CW140530

Turnaround Management and Execution

Services (TMES)
SHELL PROJECT CONTRACTOR
CW140530 1102174QSH22
NUMBER CONTRACT NUMBER
CONTRACTOR JOB
1102174QSH22 CONTRACTOR NAME MADINA GROUP W.L.L.
NUMBER

CONTRACTOR DOCUMENTATION

Turnaround Management and Execution Services STATUS OF SUBMISSION

PROJECT NAME
(TMES) (Contractor must indicate one status only)

SCOPE PACK NUMBER - Issued for Information

SCOPE PACK TITLE - Issued for Approval (IFA)

CONTRACTOR
Rev.: 3 Issued for Construction (IFC)
DOCUMENT NUMBER

TITLE Issued As-Built (IAB)

TAG/ITEM NUMBER(s):

CONTRACTOR (Prepared By) CONTRACTOR (Check/Approved By) Initials /

CONTRACTOR (Revision Date)
Initials / Signature: Signature:

Sajin Shanmughan 31-Oct-2021

QSGTL
REVIEW CODE and STATUS (indicate one Code & Status only) Date
Initials/Signature

Digitally signed by Pradeesh

A Final - Accepted Kannan
Date: 2021.11.11 10:20:36 +03'00'

B Up-rev and Re-submit. Work May Proceed

C Retain For Information Only

Rejected. Up-rev and Re-submit.

D Work May NOT Proceed

UNIT - DOC CLASS - DISCIPLINE QA/QC

DOCUMENT DOCUMENT SUB -

IFC
STATUS TYPE CODE

PROJECT DOCUMENT
T-4.820.410 PROJECT REVISION 3
NUMBER
CONTRACTOR: CW140530 CLIENT:
MADINA GROUP W.L.L. QATAR SHELL GTL
Turnaround Management and LIMITED (QSGTL)

Execution Services (TMES)

Flange Management Procedure
PROJECT TITLE: CLIENT CONTRACT NO.:
CW140530
Turnaround Management and Execution Services
(TMES) CONTRACTOR PROJECT NO.:

1102174QSH22

CLIENT DOCUMENT NO.: CONTRACTOR DOCUMENT NO.:

T-4.820.410 Q_(1102174QSH22)_PRO_013_R3

DOCUMENT TITLE: REVISION NO.: PAGE NO.:

Flange Management Procedure 3 Page 1 of 46

Flange Management Procedure

Digitally signed
by Pradeesh
Kannan
Date: 2021.11.11
10:24:35 +03'00'

3 31-Oct-2021 Issue for construction SV SS DM PK

PK
2 26-Aug-2021 ISSUED FOR APPROVAL SV SS DM
PK
1 06-July-2021 ISSUED FOR APPROVAL SV SS DM
PK
0 15-Dec-2019 ISSUED FOR APPROVAL GM SS DM

PREPARED CHECKED APPROVED APPROVED

REVISION DATE DESCRIPTION
MGW MGW MGW QSGTL
 PROJECT TITLE:
CW140530
Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
CW140530 1102174QSH22
CLIENT DOCUMENT NO.: CONTRACTOR DOCUMENT NO.:
T-4.820.410 Q_(1102174QSH22)_PRO_013_R3
DOCUMENT TITLE: REVISION NO.: PAGE NO.:
Flange Management Procedure 3 Page 2 of 46

REVISION RECORD

Rev. Date Description of Change

0 15-Dec-2019 First formal issue. Issued for Approval (IFA).

1 06-July-2021 Re-Issued for approval (IFA)

2 26-Aug-2021 Comments incorporated and issued for approval (IFA)

3 31-Oct-2021 Issued For Construction (IFC)

Approval History

APPROVED APPROVED
ORIGINATOR REVIEWED BY
BY(MADINA) BY (QSGTL)

POSITION Lead QAQC QAQC Manager Site Manager TA Flawless Lead

NAME Subhash Sajin Shanmughan Durai Murugan Pradeesh Kannan

Digitally signed
SIGNATURE by Pradeesh
Kannan
Date: 2021.11.11
DATE 31-Oct-2021 31-Oct-2021 31-Oct-2021 10:24:53 +03'00'

Note:
 PROJECT TITLE:
CW140530
Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
CW140530 1102174QSH22
CLIENT DOCUMENT NO.: CONTRACTOR DOCUMENT NO.:
T-4.820.410 Q_(1102174QSH22)_PRO_013_R3
DOCUMENT TITLE: REVISION NO.: PAGE NO.:
Flange Management Procedure 3 Page 3 of 46

Contents
1 PURPOSE .......................................................................................................................... 5
2 SCOPE ............................................................................................................................... 5
3 REFERENCE DOCUMENTS .............................................................................................. 5
4 DEFNITIONS ...................................................................................................................... 5
5 RESPONSIBLITES ............................................................................................................ 6
5.1 QA/QC ............................................................................................................................... 6
5.2 Supervisor.......................................................................................................................... 6
5.3 Technician ......................................................................................................................... 6
6 FLANGE TECHNICIAN QUALIFICATION ......................................................................... 6
6.1 Selection, Trade test and Training...................................................................................... 7
6.2 Certification ........................................................................................................................ 8
7 PROCEDURES .................................................................................................................. 8
7.1 General Requirement ......................................................................................................... 8
7.2 Conventional Spanners / Wrenches ................................................................................... 8
7.3 Torque Wrenches .............................................................................................................. 8
7.4 Hydraulic Bolt Tensioning Equipment ................................................................................. 8
7.5 Factors Affecting Performance of Flanged Bolted Joints .................................................... 9
7.5.1. Flange Tightening technician Qualification ......................................................................... 9
7.5.2. ....................................................................... 9
7.5.3. Calibration of equipment .................................................................................................. 10
7.5.4. Gasket Type..................................................................................................................... 10
7.5.5. Gasket Contact Surface ................................................................................................... 10
7.5.6. Flange Alignment ............................................................................................................. 11
A. Types of Alignment .................................................................................................................. 12
B. Set Up prior to Measurement ................................................................................................... 12
C. Acceptance criteria for Misalignment ....................................................................................... 12
1 Lateral alignment .................................................................................................................. 12
2 Parallelism ........................................................................................................................ 13
7.5.7. Bolt and Nut quality / calibration ....................................................................................... 13
7.5.8. Bolt Lubrication ................................................................................................................ 14
7.5.9. Bolting up sequence......................................................................................................... 14
 PROJECT TITLE:
CW140530
Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
CW140530 1102174QSH22
CLIENT DOCUMENT NO.: CONTRACTOR DOCUMENT NO.:
T-4.820.410 Q_(1102174QSH22)_PRO_013_R3
DOCUMENT TITLE: REVISION NO.: PAGE NO.:
Flange Management Procedure 3 Page 4 of 46

7.5.10. Bolt stresses .................................................................................................................... 15

a. Bolt Torquing.................................................................................................................... 15
7.6.1. General Requirements ..................................................................................................... 15
7.6.2. Torquing Procedure ......................................................................................................... 15
b. Bolt Tensioning ................................................................................................................ 16
7.7.1. General Requirements ..................................................................................................... 16
7.7.2. Tensioning Procedure ...................................................................................................... 17
c. Thread lubricants and preservation fluid........................................................................... 18
d. Oxygen services .............................................................................................................. 19
e. Hot bolting and Half bolting .............................................................................................. 19
3 QUALITY ASSURANCE/TRACEABILITY........................................................................ 20
a. Flange Technician Qualifications...................................................................................... 20
b. Flange Protocol Documentation ....................................................................................... 20
c. Flange Joint Assembly Label/Tag .................................................................................... 21
d. Lesson Learned ............................................................................................................... 21
Appendix B. Non-Lubricated: Bolts for Oxygen service .................................................................. 27
Appendix C. Flange Torquing Values & Tightening Methods ........................................................... 28
Appendix D: Bolt stress for different types of flanges and fluid temperature. .................................. 29
Appendix E Flange joint Assembly Label/tag sample format......................................................... 30
Appendix F -Hidden Gasket ............................................................................................................ 35
Appendix G -Gasket Colour code .................................................................................................... 37
Appendix H Flange Torquing Form ............................................................................................... 38
Appendix I Flange Tensioning Form ............................................................................................. 40
Appendix J Flow chart for Flange data base updation .................................................................. 42
Appendix K Flawless program for Tightness ................................................................................. 43
1.Procedure..................................................................................................................................... 43
1.1 General: ........................................................................................................................... 43
1.2 Consequences: ................................................................................................................ 43
1.3 Instructions:...................................................................................................................... 43
2.Performance indicators................................................................................................................. 46
3.Attachment ................................................................................................................................... 46
 PROJECT TITLE:
CW140530
Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
CW140530 1102174QSH22
CLIENT DOCUMENT NO.: CONTRACTOR DOCUMENT NO.:
T-4.820.410 Q_(1102174QSH22)_PRO_013_R3
DOCUMENT TITLE: REVISION NO.: PAGE NO.:
Flange Management Procedure 3 Page 5 of 46

1 PURPOSE

The purpose of this procedure is to specify requirements for tightening flange bolting using
spanners, wrenches, torque wrenches (manual and hydraulic) and hydraulic bolt tensioning
equipment, providing guidance on the method of flange tightening to be used, the bolt stresses
and torques required to ensure a lasting leak free joint.

2 SCOPE

This procedure is applicable for Tightening of piping & equipment flange joints, and it is not
applicable for GRP/GRE Flanges which is available in the QSGTL Plant. Bolt Values shall be
obtained from the GRP/GRE System Manufacturer (OEM) or in case these are not specified the
Engineering Services Manager or Mechanical Integrity Manager.

3 REFERENCE DOCUMENTS

NAME NUMBER

TA Quality plan R-0000001205 Rev.6

Shop & DEP 31.38.01.31 Gen

Pressure Vessel (based on ASME Sec VIII) DEP 31.22.20.31 Gen

Piping -General requirements DEP 31.38.01.11-Gen
Piping classes - Basis of Design DEP 31.38.01.10-Gen
Installation of Rotating Equipment DEP 31.29.00.10
Appendix-4 "Equipment and tools for maintenance
Mechanical Maintenance equipment tools and bolts DEP 70.08.10.11-Gen
tensioning
Rules for bolted flange connections with flat ring types of ASME VIII Div. 1&2-Appendix
gaskets. -2
ASME VIII Div. 1&2
design considerations for bolted flange connections. Appendix-S
Site-Wide Flange Tightening and Management Procedure E. PR.O.WS.0464 Rev.7

4 DEFNITIONS

TERM DEFNITIONS

MESC Material & Equipment Specification Code

 PROJECT TITLE:
CW140530
Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
CW140530 1102174QSH22
CLIENT DOCUMENT NO.: CONTRACTOR DOCUMENT NO.:
T-4.820.410 Q_(1102174QSH22)_PRO_013_R3
DOCUMENT TITLE: REVISION NO.: PAGE NO.:
Flange Management Procedure 3 Page 6 of 46

OEM Original Equipment Manufacturer

Joints that are typically more difficult to seal, joints that have a history of
Critical Flanges leakage, or joints where leaks could result in high consequence incidents
due to their size or service conditions.
Tightening The making tight of a flanged joint by torquing or tensioning the flange bolts
The loading/stressing of flange bolts using manual or hydraulic torque
Torquing
wrenches
Tensioning The loading/stressing of flange bolts using hydraulic jacking tools
a method where the loading/stressing of flange bolts is measured to
Controlled
achieve a pre-determined value
Dry-bolt Stud-bolt without thread lubricant

5 RESPONSIBLITES

5.1 QA/QC

Ensuring all stages of the Bolt torquing & tensioning activities are carried out in line with
Contract requirements and client specifications. He may be responsible for the safe and
proper execution of this procedure.

5.2 Supervisor

The designated Supervisor is responsible for ensuring that only trained personnel are
present in the job execution. He shall be responsible for the safe completion of Bolt
torquing & tensioning as per the Scope of work.

5.3 Technician

The Bolt torquing & tensioning technician shall be trained and experienced in the job. He
shall be familiar with the instrument and its operational features.

6 FLANGE TECHNICIAN QUALIFICATION

The Flange technician is responsible for making the Flange Joint. The Flange technicians shall
be trained, qualified, competent and shall have sufficient experiences for the Flange tightening
works to be done.

Flange Technicians qualifications / training records shall be maintained in a Madina database

and shall be handed over on request to QSGTL before the works starts or without slowing down
the works.
 PROJECT TITLE:
CW140530
Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
CW140530 1102174QSH22
CLIENT DOCUMENT NO.: CONTRACTOR DOCUMENT NO.:
T-4.820.410 Q_(1102174QSH22)_PRO_013_R3
DOCUMENT TITLE: REVISION NO.: PAGE NO.:
Flange Management Procedure 3 Page 7 of 46

Table -1 Flange Technician Qualification

Flange Technician Training Years of
Job Title
Requirements Experience

Trained and qualified to work with standard Min.3 years

Flange Technician 1
hand spanners/wrenches and Manual
(FT-1)
torque wrenches
Trained and qualified to work with Min.5 years
Flange Technician 2
Hydraulic torque wrenches
(FT-2)
Trained and qualified to work with Min.5 years
Flange Technician 3
Hydraulic tensioning
(FT-3)
Additional training for work on pure O2 Training Passed
Oxygen Flange
systems. Only applicable for FT s working
Technician (FT-OX)
on Pure O2 systems

6.1 Selection, Trade test and Training

FT1 Technicians from Madina

Technicians selected based on CV review, face to face interview and finally trade test with flange
tightening rig. Madina should select FT1 technicians based on their experience, knowledge, and
assembling/tightening performance score during their trade test. Madina shall intimate QSGTL in
advance for witnessing trade test during the selection process, final approval status shall be
aligned with QSGTL delegated witness party.

After selection and approval, technicians shall be mobilized to turnaround, and prior to work site
assignment they shall undergo specific training (Online or classroom) to get awareness and
knowledge in flange management and tightening requirements based on QSGTL procedure and
previous lessons learned and best practices.

performing the bolt torquing and tensioning shall be trained by in-house or external trainer. The
Flange Tightening Training manual shall be approved by the QSGTL Subject Matter Expert
(SME).

Technicians (FT1/ FT2/FT3/FT-OX) from Tightening subcontractor

Tightening subcontractor personnel are not required to undergo practical examination.

Based upon subcontractor qualification certificates, clients approve flange technicians.

Subcontractor shall ensure all their technicians are trained and qualified as per their
internal qualification procedure and meeting the requirements identified in the table
 PROJECT TITLE:
CW140530
Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
CW140530 1102174QSH22
CLIENT DOCUMENT NO.: CONTRACTOR DOCUMENT NO.:
T-4.820.410 Q_(1102174QSH22)_PRO_013_R3
DOCUMENT TITLE: REVISION NO.: PAGE NO.:
Flange Management Procedure 3 Page 8 of 46

above. Subcontractor shall submit their technicians qualification/training records upon

request.

Subcontractor technicians working on oxygen service flanges shall have attended oxygen
awareness training and they must have identified with O2 sticker on their helmet.

6.2 Certification

After the successful completion of selection trade test and training a wallet card will be
issued for all person
card with them while working in site.

The certificate shall be valid for 2 years and revalidation shall be followed by conducting
a refresher Training or based on his past performance.

7 PROCEDURES

7.1 General Requirement

The method of flange tightening is dependent upon bolt size, system pressure rating and
system service and shall be as follows:

7.2 Conventional Spanners / Wrenches

Flange bolts may be tightened by conventional (ring) spanners on class 150 utility piping
Systems only (excluding Flare System), but NOT on GRP flanges or steel flanges on GRP
lap joints. Use of adjustable spanners and open-end spanners shall be avoided.

7.3 Torque Wrenches

Flange bolts shall be tightened by torque wrenches on all hydrocarbon systems & critical
services in all pressure classes and utility systems . Bolt torque values for flanges in GRP
systems and/or pipe clamp connectors (PCCs) shall be obtained from the Manufacturer
and shall be reconciled with target gasket seating stress. Flogging of bolts is not permitted
because it is inaccurate and unsafe. As well as the risk of injury to personnel, there is a
risk that the bolts, the flange or the gaskets are damaged. Above 680 Nm torque value
hydraulic torque wrenches shall be used.

7.4 Hydraulic Bolt Tensioning Equipment

Where more stringent control of joint stresses is required, flange bolting should, whenever
practical, be tightened using hydraulic jack tensioning equipment, and is strongly
recommended for following services and pressure ratings:

-1/2" in all services for ratings Class 1500# and above

 PROJECT TITLE:
CW140530
Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
CW140530 1102174QSH22
CLIENT DOCUMENT NO.: CONTRACTOR DOCUMENT NO.:
T-4.820.410 Q_(1102174QSH22)_PRO_013_R3
DOCUMENT TITLE: REVISION NO.: PAGE NO.:
Flange Management Procedure 3 Page 9 of 46

Bol -1/2" in hydrogen service for rating class 600# and above.

Critical applications are considered to be joints exposed to cyclic stress i.e. frequent
changes of pressure and/ or temperature.

7.5 Factors Affecting Performance of Flanged Bolted Joints

Apart from Bolt tightening Procedure, there are several independent factors which are
essential to obtain good performance from a bolted flange connection. These are.

Flange tightening technician Qualification.

Flange Tightening Equipment

Gasket Type

Gasket Contact Surface

Flange Alignment

Bolt and Nut Quality

Bolt Lubrication

Bolting up Sequence

Bolt stress applied.

7.5.1. Flange Tightening technician Qualification

to be done as per Clause 6.0

7.5.2. Selection of Flange Tightening

Flange tightening equipment shall be suitable for the works to be done. Depending on the
consequence and bolt size different type of tightening equipment shall be used.

Non-controlled tightening using spanners, wrenches or impact wrenches can achieve the
correct bolt loading, but this cannot be confirmed and repeatability and is dependent on
the skill of the individual Flange Technician.

Flogging of bolts is not permitted because it is inaccurate and unsafe. As well as the risk
of injury personnel, there is a risk that the bolts, the flange, or the gaskets got damaged

For TA events only, a controlled procedure is in place for usage if flogging spanners

Controlled Bolt Torquing will achieve much more uniform gasket loading. Tools can apply
torque accurately to within ±10% of the set value, however due to the friction variables it
 PROJECT TITLE:
CW140530
Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
CW140530 1102174QSH22
CLIENT DOCUMENT NO.: CONTRACTOR DOCUMENT NO.:
T-4.820.410 Q_(1102174QSH22)_PRO_013_R3
DOCUMENT TITLE: REVISION NO.: PAGE NO.:
Flange Management Procedure 3 Page 10 of 46

is not uncommon for actual bolt load/stress values to be ±30% of the target stress,
resulting in deformation of the gasket contact surface or under compression of the gasket.

Bolt Tensioning (Bolt elongation/stretch control) is a more accurate way of achieving the
required bolt/stud pre-load (stress). Some of the initial load is lost when the strain is
transferred from the hydraulic jacking tool to the nut, but experienced and qualified
controlled bolting contractors can compensate for this. Using these method pre-load
values within ±10% of the target stress can be achieved.

7.5.3. Calibration of equipment

Manual torque wrenches / spanners, hydraulic torque equipment and hydraulic tensioning
equipment shall be calibrated before use. Calibration and re-calibration date shall be
shown on the equipment itself. Calibrations shall be carried out every 6 (six) months by
an in house or External Party. Refer to the Madina procedure(T-4.820.401) for control of
measuring and test equipment.

7.5.4. Gasket Type

Gaskets shall be suitable for operating conditions and remain flexible under varying load
due to fluctuations in pressure and temperature. The type of gaskets used shall comply
with the gasket shown in the Piping Class or equipment drawing.

Any deviation, permanent or temporary, with respect to gaskets from piping class or
manufacturing drawing shall be subject to Management of Change (MOC) Procedure.

Gaskets can only be used once and shall not be re-used.

When installing new gaskets, you shall ensure that flange and gasket faces are
completely clean and dry, see also paragraph 7.5.5.

7.5.5. Gasket Contact Surface

The gasket contact surface shall comply with the piping class material specification,
normally raised faced. Examine surfaces for damage such as scratches, nicks, gouges,
corrosion, and burrs. Indications running racially are of particular concern and should be

for new flanges and, PCC1 Table D- vs. Width Across

.

The contact surface shall also be clean and free from grease, dirt, sealant, protective
coating etc. For severe blemishes consider flange face machining (which may require T
min calculation and supporting documentation). The back of the flange at the nut seating
area should be smooth finished.
 PROJECT TITLE:
CW140530
Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
CW140530 1102174QSH22
CLIENT DOCUMENT NO.: CONTRACTOR DOCUMENT NO.:
T-4.820.410 Q_(1102174QSH22)_PRO_013_R3
DOCUMENT TITLE: REVISION NO.: PAGE NO.:
Flange Management Procedure 3 Page 11 of 46

Notes: Special cleaning for oxygen services is required (see paragraph 7.9)

Open gasket facings shall always be properly protected against damaging, i.e. by a
wooden ring in case of a manhole.

7.5.6. Flange Alignment

The flange faces should be aligned such that bolts can be easily inserted through the bolt
holes. A maximum of 3mm rotational misalignment is allowable, see picture below

Allowable Rotational Flange misalignment

 PROJECT TITLE:
CW140530
Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
CW140530 1102174QSH22
CLIENT DOCUMENT NO.: CONTRACTOR DOCUMENT NO.:
T-4.820.410 Q_(1102174QSH22)_PRO_013_R3
DOCUMENT TITLE: REVISION NO.: PAGE NO.:
Flange Management Procedure 3 Page 12 of 46

A. Types of Alignment

Two types of alignment are recognized:

1 Lateral alignment that is the offset of the aligned flange centrelines, applicable to the
complete flange set as well as the relative positioning of bolt holes.

2 Parallelism of the aligned flange faces, sometimes referred to as angular alignment.

Parallelism (Left) and Lateral alignment (Right)

B. Set Up prior to Measurement

The flanges shall be lined up so that the bolts can be inserted without force.
A gasket and 25 percent of the bolts (with at least four) shall be inserted. The bolts shall
be uniformly fastened using manual spanners to take out the free slack, to ensure the
real misalignment will be measured.

C. Acceptance criteria for Misalignment

1 Lateral alignment

For standard flanges, the free insertion of the bolts is generally sufficient to demonstrate
acceptable alignment. Lateral alignment may also be checked by laying a straight edge
along the outside diameter of the flange. Measurements should be taken at locations
90° apart around the flange circumference.

The measured lateral misalignment shall not exceed the following values:

Pipe Size Maximum

misalignment

DN 100 (NPS 4) 2 mm (0.08 in)

DN 100 (NPS 6) 3 mm (0.12 in)

Bolt holes shall straddle the natural centreline unless specified otherwise.
 PROJECT TITLE:
CW140530
Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
CW140530 1102174QSH22
CLIENT DOCUMENT NO.: CONTRACTOR DOCUMENT NO.:
T-4.820.410 Q_(1102174QSH22)_PRO_013_R3
DOCUMENT TITLE: REVISION NO.: PAGE NO.:
Flange Management Procedure 3 Page 13 of 46

2 Parallelism

Flange face alignment shall be checked by measuring the distance between the mating
flanges of the pre-assembled joint. Measurements shall be taken around the
circumference at equal distances from the centre line (the outside rim of the flange will
normally be the most convenient position).

The difference between the measurements shall not exceed the following values:

Maximum of 0.8mm difference between the widest and narrowest gap at the OD of the
sealing surface, as mentioned when the bolt load is no greater than 10% of the target
bolt assembly stress for any bolt.

For flanges connecting to the rotating equipment (Pumps, Compressors), the

flange face alignment check shall be performed with bolting inserted loosely.

The acceptance criteria shall be below as per DEP 31.38.01.31 Table H2.

< DN 300 (NPS 12) 0.2 mm (8 mil)

DN 300 to DN 600
0.3 mm (12 mil)
(NPS 12 to NPS 24)

DN 600 (NPS 24) 0.5 mm (0.02 in)

7.5.7. Bolt and Nut quality / calibration

The flange bolt assembly must be capable of generating sufficient load to initially seat the
gasket, and to maintain load on the assembly during operating conditions to ensure the
seal. The bolt and nut material and size are specified in Piping Spec or construction
drawings and should be checked to be correct for the application and should be examined
for any visual damage or imperfection. Defects shall be reported by the supervisor to the
appointed Engineer. If bolts are to be re-used, ensure the following

Bolts shall be thoroughly cleaned (wire brushed)

Bolts and nut must be free of any galling or thread deformation.
Bolts shall be inspected for elongation, thread damage, deformities, and
corrosion/cracks
For H2, O2 and critical flanges the stud bolts and nuts should be replace after every use
 PROJECT TITLE:
CW140530
Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
CW140530 1102174QSH22
CLIENT DOCUMENT NO.: CONTRACTOR DOCUMENT NO.:
T-4.820.410 Q_(1102174QSH22)_PRO_013_R3
DOCUMENT TITLE: REVISION NO.: PAGE NO.:
Flange Management Procedure 3 Page 14 of 46

To ensure consistent performance of bolts it is essential that bolts and nuts are supplied
with the precise specification for tolerance and fit as required by MESC description, which
is ANSI B1.1 class 2A/2B.

Note: Special cleaning of bolts and nuts are required for oxygen services, see paragraph
7.9.

Although bolts and nuts are designed for a particular service, sometimes elongation will
happen due to temperature runaways, pressure surge or creep. Bolts shall be calibrated
for this reason.

shall be done between the nuts, so in the stressed area. In case 2% elongation is
observed, the bolts shall be rejected and replaced by new.

The procedure how to perform this bolt calibration shall be developed by the Bolt
Tensioning / Torquing Contractor. The calibration shall be done while breaking the flange
connection. By doing so, we are able to order new bolts and nuts if needed.

7.5.8. Bolt Lubrication

Bolt lubrication is essential for providing the low coefficient of friction for manual
techniques as well as providing anti-seize properties at temperature. See lubrication of
bolts in section 7.8.

Note: No bolt lubrication shall be applied on flanges in Oxygen Services, see paragraph
7.9.

7.5.9. Bolting up sequence

Correct bolt up sequence is essential for ensuring that the gasket compression is applied
 PROJECT TITLE:
CW140530
Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
CW140530 1102174QSH22
CLIENT DOCUMENT NO.: CONTRACTOR DOCUMENT NO.:
T-4.820.410 Q_(1102174QSH22)_PRO_013_R3
DOCUMENT TITLE: REVISION NO.: PAGE NO.:
Flange Management Procedure 3 Page 15 of 46

three stages when methods other than hydraulic bolt tensioning are used. This sequence
method is outlined in paragraph 7.6.2.

7.5.10. Bolt stresses

The required torque values, recommended bolt stress (40% to 70% of allowable stress)
and bolt load to achieve joint tightness for piping classes and equipment are given in
tables Appendix C. The torque values and tensioning bolt load will generate the bolt
stresses necessary for gasket seating (20 Ksi) for design and hydrostatic test pressures,
differences in coefficient of thermal expansion and bolt relaxation, but will not overstress
the flange or crush the gasket. Any temperatures or material combinations not covered in
Appendix C should be referred to Engineering Services Department and shall be reported
to the QSGTL Area Maintenance Manager.

a. Bolt Torquing

7.6.1. General Requirements

Controlled torque wrenching shall be carried out using either manual or hydraulic torque
wrenches. The method chosen is dependent upon bolt loading, access, clearance, and
tooling availability, which can be determined by site personnel. When the bolt loading
requires a torque figure of more than 500Lbs.ft (678Nm) to be applied, hydraulic torquing
is recommended, using hydraulic torque wrenches.

7.6.2. Torquing Procedure

(As per E. PR.O.WS.0464 Rev 7 with technical note Flange tightening Procedure)

To achieve joint tightness, it is important that the following procedure is adhered to:

a) Check and ensure that the general requirements of section 7.6.1 have been
satisfied.

b) To achieve uniform joint load / stress distribution the bolts shall be tightened in
three stages representing 30%, 60% and 100% of the torque values stated in
Appendix-A. At each stage of tightening, bolts shall be tightened in a controlled
sequence as follows:
 PROJECT TITLE:
CW140530
Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
CW140530 1102174QSH22
CLIENT DOCUMENT NO.: CONTRACTOR DOCUMENT NO.:
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(Bolts numbered clockwise around the flange)

4 bolt flange 1,3,2,4

bolt flange 1,5,3,7,2,6,4,8

12 bolt flange 1,7,4,10,2,8,5,11,3,9,6,12

16 bolt flange 1,9,5,13,3,11,7,15,2,10,6,14,4,12,8,16

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

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

28 bolt flange 1, 15, 8, 22, 4, 18, 11, 25, 6, 20, 13, 27, 2, 16, 9, 23, 5, 19, 12, 26,
3, 17,10, 24, 7, 21, 14, 28.

32 bolt flange 1, 17, 9, 25, 5, 21, 13, 29, 3, 19, 11, 27, 7, 23,15, 31, 2, 18, 10, 26,
6, 22, 14, 30, 8, 24, 16, 32, 4, 20, 12, 28.

Finally, the bolts shall be chased round using 100% of the torque value (4th Pass) and
100% of the torque value (5th Pass) until no nut movement occurs.

b. Bolt Tensioning

7.7.1. General Requirements

Controlled hydraulic bolt tensioning enable high integrity jointing to be achieved by

uniformly stretching the bolt shanks in the cold condition by means of hydraulic oil
pressure. The elongation produced in the bolt corresponds to calculated load required to
make the flanged joint tight /leak free.

Whilst the bolts are elongated, nuts can easily be run down the thread by hand, until they
bear against the flange. When the hydraulic pressure is released virtually all the bolt
extension is retained over its active length between the nuts, and the required bolt load is
obtained.

A jacking tool screws onto one end of the bolt; therefore, the bolt needs an additional
length of thread protruding out of the hexagonal nut at one end by about 1 to 1.5 times
the bolt diameter. After the tightening procedure is complete the extended thread length
should be protected against corrosion and damage to allow the nuts to be subsequently
unscrewed. Grease filled rubber or plastic caps are recommended for this purpose. In the
loosening procedure the bolts are stretched again, and the nuts unscrewed easily
providing the threads has been protected.
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The hydraulic pressure is supplied by a high-pressure oil pump via a distribution ring main
to several jacking tools. The number of tools used depends on application or total number
of bolts to be tightened. See section 7.7.2 for details.

Controlled hydraulic jack bolt tensioning shall be carried out on the following flanged
connections (where inadequate space or availability of restricts the use of tensioning, the
controlled torquing should be used)

-1/2" in all services for ratings Class 1500# and above.

-1/2" in hydrogen service for rating class 600# and above.

Critical applications are considered to be joints exposed to cyclic stress i.e. frequent
changes of pressure and/ or temperature.

7.7.2. Tensioning Procedure

To achieve joint tightness, it is important that the following procedure is adhered to.

Check and ensure that the general requirements of section 7.5 have been
satisfied.

The application of hydraulic jack bolt tensioning equipment shall be in strict

accordance with manufacturer instructions and safety procedures.

Personnel using the equipment shall be properly trained in its application.

The tensioning load/value and break loose pressure shall be validated by the PEI
engineer

The hydraulic bolt tensioning shall be followed by the procedure given below.

100 % Tensioning

1) Set up Hydraulic tools on all flange bolts simultaneously (50% of tensioners are
assembled on opposite side)

2) Apply Pressure-B to all bolts and tighten nuts with tommy-bar.

3) Release system pressure & Repeat applying Pressure-B twice further.

4) As a check, apply Pressure-B once more and attempt to further tighten flange
nuts. If nuts cannot be tightened, then tensioning is complete, and the tensioning
tool may be removed.
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Turnaround Management and Execution Services (TMES)
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If the flange nuts can be further tightened, then apply pressure -B until no further
movement of all nuts.

5) As a final check using a

remain.

In case the bolts cannot be tightened all at once, a two-stage approach shall be applied,
this is called 50% tensioning. Note: less than 50% bolt tensioning in principle is not
allowed. However, in case of very large diameter flanges, less than 50% tensioning can
be applied with the approval of QSGTL Engineering Department and/or Area
Maintenance Manager.

1) Set up hydraulic tools on first half set of alternate flange bolts, which shall be
positioned equi-spaced around the flange.

2) Apply pressure- A and tighten nuts with tommy- bar. Release pressure

3) Repeat step-2 twice further.

4) Apply pressure-B and tighten nuts with a tommy- bar. Release pressure

5) Repeat step-5 twice further.

6) As a check to see if an excessive load has been lost in the initial 50% of Bolts
tightened. Assemble two tensioner tools to randomly select but diametrically
Opposite odd numbered bolts Apply Pressure-B and attempt to further tighten of
the flange bolts. If the nuts cannot be further tightened, then tensioning is complete
& tensioners may be removed.

7) If the flange nuts can be further tightened then reassemble the tensioners to all
the odd numbered bolts, Apply Pressure -B and turn down the flange nuts once
more. The bolt tensioners may be removed now.

8) each bolt to ensure that no loose bolts

remain.

c. Thread lubricants and preservation fluid

Bolts and nuts shall be treated with a preservative lubricant using the approved grade
below:

Molykote P-37 can be used for very high temperature applications.

Note: The approved lubricant (molykote P37) shall not be mixed with any other liquids to
ease application. (e.g.: WD40). Adjustable Spanners or open-end spanners shall not be
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used by any means. In an event where accessibility is a concern MADINA shall raise
the concern to Asset Mechanical Integrity or Engineering Services or the Turnaround
Quality Team and shall use ring spanners (correct size) provided there is approval.

When the flange tightening is completed, to prevent corrosion a liberal coating of grease
shall be applied to the nuts up to the back of the flange and to the stud ends protruding
from the nuts. This is particularly important where low alloy bolts are used on unpainted
stainless-steel flanges.

Important note for oxygen services

Thread lubricants shall not be used on stud-bolts and nuts used for flanges in oxygen
service. After flange tightening is completed, no grease shall be applied for corrosion
prevention.

d. Oxygen services

Working on (pure) oxygen systems require special training. Training must be completed
before working on these systems.

Any dirt, debris (like foreign metal parts) or grease / lubricant can cause a spontaneous
fire once it becomes in contact with oxygen. A very high level of cleanliness and
cleanliness shall be applied and from this point of view grease or lubricants are not
allowed to use.

Flange Technicians working on pure oxygen systems shall be trained and for training
consult QSGTL Mechanical Integrity Manager.

e. Hot bolting and Half bolting

Hot bolting (single stud replacement) and half bolting are two different techniques. Hot
bolting refers to replacement of bolts (one by one) OTR while half bolting is the
technique used during a depressurization event to expedite bolt removal.
at the beginning of the turnaround. More details related to these techniques can be
found in Article 3.11 of ASME PCC-2. Few limitations on hot bolting and half bolting are
given below:

ssure is greater than 50%

of maximum pressure rating of the flanged joint, unless otherwise justified by
engineering risk assessment.
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less than 25% of the maximum flange pressure rating or 3.4 barg, whichever is lower.
Unless otherwise justified by engineering risk assessment.

otherwise justified by engineering risk assessment.

ting should not be performed on flanged joints in LPG service or other category
M fluids as defined in ASME B31.3. Hot bolting is not allowed unless written permission
is obtained from Area Maintenance Manager and Operation Area Manager.

3 QUALITY ASSURANCE/TRACEABILITY

a. Flange Technician Qualifications

For the required Flange Technician Qualifications, refer to Clause 6.0.

b. Flange Protocol Documentation

All flange connections shall have a unique identification and sometimes a pre-determined
Flange Identification Number (FIN number) which is preferably marked on PEFS.

In case a FIN number and protocol is required (Refer. Table -2), the following is
applicable:

A copy of the PEFS or isometric drawing showing the applicable flange

connection.

Mark the applicable flange connection on the document and give it a number.

The Flange Tightening Protocol FTP (Appendix C) showing the applicable

tightening information and the requested information.

The flange connection shall be marked in the field with the FIN number (label showing
this information).

Once the flange connection is made, the Flange Technician shall add his details / date /
torque values to the flange label (see par. 8.3) and shall complete the Flange Tightness
Protocol (FTP).

department for completeness and compliance with this Procedure and shall handed over
to QSGTL supervisor or appointed engineer who will review and archive the information
till the flange connection will be reopened.
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In case the flange is made by a QSGTL Flange Technician, the documentation shall be
reviewed by his / her Supervisor.

For Turnaround, Madina shall compile and maintain a spreadsheet showing all the flange
tightness information Madina has to work on. Madina shall show the database setup
before the works starts.

c. Flange Joint Assembly Label/Tag

The type of flange labels shall be:

Tear off tag.

Metal tag

Before breaking the flange, the tear off tag shall be filled with relevant information as per
flange database/flange tightening summary and same shall be hanged by supervisor or
his delegates. The tear of tag should have a unique number and the same should be
tracked after

After completion of the joint, the Flange Technician shall label the flange connection with
a metal label showing the following:

The unique flange joint number.

The date / name and signature of the Flange Technician responsible for making
the joint,

d. Lesson Learned

Lesson learned are the documented information that reflects the positive and negative
experience of a turnaround. Lesson learned need to collect during all phases of
Turnaround especially during Pre-TA and Execution. Madina shall maintain a lesson
learned register to actively record learnings as part of continuous improvement and same
shall be shared to QSGTL during and after the event.
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Table 2 Flange Protocol Requirements

Flange protocol shall be prepared for each work pack. Execution team shall follow the
protocol which is attached in work pack.

Class 150 Utility

All except O2
system Flanges Torque
and / or H2 Required Not required FT-1
only (excluding Wrench
services
Flare system)
All Hydrocarbon
systems in all
pressure classes Manual /
and Utility systems Hydraulic FT-1-Manual
All services Required Required
class 300 &above Torque FT-2- Hydraulic
(below Hydraulic wrench
Bolt-tensioning
bolt dia)

Hydraulic
All services Required Required
all the flanges Tensioning
FT-3
Hydraulic
All Services Required Required FT-3
1500# and up Tensioning
Hydraulic
Hydrogen Required Required FT-3
for 600# and up Tensioning
Critical
Hydraulic flange / FT-3 and FT-
Required Required
Tensioning applications OX
/Oxygen
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Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
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APPENDIX A Quality Control of Flange Joints during Turnaround Execution

1) Flange Quality Control (Spading/De-Spading) Process Flow

For detailed flow chart to refer site wide flange management procedure section
D4(E. PR.O.WS,0464 )

For Ops Support: FT-1 for all manual torquing with Torque wrench. For flanges where hydraulic torquing
or tensioning applies as per QSGTL procedure Contractor shall use FT2 and FT3 accordingly.

All the personnel working with flanges shall be followed Flange Quality Control (Spading/Despading)
Process Flow and Responsibility Assignment Matrix as below.

Contractor supervisors are responsible for hanging the tag on the flange to be broken as per the Flange
Tightening Summary attached in ROSER. Or Flange database.
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Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
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The required information as per the Flange Tag shall be filled by supervisor prior to hanging.

Once the flange is broken, either spaded or kept opened the Blue Tag is filled with relevant info by the
supervisor/technician and tear off. The teared off blue tag will be handed over to Contractor QC for their
records.

The supervisor / Technician in charge of mechanical scope is responsible for the visual inspection of the
flanges at break-up. Should a discrepancy be observed on the flange face or the condition of the bolts,
the supervisor / Technician shall report immediately to Contractor QC so as to ensure corrective action
is taken with minimum impact to Execution schedule (i.e. machining of flange face, ordering new bolts
from warehouse etc.)

Vents and Drains have not been included in this process, Quality Control of vents and drains fall under
Operations. Operations shall ensure qualified flange technicians are allocated to carry out final torquing
of vents and drains prior to start. Mechanical Contractor shall ensure only competent personnel are
allocated to any torquing or tightening activities.

In the field the flange which is been broken either kept as spaded or blinded in some cases kept open
will bear the above tag. The Red tag is filled and tear off. The teared off Red tag will be handed over to
Contractor QC for their records.

In addition, Temporary Tag will be provided by Tightening sub-contractor. This gives indication that the
line is Isolated or Disconnected.

When Flange is tightened for De Isolation or Flange is normalized, the yellow Tag and flange check list
Tag (white) is filled by flange technician who has boxed up. The Flange protocol is filled and signed off
which is attached with Work pack. The teared off yellow tag and Flange protocol will be handed over to
Contractor QC for their records. Where protocol is not required, Torque value shall be as per flange
tightening summary attached in the Roser work pack

The Green Tag will be filled by Contractor QC and tear off after verification and acceptance of the
flanges.

While breaking/spading /de-spading the flanges the flange database shall be updated with relevant
information, The flange database shall be updated as per appendix J
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Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
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Table 3 Flange Quality Control (Responsibility Assignment Matrix)

Note:

The supervisor in charge of mechanical scope is responsible for the visual inspection of the flanges at
break-up. Should a discrepancy be observed on the flange face or the condition of the bolts, the
supervisor shall report immediately to QSGTL Integrity or Maintenance or Block Quality Lead and
Contractor Lead Planner to ensure corrective action is taken with minimum impact to Execution schedule.
(i.e., machining of flange face, ordering new bolts from warehouse etc.)

y the joint until QSGTL Integrity clearance. The repair log shall be
maintained by the Contractor to ensure Control.

Vents and Drains have not been included in this process, Quality Control of vents and drains fall under
Operations. Operations shall ensure qualified flange technicians are allocated to carry out final torquing
of vents and drains prior to start. Madina shall ensure only competent personnel are allocated to any
torquing or tightening activities.
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CW140530
Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
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Table- 4 Flange Criticality and Inspection Matrix

LEGEND:

FC-Field Check Actual witnessing of the torquing/tensioning work.

FP-Flange Protocol Review, witnessing and sign off of Torquing/Tensioning Sheets

FT Flange Technician Torquing & Tensioning of flanges

Cont. QC Madina Quality Control

Shell QA Shell Quality Assurance

Random Flexible frequency of Field Checks done by Shell QA at any point during
Turnaround Execution.

* Percentage denotes number to be completed against total number of Flange

Protocol.
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Turnaround Management and Execution Services (TMES)
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Appendix B. Non-Lubricated: Bolts for Oxygen service

Stud bolts for piping metallic flanges, all values in NM

TABLE 5 :

NOTE 1: For torques higher than 678 Nm, hydraulic bolt torquing must be used.
NOTE 2: Torque values are for dry non-
NOTE 3: To achieve uniform joint load/stress distribution, bolts shall be tightened in three stages.
representing 30%, 60% & 100% of torque values
NOTE 4: In case of difficulty in bolt-tensioning, please contact respective area lead PEI engineer.
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Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
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Appendix C. Flange Torquing Values & Tightening Methods

TABLE- 6
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Appendix D: Bolt stress for different types of flanges and fluid temperature.
TABLE- 7
 PROJECT TITLE:
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Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
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Appendix E Flange joint Assembly Label/tag sample format

Dog tags for critical flange

Critical Flanges:

Critical Flanges shall be identified with a pink dog tag. Strict quality control shall be practiced
during the reinstatement of critical flanges; Madina QC shall be present to witness the final
reinstatement. QSGTL QA shall provide the final list of Critical Flanges to Madina. Madina
shall notify the QSGTL QA during reinstatement of the flanges identified in the list.

For Turnaround purposes, selecting critical flanges is also under the discretion of the
Operation Turnaround Coordinator (OTC) per block or the Block Leader to identify critical
flanges based on previous history or known problems (i.e: leaks or misalignment due to
original engineering or construction flaws) around a joint within any system or of any service
regardless of size and rating of the flanges, in a particular block of the Pearl GTL complex.
By any means all critical flanges shall be identified prior to Turnaround Execution.
 PROJECT TITLE:
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Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
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The H2-systems will be identified with an olive tag, O2-systems with a brown tag.

Field Verification of Critical, O2 and H2 Flanges shall be carried out in the Pre-turnaround
phase by Mechanical partner; flanges shall be marked up on the existing PEFS or Plot Plan.
A Cross Reference to this information shall be made to the Flange Database. Flange
Protocols of Critical, O2 and H2 Flanges shall have a stamp indicating respective
classification.

Critical flange identification criteria

Joints in highly hazardous chemical service as defined in CFR 1910.119 (OSHA

PSM rule), Lethal service as defined in the ASME Section VIII Divisions 1 and 2
Codes, or Category M Fluid Service as defined in ASME B31.3.
Flange sizes NPS 6 (DN 150) and greater, class 600 and greater in hydrogen
service, with an operating temperature above 600°F (315°C).
Flange sizes NPS 8 (DN 200) and greater, class 900 in hydrocarbon or sour
service, with an operating temperature above 600°F (315°C).
Flange sizes NPS 6 (DN 150) and greater, class 1500 in hydrocarbon or sour
service, with an operating temperature above 600°F (315°C).
Flange sizes NPS 4 (DN 100) and greater, class 2500 in hydrocarbon or sour
service, with an operating temperature above 600°F (315°C).

Chronic leaking flanges should be assessed, and measures taken to prevent

future leakage. Additional actions may be needed beyond controlled tightening of
bolts.
Joints of a unique or unusual design (e.g., connections between aluminium and
stainless-steel flanges on a cold box heat exchanger).
Flange joints in Oxygen service Criteria for identifying the critical flanges.
 PROJECT TITLE:
CW140530
Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
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Tear off tag

 PROJECT TITLE:
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Turnaround Management and Execution Services (TMES)
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Metal tag
 PROJECT TITLE:
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Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
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List of H2 & O2 systems by Area & Train (Common)

Below the overall system-list of H2 and O2-systems on Pearl GTL. This sheet includes Train
1, Train 2 and Common Systems.

The Common Systems are only H2-systems in FGP and LPU. There can be scope on these
systems during TA

Turnaround of Train 2. The remaining H2-systems are predominantly in LPU, and one system
in GTL.

The O2-systems are in ASU and GTL. The GOX header (pipe spec 63200) is the only O2-
line in the ASU pipe rack and GTL area. The line is split in multiple systems.
 PROJECT TITLE:
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Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
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Appendix F -Hidden Gasket

Which after final alignment / make up the gasket type and material cannot be verify by
viewing between flanges. Includes,

Shell and Tube exchanger components

Block valve bonnets
RTJ ring Joints and etc,

Hidden gasket installation shall be witnessed by QSGTL QA representative to conform the

proper type, material, Gasket orientation & proper closure of the mechanical joint on the
gasket to attain a proper gasket compression.

During Pre-Turnaround identify the known joint and log in log sheet, if find any additional
hidden gasket flange joint shall be capture in log sheet and follow the same process

Authorized contractor QA/QC personnel and QSGTL QA representative shall witness the
gasket installation and sign. Off the hidden gasket report. Hidden gasket log shall be update
and keep updating until end of Turnaround / Projects.
 PROJECT TITLE:
CW140530
Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
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CLIENT DOCUMENT NO.: CONTRACTOR DOCUMENT NO.:
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 PROJECT TITLE:
CW140530
Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
CW140530 1102174QSH22
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Appendix G -Gasket Colour code

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Appendix H Flange Torquing Form

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 PROJECT TITLE:
CW140530
Turnaround Management and Execution Services (TMES)
CLIENT CONTRACT NO.: CONTRACTOR PROJECT NO.:
CW140530 1102174QSH22
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Appendix I Flange Tensioning Form

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Appendix J Flow chart for Flange data base updation

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Appendix K Flawless program for Tightness

1.Procedure

1.1 General:

1.2 Consequences:

1.3 Instructions:
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Control measure for system leaks in above ground piping:

(e.g., steam coils, column draw-off trays, out of level column trays, wrongly installed
reactor/column packed bed support rings/beams)
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2.Performance indicators

3.Attachment

2.