparation
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 an 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. Attention shall be
paid to seating surfaces for ring type joints. Appendix 1 shows the acceptance criteria for flange imperfections.

Bolts shall be checked for correct length, diameter and conformance with material specification. All bolts shall be coated
with Moly Coat lubricant. All other lubricants require written Company approval prior to use.

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.

Page 7 of 13 | KURD-SPC-PRJ-002 Flange Joint Integrity Specification |

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 9.2 Method of Tightening of Bolts

Select the relevant target torque value for the size and rating of the flange from Table 1 in section 9.3.

Select the relevant bolt tightening pattern from Appendix 2 and mark the pattern on the outer rim of the flange circumference
to use as a guide for the sequence of bolting.

The following procedure shall be used when wrench tightening bolts:

• Round 1: Tighten bolts in sequence to 30% of the target torque value. Check the flange gap around circumference
for uniformity. If the gap around the circumference is not reasonably uniform, make the appropriate adjustments
by selective tightening/loosening before proceeding.

• Round 2: Tighten bolts in sequence to 70% of the target torque value. Check the flange gap around circumference
for uniformity. If the gap around the circumference is not reasonably uniform, make the appropriate adjustments
by selective tightening/loosening before proceeding.

• Round 3: Tighten bolts in sequence to 100% of the target torque value. Check the flange gap around
circumference for uniformity. If the gap around the circumference is not reasonably uniform, make the appropriate
adjustments by selective tightening/loosening before proceeding.

• Round 4: Continue tightening the bolts, but in a circular clockwise pattern until no further nut rotation occurs at
the Round 3 target torque value. For indicator bolting, tighten bolts until the indicator rod retraction readings for
all bolts are within the specified range.

• Round 5: Time permitting, wait a minimum of 4 hours and repeat Round 4; this will restore the short-term creep
relaxation/embedment losses.

9.3 Disassembly and Reassembly

When disassembly of a joint is required, the bolts shall be loosened in the same sequence specified in section 9.3 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 re-lubricated
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.

Gaskets shall be replaced; reuse is not permitted.

9.4 Torque Values

Table 1 provides the target torque values to be used when tightening bolts.

These values have been calculated based on using ASTM A193 Grade B7 bolts with MolyCoat lubricant.

All values are stated in ft-lbs and Nm.

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 Table 1 - Bolt Torque Value Selection Table

150# 300# 600#

NPS (in) NPS (mm)
ft lb Nm ft lb Nm ft lb Nm

1/2 15 45 61 45 61 45 61

3/4 20 45 61 90 122 90 122

1 25 45 61 90 122 90 122

1 1/2 40 45 61 150 203 150 203

2 50 90 122 90 122 90 122

3 75 90 122 150 203 150 203

4 100 90 122 150 203 240 325

6 150 150 203 150 203 368 499

8 200 150 203 240 325 533 723

10 250 240 325 368 499 750 1017

12 300 240 325 533 723 750 1017

14 350 368 499 533 723 750 1017

16 400 368 499 750 1017 1020 1383

18 450 533 723 750 1017 1650 2237

20 500 533 723 750 1017 1650 2237

24 600 750 1017 1200 1627 3000 4067

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 Appendix A: Flange Face Acceptance
Criteria

In the event any damage to flanges is observed during visual inspections, it shall be raised as a Non Conformance Report,
and the following criteria shall be used to determine the classification of the non-conformance:

Contractor QC inspector shall inspect and determine ANY defects in the gasket seating surface. If the scratches or pits are
deeper than 0.2 mm and cover more than half the width of the face, the flange will also have to be machined or replaced.

Any mechanical damage and/or corrosion (scratch or pit) at the gasket contact area is regarded as a deficiency. If the
scratches or pits are deeper than 0.2 mm and cover more than 30% of the gasket contact area width (measured in a radial
direction), the flange will also have to be machined or replaced.

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 Appendix B: Bolt Tightening Sequence

4 Bolt Tightening Sequence

Sequential Order: 1-2, 3-4

Rotation Order: 1, 3, 2, 4

8 Bolt Tightening Sequence

Sequential Order: 1-2, 3-4, 5-6, 7-8

Rotation Order: 1, 5, 3, 7, 2, 6, 4, 8

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 12 Bolt Tightening Sequence

Sequential Order: 1-2, 3-4, 5-6, 7-8, 9-10, 11-12

Rotation Order: 1, 5, 9, 3, 7, 11, 2, 6, 10, 4, 8, 12

16 Bolt Tightening Sequence

Sequential Order: 1-2, 3-4, 5-6, 7-8, 9-10, 11-12, 13-14, 15-16

Rotation Order: 1, 9, 5, 13, 3, 11, 7, 15, 2, 10, 6, 14, 4, 12, 8, 16

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 20 Bolt Tightening Sequence

Sequential Order: 1-2, 3-4, 5-6, 7-8, 9-10, 11-12, 13-14, 15-16, 17-18, 19-20

Rotation Order: 1, 13, 5, 17, 9, 3, 15, 7, 19, 11, 2, 14, 6, 18, 10, 4, 16, 8, 20, 12

24 Bolt Tightening Sequence

Sequential Order: 1-2, 3-4, 5-6, 7-8, 9-10, 11-12, 13-14, 15-16, 17-18, 19-20, 21-22, 23-24

Rotation Order: 1, 9, 17, 5, 13, 21, 3, 11, 19, 7, 15, 23, 2, 10, 18, 6, 14, 22, 4, 12, 20, 8, 16, 24

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