RAPED EOS: SOUTHERN AREA PROJECTS INSPECTION DIVISION EYH/ RD RAPIU Supervisor - Haimoud, Yousif A | amen cu-32,West Admin.Bldg. #1020, UDHALIXAR | gel: 577-8603 Fax: 577-6058 QC DOCUMENT REVIEW RESPONSE Lpaw; ae NASER, PROJECT ENGINEER nee | DEPT: oNEPD/coeD/unwerens GAS UNE Lassa onFrcn,, HAWIYAH CONTRACTORS PARK FAK: 576-7462 projects: Hiuravvenmve| RR; T-GUPD-HGU-O05-14 Jpare 2-Jan-14 STEERS Wour® Go ProSect AARC areu les ee SORMINEAL: Flange Bolting and Gasket Verification Procedure Approval Deseript ference No eccription Referenc prove 1 COMMENTS: Icontolled copy to be available insite locaton during the Process. approved 2. APr s. Resubmit for record 3.Reviewed and accepted. alNot Approved. Resubmit Incorporating conments IS Reviewed. Incorporate comments and few not required. Document rete: Loco > RADII vatains tho wubnitted docunente for veference, Conteactor has to provide the “t gpproved docunents for RAPTU reference and get back their old Reviewed by : Ahmed Hefnawy signatu Mechanical Inspector Approved by :"Hufé, Brian K RAPIU Field Superviso:[Jem lesen DD cre FLANGE BOLTING and GASKET VERIFICATION PROCEDURE CONTRACT NUMBER: 6600026552/6600026568/6600027360 Doc. Nex GAP 770.06 | ae Cra | FLANGE BOLTING and GASKET VERIFICATION PROCEDURE Rev. C] aaa ~ Qf Manager | Project Manager ‘SAPID Rev.8| 15-05-11 |QA/aCDepartment| QC Manager | Project Manager SAPID Rev.A| 1203-11 [GA/ac Department! QC Manager | Project Manager SAPID Rev.0 | 10-06-09 /QA/Qc Department] QcManager | Project Manager ‘SAPID Rev. Date: Prepared By: Controlled By: Approved By: Approved By: anoFLANGE BOLTING and GASKET VERIFICATION PROCEDURE | Doc. No GAP 470.0 CAT. Ineo. Ls : REV.NO ic Saudi Arabia | TABLE OF CONTENTS 1. PROCEDURE NO. 3 2. SCOPE AND PURPOSE 3 3. APPLICABILITY 3 4, RESPONSIBILITY 3 5. GENERAL 3 6. METHOD OF STATEMENT 4 6.1 Pre-Assembly 62 Gasket Verification and Installation 63 Torqueing Tools 64 — Torqueing 7. STUD BOLT TIGHTENING PROCEDURE 6 7.1 Stud Bolt Additional Tightening procedure where leaks occur During pressure testing, 8. RECORDS 7 9. REFERENCES 7 10, ATTACHMENTS 8 aoFLANGE BOLTING and GASKET VERIFICATION PROCEDURE | 00e. Nos GAP T7000] Saudi Arabia | | Bent len | [revi =] 2: PROCEDURE NO. 1.1 -P170 SCOPE AND PURPOSE 24—This procedure defines the methodology ta be employed in order to control the Installation of gaskets and bolting of flanged joints to meet Saudi Aramco standard And international codes. This procedure shall be implemented and shall apply to all Flange bolting activities as highlighted in SAEP 351, APPLICABILITY 3.1 = General, All Project, RESPONSIBILITY 1.1 Project Manager 1.2 QA/QC Manager 1.3 Discipline Engineer 1.4 Material Controller 15 OC Personnel 1.6 Mechanical Foreman 1.7 Mechanical Technician GENERAL This procedure describes and defines the requirements for the bolting of flanged joints and verification of gasket installed, The project manager shall be responsible for control and implementation of this proceduro It shall be the responsibility of the mechanical engineer and QC Manager to define the correct, Torque values for each type and size of flange in accordance with tables 01,02 or 03 of SAEP 351, ft shall be the responsibility of QC supervisor or inspector to verify torque wrench is maintained And calibrated as required by SAEP 351 section 6.3. 3/10FLANGE BOLTING and GASKET VERIFICATION PROCEDURE | Doc. No. GAIP 170.00 Be. GAT. nfo, Lid REV. NO Sauai Arabia | The mechanical engineer shall be responsible for ensuring that correct gaskets, bolts and nuts ‘Are issued and installed in accordance with project drawing and specifications. Material shall be |ssued by material controller in accordance with specific material take off in order that materials Employed are as specified. The QC Supervisor and QC Inspectors are responsible for the inspection of flange joints to verify Correct gasket installation and to ensure that bolting / torqueing operations conform to this Procedure and SAEP 351. All required quality forms and records shall be maintained in Accordance with procedure QAIP 109 Control of quality records. This documents defines general requirements and all personnel supervising or verifying flanges ‘Assembly shall carefully read and understand SAEP 351 prior to start of work. Where any conflict arises ‘between this document and SAEP 351 the requirements of SAEP 351 shall toke precedence. METHOD OF STATEMENT 6.1 Pre-Assembly Inspection. The flange facing, particularly the seating area, shall be visually examined for cleanliness And ensure that no damage, such as scratches exist for ring joint type flanges, the ring and the ring groove shall be free of damage and dirt. All bolts and nuts will be inspected to ensure correct materials are being used and items are free from any damage which may interfere with assembly or performance Gaskets shall be checked for size, ratings, type and condition prior to installation. (All gasket that shall be fitted on temporary basis shall be clearly marked on the outer rim with red paint). Tightening tools shall be checked for adequacy, performance and calibration, if required. Verify that proper lubricant is used. Lubricant for bolts and nuts shall be lubricated acceptable lubricants listed in table-SAEP-351.-01. Verify that lubricant is not used on the gasket seating area. aioSaual Arabia FLANGE BOLTING and GASKET VERIFICATION PROCEDURE | Boe. No GNP 170,006 Br. CAT. Into. Lis | REV.NO 6.2 GASKET VERIFICATION AND INSTALLATION All gasket shall be issued in accordance with material take offs, drawings and specification the control of issuance of gasket shall be responsibility of material controller and mechanical engineer. Gaskets shall be installed and flanges aligned in order to ensure no damage to gasket ‘occurs during subsequent tightening operations. Final inspection and verification of the correct gasket installation shall be recorded on form SATR-L- 2001 by QC Inspector and initialed by client inspector. 6.3 TORQUING TOOLS ‘There are various types of tools available ta achieve the proper torque value. Selection of the proper tools depends on the stud bolt size, physical location of the flanged joint, and critically of the flange. Torque wrench calibration shall be performed in accordance with manufacturer's recommendations, Asall flanges utilized at Khuff Gas & Maintained Potential projects were 8” and below. C.A.T propose to use calibrated dial torque wrench as a default torqueing method. For torque tightening bolts of 8” and above method should be initiated & accepted by the concerned parties (1-contractor 2-SMPT 3-SAPID, & 4-Proponent) and on each Torqueing. Process 6.4 TORQUING Torque values vary according to flange rating, bolt the thread lubricant, The torque values are specified in Table SAEP-351-02 and Table-SAEP-351-03. , type of gaskets and friction factor of ‘Table SAEP-351-02 Applies to all gaskets listed in SAES-L-109 except for insulating gaskets, based on a friction factor of 0.12, using graphite and oil Table SAEP- 351-03 applies to isolating gaskets (e.g PIKOTEK) based on a friction factors of 0.125. 5/10[ FLANGE BOLTING and GASKET VERIFICATION PROCEDURE | Doc. No GAVP 170.D0C Br. GAT. Intl Co, Led REV.NO € Saudi Arabia 7. STUD BOLT TIGHTENING PROCEDURE Step 1 Align flanges and gasket, forced tightening is not allowed to overcome non acceptable Alignment tolerances. Clamp securely in place. Step 2 Apply lubricants to stud threads aver length and nut engagement and to face of nut which contacts flanges. Ensure that the nuts run freely down the thread of the stud. Step 3. Install all studs and nuts hand tight, ensure that the stud such that only the crawn of, the stud projects beyond the face of the nut. The excess stud length should project beyond the nut on the other side. Step 4 Number each stud according to its position in the flanges as shown on figure 1: stud bolt tightening sequence. StepS Tighten studs per the stud bolt tightening sequence per figure SAEP-351-01 with an appropriate tool such as an air impact wrench or equal. Step 6 For joint containing RT Joint or spiral wound gaskets, repeat step 5. Step 7 Tighten the stud bolts in stages to obtain the final required torque from the appropriate torque Table-SAEP-351. The first stage should not be more than 30% of the final torque. ‘The final torque shall be within + 5% of the required torque value. ‘Stud bolts shall be tightened in stage to obtain final torque values in accordance with relevant Table, the first stage shall not exceed 30% of the final value with final value attained within +/- 5% of required torque. 7.1 ACTIONS WHEN LEAKS OCCUR DURING PRESSURE TESTING Steps-1 Depressurizing the piping system and re-torque stud bolts to maximum torque Value shown on table SAEP-351, Step-2 If leak does not stop after re- torqueing has been performed, disassemble the flange joint and inspect as follows: a. Inspect stud bolts and nuts for defects or damage to threads or improper cleaning of threads. b. Inspect flange faces for damage misalignment, ¢. Inspect gasket for damage or defects. 6/10CAT. Into. Ld ‘Sau Arabia FLANGE BOLTING and GASKET VERIFICATION PROCEDURE | Doe. No.2 QAP 170.006 ~ REV.NO ce Step-3 After all defective and damaged items have been repaired or replaced. re- assemble the flange joint using a new gasket and tighten the bolts using the maximum torque values. 8. RECORDS All records pertaining to this procedure shall be filed and maintained in the project QA/QC office until completion of the project at which time they shall be transferred for achieving in ‘accordance with project requirements, 9, REFERENCES OWP 109 Control of Quality Records. SAEP-351 Bolted Flange Joint Assembly SAES-1-109 Selection of Pipes Flanges, Bolts and Gaskets ‘SAES-L-350 Construction of Plant Piping ASME 816.5 Pipe Flanges and Flanged Fittings NPS in Through NPS24 ASME 816.47 Large Diameter Steel Flanges NPS 26 through NPS 60 10. ATTACHMENT 10.1 10.2 10.3 10.4 Table SAEP-351-01 Friction Factors for different lubricant Table SAEP-351-02 Torque Value for A193 67 and 87M stud bolts with A194 2H and 2HM nuts. Table SAEP-351-03 Torque values for isolating gaskets (PIKOTEK) on ASME B16.5 and ‘ASME B16.47 Series A & B, Class 150 through class 2500 flanges. Figure SAEP-351-01 Stud Bolt Tightening Sequence. 7/10| Br. CAT. Intl Co. Li ‘Sau Arabia REV.NO c FLANGE BOLTING and GASKET VERIFICATION PROCEDURE | Doc. Nox QAP 170.06 ] Figure SAEP-351-04 ~ Stud Bolt Tightening Sequence (4 to 32 Bolts) 8/10FLANGE BOLTING and GASKET VERIFICATION PROCEDURE | Doe. No? GAP 170.00 1. CAT. Int Co. Lia Sau Arabia Table-SAEP-351-02 ~ Sugar Se inch Nonsatea Bas Coned Bats 42 a 50 45 ae 120 2 avs zo 180 78 0 259 1 500 200 To 750 50 M4 “80 500 5 100 780 free 1800 “00 [ere 2350 1800 134 2360 2300 18 2600 2800 2 #800 3100 is 6800 2800 000 809 12000 a 9100 3 15700 11900 bin 20100 15500 7 25300 "S100 334 31200 23800 4 2009 zas00 | Notes: 1) Torque values are based on 50,000 psi prestrass on stud halts and Friction Factor of 0.18 for oncoated surfaces and 0.12 for new coated surfaces. A combination of various elemants such as the conditions of the threads, the condition of the flange to the nut bearing surface and the type of lubricant user, makes up the ffiction factor which ean vary from .04 {9.20 ar as much as 500%. 2) Torque. values for stainless stee! or other alloy stud bolts can be obtained by muttinlving the Fatio of the specified minimum yield strengtn (SMYS) of stainlace elool stud bolts 42.4193 57 stud bolts, to the torque values in the Table-SAEP-351.02, The SMYS values for all bling Materials are listed in ASME 831.3 code (Note: SMYS depends on grade, class and eiz0), 9/10® FLANGE BOLTING and GASKET VERIFICATION PROCEDURE | Doc. Nov GAP 170.000 Br. CAT. IntiCo, id REV.NO ce Saudi Arabia as Sud Bor Si Torque Value] inch feb ia = ne = a © we 709 7 789 7 25 ie 5 4 eo 738 m0 7a 00 er 00 7500 2000, a 00 s1a0 4400 Ee 220 { 3 ‘0 314 8400 Bz 000, ia sso0 a ‘Doo Note: Torque values based on 30,000 ps tension load and 0,16 Friction Factor from ‘APIBULL 5A2 thread compound, See Table-SAEP-351.02 Nola (1) for other factors, Commentary Notes: a) For ASME Class 200 through Class 2500, API-6B and AP-6BX Class 2000 through Glass 15000, and RTJ Flanges, the maximum compressive stresses induced during installation should not exesed 25,000 psi. Design to 12,500 psi when possible. 5) Caloulations for compressive stresses apolied during forque-up procedures must account for rng joint grooves, gasket seal grooves, ralsed face dlameters, and gasket inside diameter. (See PIKOTEK Gasket User's manual) ©) Bolt tensioning equipment such as HYDRATIGHT may be used for class 900 andt above resulting in @ minimum residual bolt stress of 30000 pal and w maximum of 50,000 psi. Refer to PIKOTEK Gasket User's manual or specific bolting Instructions. 10/10