01266239/Rev.A/01222008 - gltplusgoalzero.com · Table 5.2.1 Recommended bolt torque values for ASME B16.5 and/or API 6A flange connections Table 5.2.2 Recommended bolt torque values

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01266239/Rev.A/01222008

GLT- PLUS

TABLE OF CONTENT

1.0 INTRODUCTION ................................................................................................................ 3

1.1 Scope........................................................................................................................... 3

1.2 Contradictions and discrepancies ................................................................................. 3

2.0 METHODS OF BOLT TIGHTENING ................................................................................... 3

3.0 TORQUE AND TENSION VALUES .................................................................................... 3

4.0 INSTALLATION.................................................................................................................. 5

4.1 Training requirements .................................................................................................. 5

4.2 Pre-bolt inspection and flange/gasket assembly ........................................................... 5

4.3 Stud bolt torquing ......................................................................................................... 6

4.4 Bolt tensioning ............................................................................................................. 7

4.5 Flange face alignment .................................................................................................. 7

4.6 Protection of flanges and flange connectors against corrosion ..................................... 7

5.0 QUALITY ASSURANCE ..................................................................................................... 9

5.1 Tool calibration ............................................................................................................. 9

5.2 Flange Registration and labelling requirements ............................................................ 9

5.3 Application of Global Piping Classes .......................................................................... 10

5.4 Making up of problematic flange connections (bad actors) ......................................... 10

6.0 REFERENCES ................................................................................................................. 11

Appendix 1: Flange registration and flange labeling A1.1 Flange registration form A1.2 Flange “labeling” (tagging) example Appendix 2: Coding of gaskets Appendix 3: Colour coding of pipe clamp connector seal rings Appendix 4: Criteria for flange face condition and flange alignment Appendix 5: Bolt tightening procedure Appendix 6: Checklist for torquing / tensioning (Based on Shell Flawless approach)

Appendix 7: Checklist for bolting activities (work preparation) Appendix 8: Use of impact wrenches and pneumatic wrenches Appendix 9: Checklist threaded connections Appendix 10: LEAFLET RTJ ring Material

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1.0 INTRODUCTION

1.1 Scope

This Specification provides bolt torquing and tensioning requirements and installation procedures

for flanged connections in piping systems (plant piping/pipelines) and mechanical equipment.

Proper tightening of flange bolts is essential to ensure the leak tightness of a flanged joint. Insufficiently tightened bolts may jeopardize plant safety and may harm human life, environment and reputation. In addition, economic losses are of significance.

This Specification summarises the specific requirements from Piping classifications, referred in section 6. Furthermore the requirements of NAM work instruction for flange connectors and pipe clamp connectors, doc. no. EP 200902211244, rev. 10.1 [ref. 19] has been incorporated in this Specification.

1.2 Contradictions and discrepancies

In case of contradicting requirements or discrepancies between this Specification and other relevant documents the Contractor and/or Vendor shall obtain a written ruling from GLT- PLUS/NAM before proceeding with the work affected.

2.0 METHODS OF BOLT TIGHTENING

The bolt tightening methods pertaining to stud bolts, plugs and anchor bolts of plant piping,

pipelines and equipment.within NAM Asset Groningen are described in doc.no. EP201503210175 [ref. 18].

3.0 TORQUE AND TENSION VALUES

The torque and tension values of the stud bolts, plugs and anchor bolts of the plant piping, pipelines and equipment are given in the below listed tables: Plant piping / Pipelines

Appendix Description

Appendix A5.1 Tool selection

Appendix A5.2 Torque values B16.5 and/or API 6A stud bolts (when applying a mechanical or a hydraulic torque wrench)

Table 5.2.1 Recommended bolt torque values for ASME B16.5 and/or API 6A flange connections

Table 5.2.2 Recommended bolt torque values for Pikotek gaskets

Appendix A5.3 Tension values ASME B16.5 and ASME B16.47 SERIES A flanges (when applying strain controlled hydraulic bolt tensioning equipment)

Table 5.3.1 Recommended bolt tension for strain controlled bolt tensioning of ASME B16.5 and ASME B16.47 Series A flange connections

Appendix A5.4 Torque & Tension values compact flanges (Flange-plus / Destec flanges)

Table 5.4.1 Recommended bolt torque and tension values for compact flanges (Flange plus / Destec flange connections)

Appendix A5.5 Torque values clamp connectors

Table 5.5.1 Recommended bolt torque values for clamp connector (Make: Grayloc)

Appendix A5.6 Torque values GRE/GRP flanges

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Equipment

Appendix Description

Appendix A5.7 Torque/Tension values equipment girth flanges

Table 5.7.1 Recommended bolt torques for equipment girth flange connections

Table 5.7.2 Recommended bolt tension values for strain controlled equipment girth flange connections

Appendix A5.8 Torque values quick closure – Filter Separator V-4X03 (FAC locations, KSC’s)

Table 5.8.1 Recommended bolt torques for quick closure/warning device V-4X03 (FAC locations, KSC’s)

Appendix A5.9 Torque values equipment manhole flanges (Tanks, low pressure vessels)

Table 5.9.1 Recommended bolt torque values for equipment manhole flange connections

Appendix A5.10 Torque values for Air Cooler bundle plugs

Table 5.10.1 Recommended torque values for Air Cooler bundle plugs

Appendix A5.11 Torque values for Air cooler bundle rectangular cover flanges

Table 5.11.1 Recommended torque values for Air Cooler bundle rectangular cover flange connections

Appendix A5.12 Torque values for anchor bolts (vertical vessels, OV’s / FAC locations)

Table 5.12.1 Recommended torque values for anchor bolts (vertical vessels, OV’s/FAC locations)

.

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4.0 INSTALLATION

4.1 Training requirements

Work on connections may only be carried out by certified flange fitters/technicians in accordance with Safety, Health and Environment Checklist for Contractors (In Dutch: Veiligheid, Gezondheid en Milieu Checklist Aannemers (VCA)). The required trainings are specified in the SSVV Opleidingen Gids (SOG). The table below specifies training courses for the different flange tightening methods which are used by NAM.

Type of flange work and required training in accordance with VCA

Flange tightening by manual wrench

Flange tightening by hydraulic torque or

tensioning equipment

SSVV/ VOMI Code H-WFPr-PC-0111 M‐TT‐VOMI‐0113 or H-WFPrTT-PC-0215

VCA Examination Centres outside of the Netherlands The examinations can be held outside of the Netherlands. For more information, please contact the Accredited Examination Centres. The examination centres can be found at http://www.vcainfra.nl/examencentra.

In addition to the by legislation mandatory training and certification all mechanics shall follow the following additional training: NAM approved training companies with corresponding courses (random sequence)

Description

Flangeconnect Flensmonteur Vaktechniek Dijkgraaf Support B.V. Flange Integrity Management

(EN 1591-4)*

Others Consult NAM *) Recommended for supervisors, work preps, engineers. NOT for mechanics. With the training “Flensmonteur Vaktechniek” the certificate according WFPr-PC-0111 can be achieved. This prevents two separate courses are required and ref. certificate can be renewed/extended.

Unless specifically mentioned the standard validity of the training is 5 years. After this period a new training needs to be followed or alternatively ‘refresher’ training should be done.

Fitters and technicians working on the tightening of flange connections shall be able to demonstrate their certification without delaying the work.

During execution of the work with hydraulic equipment with two persons, both these persons shall meet the mentioned trainings / competence requirements.

Specifically for maintenance work on Freon cooling equipment it is stated that, in addition to the above mentioned training requirements, only “F- gasses” (previously STEK) certified technicians (or technicians under supervision of a “F-gasses” certified person) are allowed to perform maintenance tasks.

4.2 Pre-bolt inspection and flange/gasket assembly

• For the mounting of threaded connections reference is made to Work Instruction NAM72WI4314 and Appendix 9.

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• Process isolation and dismounting of flanges (including spectacle blinds and spades) is included within the scope of this instruction. However, for the detailed instructions related to isolation itself, refer to the NAM working instruction ‘Installaing and removing isolations’ [13]. The same materials, torque values, and bolting procedure need to be met when torquing bolts for isolation purposes, unless the safeguarding plan specifies different requirements.

• The Bolt torque/tensioning report (Appendix 1) must be completed for all flanges before start of the work and shall be filled out during the work and kept at the work site by the mechanic.

• All flange connections shall be ‘tagged’ (applied with a physical label placed on or near the flange), see appendix 1 for an example and specific details.

• ‘Hot bolting’, the replacement of individual bolts with the system still containing process or utility fluids under pressure, is a potentially hazardous operation and within asset Groningen this is not allowed.

• Prior to bolt torquing / tensioning a set of questions should be answered ,see appendix 6 for a specific checklist based on Shell Flawless Start-up approach.

• Bolts and threaded studs can be re-used, but only if the stud thread and the nut are still functional without visible damage and / or fretting on the thread. The nut shall able to be turned smoothly on the thread without lubrication and the condition shall be near to as new. Maximum elongation measured with a calibre shall not be more than 2%. Before re-use the threads of the studs and nuts shall be brushed clean.

• The bolt length shall be such that 2 or 3 threats are protruding from the nut (torqueing). For bolt tensioning, an additional length of a least 1 time the bolt diameter is accounted for.

• Clean the flange face surfaces and grooves and check that they are in good condition: acceptance criteria according to appendix 4.1.For pipe clamp connectors refer to appendix A5.18.

• Flanges must be aligned prior to assembly; criteria are specified in appendix 4.2. Use of centring pins is allowed.

• Use the prescribed bolts, gaskets and/or sealing rings accordance with the relevant pipe class and or design standard. - for ring joints: check material via marking on the ring and colour coding as outlined in appendix 2. See also leaflet in appendix 10. - for pipe clamp connector seal rings: check material via marking on seal ring or via specification as specified in appendix 3. Warning: colour coding may not be reliable. - for spiral wound gaskets: verify both inner and outer ring material. - Check bolt material B7 or L7 bolt & 2H nut for sweet gas applications. Identification of

material coding is specified on the bolt top face and side face of the nut. • Do not re-use gaskets (of any type). Exception: the seal rings of Pipe Clamp Connectors,

but only when not damaged or scratched (see also appendix A5.18) • Use the prescribed graphite grease as a lubricant (e.g. Molycote P1000) on the threads of the

bolts and nuts, as well as on the surface between nut and flange (to ensure a controlled friction value). Note: The use of lubricants containing molybdenum disulphide like Molycote 3694 or Molycote G-N plus are not permitted (this can result in sulphide stress corrosion in the bolt material).

• Ring joints shall be lightly greased with suitable grease to prevent galling of the flange/ring material surfaces.

• Use the correct tightening tools as specified in appendix 5. Tighten the bolts according to the procedure as described in appendix 5.

• During tightening, ‘flogging’ of bolts using impact wrenches is not allowed. For dismounting, specific instructions (tools and procedures) are given in appendix 8.

• Flange and flange connectors must be protected from corrosion as described in “Protection of flange and pipe connectors from corrosion” on para. 4.6.

• The procedure with respect to preparation and execution of tightening pipe clamp connectors is specified in appendix A5.18.

4.3 Stud bolt torquing

Bolt torquing shall be applied in accordance with tables in appendix 5.

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4.4 Bolt tensioning

Bolt tensioning shall be applied in accordance with tables in appendix 5.

4.5 Flange face alignment

Flange face alignment shall comply with DEP 31.38.01.31-Gen, see Appendix 4 of this specification [11].

4.6 Protection of flanges and flange connectors against corrosion

Maintenance of new and existing flanged connections (-20°C to 120°C)

type of flange

‘non-fixed' flanges: flanges which are unlikely to be disassembled

over a period exceeding the major shutdown intervals (6 years for

Asset Groningen)

‘fixed' flanges: flanges which are unlikely to be dissembled (and/or

permanent flanges)

Conservation of bolts and nuts on the outside of the flange (or clamp)

Application of the wax-coating system on bolt and nut (including locally damaged outer surfaces of

the flange itself) or: repair of the original coating

Application of organic coating (paint) system on bolt and nut

(including locally damaged outer surfaces of the flange itself)

or: repair of the original coating

conservation of space in between

the flanges

For both fixed and non-fixed flanges: conservation of the space between the flanges including the threads (where reachable) using the

wax-coating system (aerosol spray can).

Remark: Despite the enhanced corrosion resistance, the recently introduced „zinc plated‟ bolts

and nuts also need to be conserved according to the table above.

The preferred option for protection of carbon steel bolts and nuts is to paint according to system FC2-N/M in accordance with external coating specification, doc. no. EP201503208225 [17]. Paint should be applied if the flange connection is not taken apart more frequent than once every two years.

For temporary (up to 2 years) protection of new and existing connectors (up to 120°C) the following procedure should be applied:

Apply a wax-coating system on the bolts and nuts (including locally damaged outer surfaces of flanges). Apply a wax coating system for protection of the space between the flanges (including the threads). One of the following WAX Coatings shall be applied:

Option 1: Corroless CCI400 - 100 µm DFT Option 2: Layer 1: T-558-AMC primer - 50µm DFT

Layer 2: T-127-CGW 200µm DFT Instruction for applying wax-coating (after flange mounting and tightening):

- Degrease if necessary, and remove corrosion from bolts and nuts and/or the space between flanges as thoroughly as possible, special attention to the removal of corrosion scales is a requirement

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- When using spray application, apply wax by aiming aerosol can at nuts and the space between flanges (including threats).

- When using Tectyl brush application, apply a primer layer (Valvoline Tectyl 558-AMC). Allow to dry for at least 20 minutes before applying the final layer (Valvoline Tectyl 127 CGW)

Use of tape: With pipe systems that contain Freon, the flanges are wrapped with tape in order to detect Freon leakages. With other piping systems, permanent wrapping with tape is not permitted because of the danger of moisture of accumulation. Corrosion protection by taping is not permitted.

Maintenance of flanged connections > 120°C or < -20°C Flange connectors of pipe systems with an operating temperature exceeding 120°C or below -20°C should be protected according to the coating specification, doc. no. EP201503208225 [17] or based on specific advice from the Materials & Corrosion Department.

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5.0 QUALITY ASSURANCE

5.1 Tool calibration

The calibration of torque wrenches and tensioners shall be checked against the manufacturer's

specifications upon receipt. Any tools that are out of calibration shall be rejected. Calibration period maximum 1 year.

A recheck of the calibration shall be made as per tool manufacturer standard. Any tool found to be out of calibration shall immediately be taken out of service for repair.

All flanged joints secured with tools found to be defective shall be rechecked with a properly functioning tool.

5.2 Flange Registration and labelling requirements

A flange registration form (Appendix A1.1) must be completed for all flanges so that the work carried out can be verified and recorded according to the quality system.

In addition, all flange connections shall be „tagged‟ (applied with a physical label placed on or

near the flange), see appendix A1.2 for an example and specific details. Above requirements are valid for all activities related to breaking and make-up of flanges; construction (new projects), major shutdowns, preventive and corrective maintenance activities. Although dismounting of flanges for process isolation purposes is included within the scope of this instruction, the specific requirements with respect to the registration and labelling of spades and spectacle blinds during isolation are not specified in this instruction. For this specific activity refer to the NAM working instructions “Installing and removing isolations” [13] and “Locking and tagging for process, instrumented and electrical isolations” [14]. In Freon cooling installations all flanged connection are already provided with an unique number as recorded on a scheme which is available in the logbook at site.

Handling problems or deviations If defects are ascertained during assembly or disassembly, the manager or supervisor on-site should be notified about them immediately. For example: in the case of corrosion or damage to gaskets or flanges or severe misalignments of the flanges. If the work involves deviation from or the work is not within its scope, a plan of action must be drawn up. The plan must be submitted to GLT-PLUS/NAM (Discipline Mechanical Static) for review/approval. The plan should contain the following:

• Details of flange connector (materials, type of gasket, sizes, etc)

• Method of execution / procedure

• Equipment to be used

• A calculation to determine the required bolt load including the calculated bolt torque values.

Harmful substances

• During the disassembly of flange connectors, measures must be taken to collect any possible leaked fluids.

• Disassembly of flange connectors with asbestos-containing gasket materials (type CAF – Compressed Asbestos Fibres and SWAF – Spiral Wound Asbestos Filled) can be done with taken the specific requirements into account, see reference [15].

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Application This instruction, and it’s parts, apply to flange connectors of the following types:

• ASME B16.5 flanges

• ASME B16.47 flanges, Series A

• API 6A flanges

• Compact flanges (Destec/Flange-plus)

• Clamp connector

5.3 Application of Global Piping Classes

This work instruction also applies also to flange connections selected from the global piping classes (DEP 31.38.01.15-Gen). The following attention points shall be taken into account:

• Global Piping Classes only contain spiral wound gaskets

• The torque values apply for all bolt materials stated in the appendix A5.2.

• The split between (hydraulic) torque wrench and tensioning is different. The length of the stud bolts are longer for certain pressure / diameter combination to incorporate for this requirement. See DEP 31.38.01.31-Gen. section 3.12.4.

• Bolts that have extra length for tensioning are not supplied with a 3rd

nut.

• The torque values from DEP 31.38.01.31-Gen appendix 6 (issue Feb 2014) shall not be used.

• Teflon coated stud bolts and nuts shall not be used.

5.4 Making up of problematic flange connections (bad actors)

The following tools and methods are available for making up problematic flange connections that repeatedly fail in service. The below may only be used after approval of the GLT-PLUS/NAM Discipline Engineer Mechanical Static.

• Kamm profile gasket instead of RTJ ring when the RTJ groove is damaged or when connecting a RTJ flange to a RF flange.

• Application of special washer like the “Hytorc Washer”.

• Application of special bolts like the James Walker Rotabolt.

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6.0 REFERENCES

[1] NSS 12-D-7-00 1988 Piping classification [2] TL-7.102.988 July 1995 Piping classification (Norg UGS) [3] G.94R.C;254 Nov. 1995 Piping systems classification specification

(Grijpskerk UGS) [4] NSS 12-D-7-00 1998 Piping classification [5] 01024630-0001 Rev. F Specification for piping systems (FAC locations) [6] DEP 31.38.01.15 EPE-NL March 2005 Piping Classes – Exploration and Production [7] DEP 31.38.01.15 EPE-NL Dec. 2010 Piping Classes – Exploration and Production [8] DEP 31.38.01.15-Gen Feb. 2014 Piping Classes – Exploration and Production [9] TL-201003313240-0001 Dec. 2015 Selection of piping classes (NAM Asset

Groningen) [10] DEP 31.38.01.11-Gen Feb. 2015 Piping general requirements [11] DEP 31.38.01.31-Gen Feb. 2014 Shop and field fabrication of piping [12] EP200906220961

(NAM-71.WI.30.08) Latest issue NAM Work Instruction: Drawing up an isolation

plan [13] EP200802248248

(NAM-71.WI.30.07) Latest issue NAM Work Instruction: Installing and

removing isolations [14] EP200906243618

((NAM-71.WI.30.09) Latest issue NAM Work Instruction: Locking and tagging for

process, instrumented and electrical isolations [15] EP200804211760

(NAM-71.WI.76.14) Latest issue NAM Work Instruction: Removing asbestos

containing flange gaskets [16] Doc. No. 01327384-0001 Rev. E Specification for Piping Systems [17] Doc. No. EP201503208225 Rev. A Specification for external protective coatings

(NAM - Asset Groningen) [18] EP201503210175 Rev. A Recommended tightening figures pertaining to

stud bolts, plugs and anchor bolts (plant piping, pipelines & equipment) NAM - Asset Groningen

[19] EP 200902211244 Rev. 10.1 NAM Work Instruction: Flange connections and clamp connectors

[20] EP201503223414 00 UIE Werk Instructie: Hoge druk warmtewisselaar plug montage

[21] NAM71WI3002 Latest issue Work Instruction Het opstellen van een veiligstelplan incl. procesveiligstelling

[22] NAM71WI3007 Latest issue Work Instruction Het aanbrengen en opheffen van een veiligstelling

[23] NAM71WI3009 Latest issue Work Instruction Locken en taggen van veiligstellingen

[24] NAM72WI4314 Latest issue Work Instruction Het opmaken van de schroefverbinding van API/NPT schroefdraden (1/8" t/m 1") voor instrumentatie fittingen

[25[ ASME PCC-1 2013 Guidelines for pressure boundary bolted flange joint assembly

[26] API 6A Issue 2010 Specification for Wellhead and Christmas Tree Equipment

[27] ASME B16.5 Issue 2013 Pipe flanges and flanged fittings [28] ASME B16.47

Issue 2011 Large diameter steel flanges (Use Series A)

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Appendix 1: Flange registration and flange labeling

A1.1 Flange registration form

Bout diameter

Flange Size/Class Bout materiaal

Aantal bouten

LET OP: VOOR START WERK DIENT LRMA UITGEVOERD TE WORDEN

Conditie pakkingsvlakken acceptabel (Afwijkingen noteren bij opm.)

Evenwijdigheid pakkingvlakken gecontroleerd

Uitlijning leidingen acceptabel (<DN100: max.2mm, ≥DN100: max.3mm)

Spanningsvrij gemonteerd

DEMONTAGE BOLTSET Datum uitvoering

Uitgevoerd door

Paraaf

MONTAGE BOLTSET Datum uitvoering

Uitgevoerd door

Paraaf

Opmerkingen t.a.v.

demontage /

montage boltset

Make-up TORQUE :

1e Rondgang 30% 2e Rondgang 60% 3e Rondgang 100% 4e Rondgang 100% kloksgew ijs

Aanhaal moment bouten Nm mm

Opspankracht bouten kN mm

Na fitten Na aanhalen Afwijking

K1 L1 K1-K3

K2 L2 K2-K4

K3 L3 L1-L3

K4 L4 L2-L4

Torque / tensioning tool merk

Torque / tensioning tool nummer

Vijzeldruk A ( torque pompdruk ) Bar

Vijzeldruk B Bar

Opmerkingen t.a.v.

op moment aanhalen

torquen / tensioning

Datum uitvoering

Uitgevoerd door

Paraaf

Rapport gecontroleerd Datum uitvoering

Uitgevoerd door

Paraaf

WV

BM

onte

ur

Boltset nummer

Locatie

Rapport nummer

Demontage / montage boltset

Demontage Montage

JA / NEE

NVT

JA / NEE

JA / NEE

JA / NEE

In gelabelde zak doen, → BLAUW

labeldeel invullen en inleveren

Komt boutmateriaal overeen met de specificatie JA / NEE

JA / NEE

JA / NEE

Maximaal toelaatbare afwijking in

evenwijdigheid

L1-L3

L2-L4

JA / NEE

Bouten op rek gecontroleerd (max. 2%) JA / NEE % rek:

Aanhalen op moment torquen / tensioning

Handvast en controle, → ROOD


NVT

Bolt torque/tensioning report - GLT-PLUS

Leiding nummer

Pakking type

Pakking materiaal

Lijn

toezic

ht

WV

BG

ecert

ificeerd

fle

nsm

onte

ur/

torq

uer/

tensio

ner

Aanhalen op moment, → Geel


Opmerking: Operations verwijderd

ingevuld → GROEN labeldeel (na lek /

sterkte test)

(serie)nummers

Pomp

Torquecilinder

Torquecassette

Momentsleutel

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A1.2 Flange “labeling” (tagging) example

By mounting a label („tag‟) on the flanged connection, the entire working process (assembly, tightening,

leak testing) is recorded and clearly visible. This reduces the risk on (future) flange leakages which could occur by incidentally skipping one or more of the several steps in the flange mounting procedure. An example of such a flange label is shown below. Remarks: 1. Although this format is preferred as “best practice”, it is recognised that alternatives for this label are

also possible (stickers, plastic labels without removable parts, etc.).

2. Minimum requirement of alternative labels is:

- The label should be physically connected to or placed on the corresponding flange

- The flange technician should sign off the label and also mark the corresponding torque value or bolt preload value [torque value in Nm and preload value in kN] on the label.

Example of flange labelling: Step 0: Connection of the label on the flange, as part of the preparation of a plant shutdown.

The removed labels should be stored/archived with the corresponding flange registration form. As a good practice, also the final remaining (white) tag should be removed at the end of the maintenance/shutdown activities and kept together with the other label parts.

Step 3: Fill in and remove after successful leak testing (e.g. nitrogen test) by Operations.

Step 2: Fill in and remove of this label after the bolts/studs have been tightnened with the correct torque / force by the flange technician / torquing crew

Step 1: Fill in and remove of this label after the flange has been aligned and applied with the correct gasket. Bolts/nuts already present but only hand tightened.

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Appendix 2: Coding of gaskets A2.1 Ring joints

Flange material

ring material marking

Material Coding on ring

stainless steel – stainless steel S-316 SS Green

stainless steel – carbon steel D Soft iron (none)

carbon steel – carbon steel S Soft iron (none)

A2.2 Spiral wound gaskets New spiral wound gaskets should consist of a stainless steel inner ring and outer ring. (consistent with NAM Piping class [2], modification in place since 2005). For existing rings it is known that different variants with regards to inner and outer ring material are still present. The colour coding on the outside ring of a spiral wound gasket is consistent with ASME B16.20. For the new NAM standard (stainless steel inner and outer ring) the colour coding is green with gray stripes. For the Shell Global piping classes the material of the inner and outer ring is based on the pipe material of the piping class. For CS piping classes the outer ring is CS, For corrosive resistance materials the outer ring is CS or SS as per details of the applicable piping class.

S

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Appendix 3: Colour coding of pipe clamp connector seal rings

Hub material

Seal ring material coding

Material Colour coding seal ring

stainless steel – stainless steel 17.4PH SS Green

stainless steel – carbon steel AISI 4140 Soft iron Blue

carbon steel – carbon steel AISI 4140 Soft iron Blue

Warning: from previous NAM experience it is found that the color codings of the different seal ring suppliers are not always consistent and therefore can deviate from the intended NAM specifications. For this reason, always check the actual material coding stamped on the seal ring or check via the material specification documentation included with the seal ring.

CLAMP

HUB SEAL RING

STAINLESS STEEL STAINLESS STEEL

STAINLESS STEEL SEAL RING MATERIAL CODING: 17.4 PH COLOUR CODING: GREEN

CARBON STEEL

CARBON STEEL SEAL RING MATERIAL CODING: AISI 4140 COLOUR CODING: BLUE

CARBON STEEL

CARBON STEEL SEAL RING MATERIAL CODING: AISI 4140 COLOUR CODING: BLUE

NE

CARBON STEEL

STAINLESS STEEL

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Appendix 4: Criteria for flange face condition and flange alignment 4.1 Condition of the flange facing („raised face” and/or RTJ) A visual check is always required prior to mounting. The inspection should aim for: - Damage or scratches (especially radial grooves: no deeper than 0.3 mm and/or longer than 3 mm) - Presence of corrosion / pitting of the flange face - Gasket themselves should be free from any visible defects (new condition) and shall never be reused. Remark: In practice, during maintenance, normally no detailed check is done focusing on the levelness of the gasket face. Only in exceptional cases a detailed check may be required when: - There is a specific concern regarding the condition of the facing - The flange facing has just been re-machined - Repeated flange leakages have occurred without a clear cause In case of doubt the GLT-PLUS QC department and/or GLT-PLUS/NAM discipline engineer should be consulted. Criteria for out of flatness Less than 0,2 mm measured over the width of the sealing area (B).

Criteria for out of plane

Less than 0,2 mm

4.2. Types of alignment Two types of alignment are recognised:

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

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

4.3 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.

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4.4 Acceptance criteria for misalignment 4.4.1 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

> DN 100 (NPS 4) 3 mm

Bolt holes shall straddle the natural centreline unless specified otherwise. The maximum deviation from the required theoretical bolt hole position, as measured along the bolt circle, shall be 1.5 mm. 4.4.2 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:

a. ASME B16.5 flanges, all sizes, all ratings:

2.5 mm/m NOTE: This is more stringent than the ASME B31.3 requirement of 5 mm/m but it has been found realistic to achieve these

limits with little or no additional manufacturing effort.

Table 4.1 give these values computed for the flange outside diameter.

b. ASME B16.47 flanges, all sizes, all ratings:

1.75 mm/m absolute (regardless of the diameter), measured along the outside diameter of the flange. Tables 4.2 give these values computed for measurements along the flange outside diameter.

c. Flanged pipe spools

The misalignment tolerances given in (a) and (b) above apply to pairs of pre-assembled flanges. For the terminal flange of a pipe spool, the misalignment can only be measured as the deviation from the design plane. Instead of simply halving the allowed tolerance for pre-assembled flanges, allowance should be made for the possibility that the misalignment of an individual flange can be in either direction and the misalignment of its eventual mating flange may compensate. Therefore, a statistical factor is appropriate, so that for the terminal flange of a pipe spool the deviation from the design plane

shall not exceed , where M is the allowable misalignment for the pre-assembled flanges as given in (a) and (b) above.

d. Flanged accessories

Accessories are flanged items which are rigid in themselves (e.g., valves, strainers, etc.). The individual flange face misalignment from the design plane shall not exceed 2.5 mm/m. Also, the misalignment of the two flange faces shall not exceed 2.5 mm/m.

e. Face alignment for flange-less components (e.g., wafer type control valves, sandwiched between flanges): Misalignment as per (a) and (b) above.

f. Nozzle faces on static equipment.

Alignment of nozzle flange face with the indicated plane shall be within 0.5° in any direction. NOTE: This tolerance is in line with that specified in DEP 31.22.00.31-Gen.

g. Flanges connecting to rotating equipment (pumps, compressors, etc.)

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The flange face alignment check shall be performed with bolting inserted loosely, and the acceptance criteria shall be as given below:

Flange diameter Maximum misalignment at OD of flange

< DN 300 (NPS 12) 0.2 mm

DN 300 to DN 600

(NPS 12 to NPS 24) 0.3 mm

≥ DN 600 (NPS 24) 0.5 mm

NOTE: The above figures are the practical implementation of the tolerances specified in the relevant rotating equipment DEP

(i.e. 0.05° in all directions).

Table 4.1 ASME B16.5 flanges, all sizes, all ratings (SI Units) Maximum flange face misalignment at outside diameter of flange:

• for a pre-assembled joint, maximum difference in measured values (M) = 2.5 mm/m

• for an individual flange, maximum difference to design plane (N) = mm/m

This results in the following figures for measurements taken at the outside diameter of the flange: NOTE: Blank cells indicate size rating values not standardized in ASME B16.5.

Size

M (mm) (Note-1)

Size

N (mm) (Note-1)

150# 300# 600# 900# 1500# 2500# 150# 300# 600# 900# 1500# 2500#

DN 15 0.5 0.5 0.5 0.5 0.5 0.5 DN 15 0.5 0.5 0.5 0.5 0.5 0.5

DN 20 0.5 0.5 0.5 0.5 0.5 0.5 DN 20 0.5 0.5 0.5 0.5 0.5 0.5

DN 25 0.5 0.5 0.5 0.5 0.5 0.5 DN 25 0.5 0.5 0.5 0.5 0.5 0.5

DN 40 0.5 0.5 0.5 0.5 0.5 1.0 DN 40 0.5 0.5 0.5 0.5 0.5 1.0

DN 50 0.5 0.5 0.5 1.0 1.0 1.0 DN 50 0.5 0.5 0.5 1.0 1.0 1.0

DN 80 0.5 1.0 1.0 1.0 1.0 1.0 DN 80 0.5 1.0 1.0 1.0 1.0 1.0

DN 100 1.0 1.0 1.0 1.0 1.0 1.0 DN 100 1.0 1.0 1.0 1.0 1.0 1.0

DN 150 1.0 1.0 1.0 1.0 1.0 1.5 DN 150 1.0 1.0 1.0 1.0 1.0 1.5

DN 200 1.0 1.0 1.5 1.5 1.5 1.5 DN 200 1.0 1.0 1.5 1.5 1.5 1.5

DN 250 1.5 1.5 1.5 1.5 1.5 2.0 DN 250 1.5 1.5 1.5 1.5 1.5 1.5

DN 300 1.5 1.5 1.5 2.0 2.0 2.0 DN 300 1.5 1.5 1.5 1.5 1.5 1.5

DN 350 1.5 1.5 2.0 2.0 2.0 2.0 DN 350 1.5 1.5 1.5 1.5 1.5 1.5

DN 400 1.5 2.0 2.0 2.0 2.5 2.0 DN 400 1.5 1.5 1.5 1.5 2.0 1.5

DN 450 2.0 2.0 2.0 2.0 2.5 DN 450 1.5 1.5 1.5 1.5 2.0

DN 500 2.0 2.0 2.5 2.5 2.5 DN 500 1.5 1.5 2.0 2.0 2.0

DN 600 2.5 2.5 2.5 3.0 3.0 DN 600 2.0 2.0 2.0 2.5 2.5

NOTE-1: Alignment tolerances rounded up to nearest 0.5 mm.

Source: DEP 31.38.01.31-Gen, issue Feb. 2014, Appendix 8

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Table 4.2 ASME B16.47, series A, all sizes, all ratings (SI units) Maximum flange face misalignment at outside diameter of flange:

1. for a pre-assembled joint, maximum difference in measured values (M) = 1.75 mm/m

2. for individual flange, maximum difference to design plane,(N) = mm

This results in the following figures for measurements taken at the outside diameter of the flange: NOTE: Blank cells indicate size rating values not standardized in ASME B16.47.

Size

M (mm) (Note-1)

Size

N (mm) (Note-1)

150# 300# 600# 900# 150# 300# 600# 900#

DN 650 2.0 2.0 2.0 2.0 DN 650 1.5 1.5 1.5 1.5

DN 700 2.0 2.0 2.0 2.5 DN 700 1.5 1.5 1.5 2.0

DN 750 2.0 2.0 2.0 2.5 DN 750 1.5 1.5 1.5 2.0

DN 800 2.0 2.5 2.5 2.5 DN 800 1.5 2.0 2.0 2.0

DN 850 2.0 2.5 2.5 2.5 DN 850 1.5 2.0 2.0 2.0

DN 900 2.5 2.5 2.5 3.0 DN 900 2.0 2.0 2.0 2.5

DN 950 2.5 2.5 2.5 3.0 DN 950 2.0 2.0 2.0 2.5

DN 1000 2.5 2.5 2.5 3.0 DN 1000 2.0 2.0 2.0 2.5

DN 1050 2.5 2.5 2.5 3.0 DN 1050 2.0 2.0 2.0 2.5

DN 1100 2.5 2.5 3.0 3.0 DN 1100 2.0 2.0 2.5 2.5

DN 1150 3.0 2.5 3.0 3.5 DN 1150 2.5 2.0 2.5 2.5

DN 1200 3.0 3.0 3.0 3.5 DN 1200 2.5 2.5 2.5 2.5

DN 1250 3.0 3.0 3.0

DN 1250 2.5 2.5 2.5

DN 1300 3.0 3.0 3.5 DN 1300 2.5 2.5 2.5

DN 1350 3.0 3.0 3.5 DN 1350 2.5 2.5 2.5

DN 1400 3.5 3.0 3.5 DN 1400 2.5 2.5 2.5

DN 1450 3.5 3.5 3.5 DN 1450 2.5 2.5 2.5

DN 1500 3.5 3.5 3.5 DN 1500 2.5 2.5 2.5 NOTE-1: Alignment tolerances rounded up to nearest 0.5 mm.

Source: DEP 31.38.01.31-Gen, issue Feb. 2014, Appendix 8

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Appendix 5: Bolt tightening procedure

A5.1 Tool Selection

REQUIRED BOLT TIGHTENING AND TENSIONING METHODS FOR ASME B16.5 AND ASME B16.47 SERIES A FLANGES

NOMINAL PIPE

(FLANGE)

PRESSURE CLASS

SIZE DN 150 (PN 20)

300 (PN 50)

600 (PN 100)

900 (PN 150)

1500 (PN 250)

2500 (PN 420)

15 u/i

80 Use of mechanical Use of hydraulic

100 torque wrench (1) torque wrench

150

200

250

300

350

400

450 Hydraulic bolt tensioning (2)

500 (strain controlled tensioning)

600

700

750

900

1050

Table 5.1.1

(1): Only in cases where the use of a mechanical torque wrench is not possible due to limited space available the use of alternative tools (simple hand wrench) is allowed. (2): Bolt tensioning is specialist activity. Specific advice with respect to working procedures, tools and materials is beyond the scope of this working instruction. For the prescribed bolt forces / bolt stresses refer to Appendix A5.3. For tightening, ‘flogging’ of bolts using impact wrenches (ring or open impact spanner) is not allowed, see Appendix 8 for details.

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A5.2 Torque values B16.5 and/or API 6A stud bolts (when applying a mechanical or a hydraulic torque wrench)

RECOMMENDED BOLT TORQUES FOR ASME B16.5 AND/OR API 6A FLANGE

CONNECTIONS

BOLT SIZE AND

THREAD COARSE

SERIES

Only for Flat Ring / Graphite Tanged

gaskets in class 150

RTJ/RF

(B7 / L7 bolts)

“old” phenolic RTJ

Insulation set

(inch) (Nm) (Nm) (Nm)

1/2 - UNC 60 80 46

5/8 - UNC 117 155 87

3/4 - UNC 185 270 152

7/8 - UNC 263 429 243

1 - UNC 401 639 367

1 1/8 - 8-UN 571 925 530

1 1/4 - 8-UN 797 1285 738

1 3/8 - 8-UN - 1727 992

1 1/2 - 8-UN 1416 2261 1298

1 5/8 - 8-UN - 2894 1662

1 3/4 - 8-UN - 3636 2088

1 7/8 - 8-UN - 4493 2581

2”- 8-UN - 5440 3125

Table 5.2.1

Notes: 1) Torque Values based on friction coefficient µ=0.13 when applying Molycote 1000. 2) In practice bolts size 1” and larger are tightened using hydraulic torque wrenches. 3) For bolt sizes 1 5/8” and larger strain controlled hydraulic bolt tensioning shall be used. 4) It is recognized that especially for carbon steel flanges the leak tightness of the Pikotek gasket can be problematic

as a result of corrosion of the flange face. For those cases, the RTJ gasket is still an accepted choice. In parallel, an improved type of gasket is being developed for the future NAM piping classes called the “Pikotek tandem” which contains two active seals. This future standard is considered to provide the best solution for these problematic flanges. For additional advice GLT-PLUS/NAM Maintenance Engineering (Discipline Mechanical Static) can be consulted.

5) For other bolt materials consult GLT-PLUS/NAM Discipline Engineering Mechanical Static.

6) Torque figures are only applicable for standard ASME RF and RTJ flanges.

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RECOMMENDED BOLT TORQUE VALUES Pikotek *)

Pressure class

Nominale pipe size

150 300 600 900 1500 2500

[NPS] [Nm] [Nm] [Nm] [Nm] [Nm] [Nm]

1/2 54 54 54 176 176 176

3/4 54 102 102 176 176 176

1 54 102 102 278 278 278

1 1/4 54 102 102 278 278 414

1 1/2 54 176 176 414 414 603

2 102 102 102 278 264 414

2 1/2 102 176 176 414 414 603

3 108 176 176 278 603 847

3 1/2 102 176 278 N/A N/A N/A

4 102 176 278 603 847 1519

5 176 176 414 847 1519 2474

6 176 176 414 603 1152 3762

8 176 278 603 1152 1959 3762

10 278 414 847 1152 3071 7532

12 278 603 847 1152 3762 10114

14 414 603 1152 1519 5430 N/A

16 414 847 1519 1959 7532 N/A

18 603 847 1959 3071 10114 N/A

20 603 847 1959 3762 13233 N/A

22 847 1519 2474 N/A N/A N/A

24 847 1519 3017 7532 21273 N/A

26 888 1959 3254 10114 N/A N/A

28 881 1959 3762 13233 N/A N/A

30 902 2474 4569 13233 N/A N/A

32 1519 3071 5430 16934 N/A N/A

34 1519 3017 5430 21273 N/A N/A

36 1519 3762 7532 21273 N/A N/A

38 1519 2359 8169 21273 N/A N/A

40 1519 2427 8094 21273 N/A N/A

42 1519 3478 8311 21273 N/A N/A

44 1519 3573 10399 26289 N/A N/A

46 1519 3518 10650 32038 N/A N/A

48 1519 3613 13606 32038 N/A N/A

*) RTJ insulation gaskets (material Phenolic) have been formally replaced by Pikotek gaskets (in NAM Piping classes Chapter 5) which can be torqued with the value from this table.

Table 5.2.2

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A5.3 Tension values ASME B16.5 ASME B16.47 SERIES A (when applying strain controlled hydraulic bolt tensioning equipment)

RECOMMENDED BOLT TENSION FOR STRAIN CONTROLLED BOLT-TENSIONING OF ASME B16.5 AND B16.47 SERIES A FLANGE CONNECTIONS WITH HYDRAULIC BOLT TENSIONING EQUIPMENT

1) FOR NON-

SOUR SERVICE APPLICATIONS

ASME CLASS

(PN)

NOMINAL DIAMETER

OF FLANGE

DIAMETER OF

BOLTS

NUMBER OF

BOLTS

GASKET TYPE

TEN-SION PER BOLT

ASSOCIATED BOLT

RESIDUAL TIGHTENING

STRESS

F = I =

R = S =

GFGR: Flat R. Grooved GAIRF: Insulation set GARJ: Ring Type GASW: Spiral Wound

DN [inch] - F I

R S [kN] [N/mm²]

600

(PN100)

450 1.5/8 20 I S 226 210

500 1.5/8 24 I S 222 205

600 1.7/8 24 I S 302 203

700 2 28 I S 328 191

750 2 28 I S 371 218

900 2.1/2 28 I S 514 186

1050 2.1/2 28 I S 665 240

900

(PN150)

350 1.1/2 20 F I R S 206 227

400 1.5/8 20 F I R S 264 243

450 1.7/8 20 F I R S 338 227

500 2 20 F I R S 397 232

600 2.1/2 20 F I R S 542 196

750 3 20 R S 760 186

900 31/2 20 R S 1077 191

1050 31/2 24 F 1244 220

1500

(PN250)

250 1.7/8 12 F I R S 367 247

300 2 16 F I R S 372 217

350 2.1/4 16 F I R S 460 208

400 2.1/2 16 F I R S 579 209

450 2 3/4 16 R S 721 213

500 3 16 R S 868 213

600 31/2 16 R S 1196 212

2500

(PN420)

150 2 8

F 337 195 2)

I 456 263

R S 505 295

200

2

12

F 353 204 2)

I 446 258

R S 495 289

250

2.

1/2

12

F 545 196 2)

I 630 226

R S 758 273

300

2.

3/4

12

F 759 222 2)

I 850 249

R S 1041 307

350 3 12 R S 1042 255

400 2.3/4 16 R S 781 230

1) For each gasket type a hydraulic pressure setting procedure shall be applied as specified for the contracted bolt tensioning equipment.

2) To achieve a uniform joint load / stress distribution the bolts shall be tightened in stages and in a controlled sequence.

3) For the bolt tension value the surface pressure on the camprofile type will be circa 325 N/mm². The maximum allowable surface pressure for camprofile gasket with

graphite layer is 400 N/mm².

Table 5.3.1

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A5.4. Torque and Tension values compact flanges (Flange plus/Destec flanges)

RECOMMENDED BOLT TORQUE AND TENSION VALUES FOR COMPACT FLANGE CONNECTIONS (Make: Flange-plus / Destec)

Stud bolt size Target residual

preload Applied tension with

tension tool

Applied torque with torque tool and lubricant

if µ = 0.12

[inch] [kN] [kN] [1]

[Nm] [2]

1 1/8 255 323 1194

1 1/4 325 412 1671

1 3/8 405 512 2261

1 1/2 492 623 2989

1 5/8 589 745 3840

1 3/4 693 878 4859

1 7/8 807 1022 6020

2 929 1177 [2]

7351

2 1/4 1199 1519 [2]

10610

2 1/2 1503 1904 [2]

14665

2 3/4 1667 2111 [2]

17766

3 2004 2539 [2]

23240

3 1/4 2373 3006 [2]

29736

3 1/2 2773 3512 [2]

37258

3 3/4 3204 4058 [2]

46046

4 3666 4643 [2]

56008

Table 5.4.1

Notes: [1] Required for determination of hydraulic pump pressure. [2] Preferably using hydraulic bolt tensioning

A5.5. Torque values clamp connectors

RECOMMENDED BOLT TORQUE FOR CLAMP CONNECTOR (MAKE: GRAYLOC)

Bolt size and thread coarse series

Make-up Torque

(inch) (Nm)

3 1/4 - 8UN 4530

Table 5.5.1

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A5.6 Torque values GRE/GRP flanges

Due to the specific characteristics of GRE/GRP flange material, the recommended bolt torque values as well as the bolt tightening procedure should be obtained from the manufacturer of those flanges.

A5.7 Tension values for equipment girth flanges

RECOMMENDED BOLT TORQUES FOR EQUIPMENT GIRTH FLANGE CONNECTIONS

Tag No. Description Manufacturer Location

Nominal bolt diameter Number

of bolts

Torque per bolt

(inch/metric) [Nm]

E-2510 VSCU Air cooler Cofely Noord FAC (SCB) 5/8 20 85

E-5001 Cold Heat Exchanger Kooiman Apparatenbouw

FAC 1 40 585

S-4002A/B Membrane Separator ComPacksys Norg UGS M20 16 103

Table 5.7.1

RECOMMENDED BOLT TENSION VALUES FOR STRAIN CONTROLLED BOLT-TENSIONING OF EQUIPMENT GIRTH FLANGE CONNECTIONS


Nominal bolt diameter

Number of bolts

Tension per bolt

(inch/metric) [kN]

E-4X02B Gas-Gas Exchanger Belleli Italy FAC M72 x 6 24 558

E-4X02A Gas-Gas Exchanger Korpershoek FAC M72 x 6 16 837

E-4X02B Gas-Gas Exchanger Korpershoek FAC M72 x 6 20 627

E-4X02B Gas-Gas Exchanger Korpershoek FAC M72 x 6 24 590

E-4X02A Gas-Gas Exchanger Sombroek FAC M72 x 6 16 766

E-4X02B Gas-Gas Exchanger Sombroek FAC M72 x 6 16 766

E-4X02B Gas-Gas Exchanger MOG FAC M72 x 6 16 766

E-4X02B Gas-Gas Exchanger d'Hondt FAC M72 x 6 16 784

V-1801 / V-1901

Free Water K.O. Vessel KTI Belgium FAC 2 3/4 28 795

V-4X12 Cold/Filter Separator KTI Belgium FAC

(DSSC/CC) 2 1/2 40 660

E-7101 Water Bath Heater Bronswerk Heat Transfer

Norg UGS 2 3/4 16 241

Table 5.7.2

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A5.8 Torque values for Quick Closure - Filter Separator V-4X03 (FAC locations, KSC’s)

RECOMMENDED BOLT TORQUES FOR QUICK CLOSURE/WARNING DEVICE FILTER SEPARATORS V-4X03 (FAC LOCATIONS, KSC’s)



Torque

[inch] [Nm]

V-4X03 Quick closure Escher/Bronswerk FAC locations 2 1/4 1356

V-4X03 Warning device (DWK)

Escher/Bronswerk FAC locations 1 1/2 80

Table 5.8.1 Note: For de-mounting and mounting instructions of the quick closure V-4X03, reference is made to appendix A5.13.

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A5.9 Torque values for manhole flanges (Tanks, low pressure vessels)

RECOMMENDED BOLT TORQUES FOR EQUIPMENT MANHOLE FLANGE CONNECTIONS

Tag No. Description Manufacturer Location Flange Size

Gasket type

Nominal bolt

diameter Number of bolts

Torque per bolt

(inch/metric) [Nm]

T-6 (shell manhole A1/A2)

Storage Tank

Dijksman TP Delfzijl ID 610/OD 830

Gylon blue 3504

3/4 28 213

T-6 (roof manhole A3/A4)

Storage Tank

Dijksman TP Delfzijl ID 522/OD 622

Gylon blue 3504

5/8 16 213

T-14 (manhole N1)

Surge Tank Dijksman BRW DN600 (24")

Gylon blue 3504

M20 36 140

T-14 (roof manhole N16)

Surge Tank Dijksman BRW DN600 (24")

Gylon blue 3504

1 1/8 20 269

V-5505 / V-5506 (manhole A1/A2/A3)

WaCo Vessels

Dijksman/Ellimetal

FAC locations

DN600 (24")

Gylon blue 3504

1 1/4 20 224

C-506/C-507 (manhole M1A/B)

Adsorber Permeca RBI Delfzijl

DN600 (24")

Sigraflex HD M33 x 3 20 214

C-506/C-507 (manhole M2)

Adsorber Permeca RBI Delfzijl

DN500 (20")

Sigraflex HD M30 x 3 20 153

V-50 (quick closure M1)

Surge tank Giems RBI Delfzijl

DN600 (24")

Viton O-ring M24 x 3 8 55

T-70 (manhole A1)

Buffer Tank JPM TP Delfzijl

DN1000 Klingersil C4400

M20 x 2.5 40 71

T-70 (manhole A2)

DN600 (24")

Klingersil C4400

M20 x 2.5 24 69

T-70 (manhole A3/A4)

DN500 (20")

Klingersil C4400

M16 x 2 20 58

T-70 (70PVV-701/702)

DN150 (6”)

Viton 3/4 8 65

T-70 (Tank door)

DN804 x DN1900

Perbinan Sh50

M16 x 2 56 35


Settle tank Mercon RBI Delfzijl

DN600 (24")

Gylon blue 3504

3/4 36 285

T-620 Fire water storage tank

Simerink RBI Delfzijl

DN600 (24")

Gylon blue 3504

3/4 36 285

V-537 (manhole N9)

Instrument air buffer

Tankbouw Rootselaar

RBI Delfzijl

DN500 (20")

Gylon blue 3504

M20 x 2.5 16 99


Slib buffer Giems RBI Delfzijl

DN600 (24")

Gylon blue 3504

1 1/4 20 880

T-3301 (nozzle ERV) Water tank Dijksman Grijpskerk UGS

DN500 (20")

Gylon blue 3504

1 1/8 22 125

Table 5.9.1

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A5.10 Torque values for Air Cooler bundle plugs


Nominal plug

diameter

Nom./target Torque per

plug

Recommended Torque (max)

per plug

[inch] [Nm] [Nm]

E-1801A/B, E-1901A/B, E-2601A/B

Suction /Interstage Coolers

Bronswerk Heat Transfer

FAC locations 1 3/8 545 650

E-1801A/B, E-1901A/B, E-2601A/B

Suction /Interstage Coolers



E-2103 Seal Gas cooler Bronswerk Heat Transfer


E-2103 Seal Gas cooler Bronswerk Heat Transfer


E-4X01/E-4X51 Inlet Gas Coolers Bronswerk Heat Transfer

FAC locations 1 243 300

E-4X01/E-4X51 Inlet Gas Coolers Bronswerk Heat Transfer


E-1101 E-1202 Gas Cooler GEA BTT France Norg UGS 1 3/8 500 570

E-1101 E-1202 Gas Cooler GEA BTT France Norg UGS 1 5/8 604 750

E-1102 / E-1201 Gas Cooler FBM Hudson Italy Norg UGS 1 1/2 480 675

E-1103 / E-1203 Regeneration Condenser

FBM Hudson Italy Norg UGS 1 1/4 300 390





E-4101 / E-4301 Interstage Cooler FBM Hudson Italy Norg UGS 1 1/8 325 370

E-4201 Interstage Cooler GEA BTT France Norg UGS 1 7/8 665 710

E-7102 Well Kick off Gas Cooler


E-1101 / E-1102 / E-1201 / E-1202

Gas Coolers OLMI Italy Grijpskerk UGS

1 3/8 607 800

E-1101 / E-1102 / E-1201 / E-1202

Gas Coolers OLMI Italy Grijpskerk UGS

1 1/2 722 900


OLMI Italy Grijpskerk UGS

1 3/8 607 770

E-3501 1st stage after cooler


Grijpskerk UGS

1 1/8 347 425

E-4101 Interstage Cooler OLMI Italy Grijpskerk UGS

1 1/8 316 325

E-7102 Well Kick off Gas Cooler


1 1/8 340 425

Table 5.10.1

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A5.11 Torque values for Air cooler bundle rectangular cover flanges

RECOMMENDED BOLT TORQUES FOR AIR COOLER BUNDLE RECTANGULAR COVER FLANGE CONNECTIONS

Tag No. Description Manufacturer Location(s) Header

cover plate connection


Torque (min.)

Torque (max.)

(inch/metric) [Nm] [Nm]

E-2401 Cooling medium cooler


FAC Front 3/4 181 285

Rear 3/4 158 285

E-3103 Recycle gas cooler


Front M16 60 160

Rear M16 53 160

E-3301 seal liquid cooler ROBOX HT NL Grijpskerk UGS

Front M16 96 160

Rear M16 96 160



Grijpskerk UGS

Front 3/4 123 285

Rear 3/4 104 285



Grijpskerk UGS

Front 3/4 121 285

Rear 3/4 105 285

E-4601 A/B

Cooling medium cooler


Front M16 52 160

Rear M16 43 160

E-4601C/D Cooling medium cooler


Grijpskerk UGS

Front 3/4 84 285

Rear 3/4 71 285


GEA BTT France

Norg UGS Front 3/4 88 285

Rear 3/4 75 285

Table 5.11.1

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A5.12 Torque values for anchor bolts (vertical vessels, OV’s/FAC locations)

Tag No. Description Location(s)

Anchor bolts

Remarks Anchor type Quantity Size

Material quality

Torque value [Nm]

V-281 V-381 V-581

Dry Instrument Air Receiver

OV-TUS OV-EKR OV-EKL

8 M24 4.6 127

V-990 Instrument Air Receiver

OV-SAP 8 M24 8.8 413

V-993/ V-994

SAM Buffer Vessels

OV-SAP 12 M24 8.8 413

V-1303 MEG vessel EKL

4 M36 4.6 757

V-1801 Free Water K.O. Vessel

All FAC locations (except SAP/FRB)

8 M30 8.8 828

V-1802 Suction K.O. Vessel


8 M24 8.8 413

V-1901 Free Water K.O. Vessel


8 M30 8.8 828

V-1902 Suction K.O. Vessel


8 M24 8.8 413

V-2601 Interstage K.O. Vessel

SCB

16 M24 4.6 29 8 x M24 lijmankers 8 x M24 chemische ankers

V-4X12 Cold/Filter Separator

SPI/EKR/SZW/TUS/SLO

8 M30 8.8 828


OV-SAP

4 M20 4.6 32

V-5518 Bulk Separator

TJM 8 M20 8.8 24



12 M30 4.6 144

V-7001 Flare K.O. Vessel


8 M24 4.6 72

V-7011 Vent K.O. Vessel

Froombosch (Sattelite SAP/FRB)

8 M36 8.8 1462

ST-001 Stack (A-5001)

TJM 8 M36 8.8 630

Table 5.12.1

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A5.13. De-mounting and mounting instructions for the quick closure V-4X03 (FAC, KSC’s)

Locatie: ............................ Tag nr.: ...........................

Seq. Nr.

Omschrijving Check

1.0 Algemeen 1,1 TRA's uitgevoerd en op locatie aanwezig? 1,2 Werkvergunning aanwezig en getekend? 1,3 Toolbox meeting uitgevoerd, door wie? 1,4 Zijn alle betrokken inspecteurs op locatie aanwezig?

2.0 Voorbereidingen - demontage 'Quick closure'

2.1 Afschermen van de bodem onder V-4X03 met plastic en plaats een opvangbak (Zorg er voor de beschikbaarheid van kolkzuiger).

2.2 Verwijder de trap naast V-4X03 tijdelijk om de bereikbaarheid te vergroten.

2.3 Plaats een rolsteiger aan de linkerzijde van de V-4X03 om het loshalen van de jukken (pos 3, fig. 1) te vergemakkelijken.

2.4 Veiligstellen van het drukvat (drukvrij opleveren).

2.5 Controleren van de drukwaarschuwingsklep (DWK) door 1/2 tot 1 slag open te draaien, pas nadat er geen overdruk meer aanwezig is kan de bronzen moer geheel verwijderd worden.

2.6 Registreer voor demontage van de jukken (pos 3, fig. 1 ) de sluitmaten met een gekalibreerde schuifmaat. Noteer de waarde op het registratieformulier.

Vanaf dit moment dient te worden gewerkt met volgelaat masker en filter bussen laarzen en wegwerp overalls.

3.0 Demontage/Montage - 'Quick closure' (uitvoering)

3.1 Demontage - 'Quick closure' (uitvoering) 1)

3.1.1 Draai de twee borgbouten (pos 2, fig. 1) onder en boven los en verwijder ze uit de jukken (pos 3, fig. 1). 3.1.2 Smeernippels doorsmeren met grafietvet (indien de smeernippels niet gangbaar of verroest zijn, dan vervangen).

3.1.3

Draai de spindelbouten gelijkmatig (pos 5, fig. 1) los, zodanig dat de schroefdraad van de nippel (DWK) niet wordt beschadigd (juk parallel houden). Let op de draad stang heeft linkse en rechtse draad afhankelijk van de positie waar de monteur staat zal hij linksom dan wel rechtsom moeten draaien om de jukken los te krijgen. Dit kan uitgevoerd worden met een luchtgedreven moersleutel.

3.1.4 Draai de spindel (pos 5, fig. 1) net zover los totdat de jukken (pos 3) geheel vrij komen te liggen. Zorg er voor dat het linker juk over de nippel van drukwaarschuwingsklep (DWK) geschoven kan worden.

3.1.5 Einde demontage werkzaamheden voor Stork M&P. Reym maakt onder volledige persoonlijke bescherming de 'quick closure' van V-4X03 open.

3.2 Montage - 'Quick closure' (uitvoering) 1)

3.2.1 Controleer of de pakkinggroef van de V-4X03 goed schoon is (geen zand, vuil, enz). Indien dit niet het geval is pakking groef reinigen met scotch brite zodat er geen vuil meer aanwezig is.

3.2.2 Controleer de pakkinggroef op eventuele beschadigingen.

3.2.3 Controleer of de 'quick closure' goed schoon is (geen zand, vuil, enz). Indien dit niet het geval is, groef reinigen met scotch brite zodat er geen vuil meer aanwezig is.

3.2.4 Controleer de 'quick closure' op eventuele beschadigingen; licht invetten van de corresponderende oppervlakten en spindel.

3) 4)

3.2.5 Lagerringen (of collar) vastzetten op spindelbout d.m.v. 3 (120

o) nieuwe inbusbouten in verzonken 5 mm uitsparingen in

de spindelbout (4 ringen totaal per Quick closure).

3.2.6 Pakkinggroef invetten met zuurvrije vaseline voordat de O-ring wordt geplaatst; plaats de O-ring.

3.2.7 Breng de 'Quick closure' in positie. Stel m.b.v. de nastelboutjes (pos 4, fig. 1) de 'Quikclosure' na (indien nodig), zodat deze goed centraal voor het vat is gepositioneerd.

3.2.8 Plaats het linker juk (pos 3) voorzichtig over de nippel van de drukwaarschuwingklep (DWK). Houd nu ook weer rekening met linkse en rechtse schroefdraad.

3.2.9

Draai gelijkmatig de spindels (pos 5, fig. 1) aan. Het is belangrijk dat de beide jukken (pos 3, fig. 1) evenwijdig naar elkaar getrokken worden. Controleer op regelmatige basis de onder- en bovenmaat van de sluitmaat. Deze waarden moeten parallel mee lopen. Gelijkmatig aanhalen van de spindels met luchtsleutel totdat een max sluitmaat van 35 mm is bereikt, daarna verder aanhalen met hydraulisch torquer in stappen op vereist moment.

1)

3.2.10 Registreer na montage van de jukken (pos3, fig. 1 ) de sluitmaten met een gekalibreerde schuifmaat. Noteer de waarde op het registratieformulier.

1)

3.2.11 Breng de borgbouten met moeren (pos 2, fig. 1) weer aan (handvast). 3.2.12 Monteer drukwaarschuwingsklep (DWK) volgens tekening.

3.2.13 Alle bouten en moeren goed invetten en plaats de beschermhulzen weer over de spindels. 3)

3.2.14 Smeernippels doorsmeren met grafietvet en afdoppen.

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Notes: 1) Indien er zich problemen voordoen met betrekking tot het openen en sluiten van de quick

closures, of wanneer tijdens de inspecties onvolkomenheden van de quick closures gesignaleerd worden, dan dient men zich te vervoegen tot de Engineer Installed Base voor verdere stappen.

2) Voor elke Filter Separator dient een separaat Stappenplan ingevuld en afgetekend te worden. 3) Schroefdraad van bouten/spindels en moeren moet voor montage met grafietvet worden gesmeerd.

Na montage moeten de moeren en de uitstekende draadeinden met grafietvet worden geconserveerd en voorzien van een speciale beschermkap. Het toepassen van een MoS2 (Molybdeen Disulphide) houdend smeermiddel is niet toegestaan.

4) De juk groeven dienen met Molykote separator spray olie (geen Molybdeen Disulphide (MoS2) houdend) te worden ingevet.

Fig. 1 Samenstelling Quick Closure V-4X03

Fig. 2 Druk Waarschuwingsklep (DWK) - V-4X03

Druk Waarschuwingsklep (DWK): Op het linker juk is aan de rompzijde een plaat gelast waarin een gat geboord is. Op de romp van het drukvat is een nippel gelast die door het gat in de plaat steekt als de jukken correct worden aangedraaid. Het uiteinde van de nippel is als een zitting uitgevoerd. Op deze nippel wordt een Druk Waarschuwingsklep (DWK) gemonteerd. Deze DWK bestaat uit een bronzen moer met een stalen klepje dat met een splitpen geborgd wordt.

Na sluiting van de snelsluiting (quick closure) dient de DWK te worden aangebracht en de wartel van deze klep met een momentsleutel te worden aangehaald.

Aanhaalmoment = 80 Nm

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Registratieformulier – Sluitmaten ’Quick closure’ van Fliter Separators V-4X03 (KSC’s)

Locatie

Tag Nr.

Sluitmaten Vóór demontage / na montage 1)

Na sluiting moet de maat worden gecontroleerd tussen beide afstandindicatoren welke boven en onder

op beide jukken zijn aangebracht. Deze maat moet zijn 30 mm ± 1 mm. Aanhaalmoment = 1356 Nm (1000 ft lbs) Sluitmaat positie 12 uur (bovenkant): ………….. mm

Sluitmaat positie 6 uur (onderkant): ………….. mm

Indien de sluitmaat afwijkt van de toegestane tolerantie, dan contact opnemen met de Engineer Installed Base (Mechanical).

Datum

Uitgevoerd door

Getekend

Noten:

1) Omcirkelen wat van toepassing is. 2) Registreer vóór demontage en na montage van de jukken de sluitmaten met een gekalibreerde schuifmaat en noteer de

waarden in dit formulier.

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A5.14 Tightening sequence (when applying a mechanical or a hydraulic torque wrench):

• Cross pattern (see sketches below)

• Repeat in 3 steps: 30%, 60% and 100% of the target value

• Final additional step: clockwise sequence (each adjacent bolt) on 100% of the target value

• Repeat this final step until nuts no longer turn.

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A5.15 Tightening sequence rectangular cover flanges (when applying a mechanical or a hydraulic torque wrench)

• Cross pattern (see sketches below)




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A5.16 De-mounting and mounting instructions for Air Cooler bundle plugs [ref. 20]

Stap Instructie Initialen

Deel 1 : Demontage van de plugs

[1.] De warmtewisselaar moet in een veilige modus staan / drukloos

[2.] Geef de plug en locatie in de plugsheet hetzelfde unieke nummer met een marker i.v.m. plug op dezelfde locatie weer monteren.

[3.] Draai de plug los

[4.] Verwijder de pakking zodanig dat er geen schade ontstaat aan de plug draad of aan het oppervlak van het afdichting vlak

[5.] Inspecteer de plug op beschadigingen aan het schroefdraad en aan het afdichting vlak

[6.] Vervang de plug door een identieke plug als deze beschadigd is

[7.] Inspecteer de plugplaat (geen schade aan de draad of het afdichtings oppervlak)

[8.] Rapporteer waargenomen schade aan de plug plaat, plug draad of het afdichtingsvlak

Part 2 : Data

[9.] Zorg ervoor dat het werkblad (zie A5.18.1) wordt ingevuld door de mechanical ingeneer voor statische onderhoud

[10.] Controleer of de plug en de pakking overeen komt met de specificatie (zie A5.18.1)

[11.] De vakken afvinken als de gegevens op site identiek zijn als opgegeven

[12.] Vul hier de aanbevolen torque waarde in (zie A5.18.1):

Aanbevolen torque : Nm

Part 3 : Pakking compressie test (voor de eerste plug)

[13.] Maak het draad van de plug plaat schoon

[14.] Maak de pakking kamer schoon

[15.] Maak de plug schoon indien nodig

[16.] Meet de dikte van de pakking voordat de plug wordt aangedraaid en vul het test blad in (zie A5.18.2)

[17.] Smeer de plug met MOLYKOTE 1000

[18.] Plaats een nieuwe pakking

[19.] Installeer met dehan de plug in de plug-plaat

[20.] Centreer de pakking indien nodig

[21.] Draai de plug aan met de aanbevolen torque

[22.] Demonteer de plug

[23.] Verwijder de pakking en voorkom schade aan de plug plaat, plug draad en aan de pakking kamer

[24.] Meet de dikte van de gecomprimeerde pakking met een schuifmaat (na het aandraaien) en vul het test blad in (zie A5.18.2)

[25.] Vergelijk de dikte vóór het aandraaien en na het aandraaien. Als het verschil op elk gemeten punt (pakking dikte voor aandraaien vs. pakking dikte na aandraaien) ten minste 0, 1mm is dan gaat u naar deel 4

Zo niet Neem contact op met de Mecanical Static Engineer

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Stap Instructie Initialen

Part 4 : Installatie van de plugs

[26.] Niet opnieuw de gecomprimeerde pakking gebruiken

[27.] Gebruik de nummering bij punt [2.] aangebracht om elke plug op dezelfde locatie in de plugsheet weer te monteren.

[28.] Maak het draad van de plug plaat schoon

[29.] Maak de pakking kamer schoon

[30.] Maak de plug schoon

[31.] Smeer de plug met MOLYKOTE 1000

[32.] Plaats een nieuwe pakking

[33.] Installeer met dehand de plug in de plug-plaat

[34.] De pakking centreren indien nodig

[35.] Pas de aanbevolen torque toe

[36.] De werkvoorbereider moet dit documenteren via SAP M3 terugrapporteren!

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A15.16.1: Werkblad (voorbeeld)

Plaats : E-1103 (Norg UGS)

Datum :

Referentie:

Vereiste gegevens

Plug

Gespecificeerd Op locatie toegepast

Materiaal A350 LF 2 (1.0488)

max. Buiten diameter1)

39 mm

min. diameter1)

30 mm

Draad maat 1 1/4" -12 UNF

Plug schroefdraad lengte min. 26 mm

Smeermiddel Molykote 1000

Pakking

Materiaal Nickel 200 (2.4066)

Hardheid2)

max. 90 HV

Buiten diameter4)

Binnen diameter4)

Dikte

Oppervlakteruwheid Sealing surface

3)

max. Ra 1,6µm

Vorm DIN 7603 Form D

Aanbevolen torque 500 Nm

ERIKS Art. No.

Opmerkingen

1) Zie Page A5.18.3

2) Rapportage Hardheidsmeting (in acc. to ISO 6506-1 or ISO 6507-1)

3) Rapportage Ruwheidsmeting (in acc. to ISO 4287)

4) Ringen altijd fabriceren middels lasersnijden (gestanste ringen zijn niet toegestaan)

5) Indien onvoldoende vervorming dan mag de torque waarde verhoogd worden tot 650 Nm

0

3,08,48

+

−

3,0

09,41

+

−

2,0

2,00,2

+

−

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A15.16.2: Test sheet

Torque Test

Toegepaste Torque:

Pakking dikte voor torque

Pakking dikte na torque

Opmerkingen

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A15.16.3: Inch omreken tabel UNF en ISO228 / buitendiameter schroefdraad

[inch] 1/8 1/4 3/8 1/2 5/8 3/4 7/8 1

[mm] UNF 3,17 6,35 9,52 12,69 15,88 19,05 22,23 25,4

[mm] ISO228 9,73 13,16 16,66 20,96 22,91 26,44 30,20 33,25

[inch] 1 ⅛ 1 ¼ 1 ⅜ 1 ½ 1 ⅝ 1 ¾ 1 ⅞ 2

[mm] UNF 28,58 31,75 34,93 38,1 41,28 44,45 47,63 50,8

[mm] ISO228 37,90 41,91 - 47,80 - 53,75 - 59,61

[inch] 2 ⅛ 2 ¼ 2 ⅜ 2 ½ 2 ⅝ 2 ¾ 2 ⅞ 3

[mm] UNF 53,98 57,15 60,33 63,5 66,68 69,85 73,03 76,2

[mm] ISO228 - 65,71 - 75,18 - 81,53 - 87,88

Thread angle

[°]

UNF 60

ISO228 55

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A5.17 Tightening sequence clamp connectors (when applying a mechanical or a hydraulic torque wrench)

[photo: Destec] A5.17.1 Preparation of PCC’s • The seal ring itself can be re-used (in contradiction to other type of flange gaskets). For the correct

material coding of the seal ring refer to Appendix 3. Note the warning on possible colour coding errors!

• PCC’s are particularly sensitive to damage of the sealing surface. Check if the seal ring and the conical sealing surfaces of the hub are fully clean and free from scratches, corrosion or other types of damage.

• Ensure that the two mating hubs are properly aligned relative from each other. • Prior to mounting the clamp the gap (‘stand- off’) between the seal ring and the flange facing should be

checked as indicated in the figure below (use a finger to press: close the clearance on one side and measure the gap using the feeler gauge on the opposite side). For the stand-off criteria refer to the vendor instructions.

• When using standard bolts (either black or ‘zinc plated’) the bolts and nuts need to be greased prior to

assembling with Molycote 1000. When using teflon-coated bolts this is not required. • Also, the conical surfaces of the pipe clamp hubs should be greased according to the vendor

instructions. The (default) lubricant Molycote 1000 can be used for this.

• Mount the PCC according to the procedure as specified in section 6.2 with the torque target values (100% values) as specified in section 6.3 of this working instruction.

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A5.17.2 Tightening sequence PCC’s

• Tighten the bolting in a criss-cross pattern (i.e. bolt #1, #3, #2, #4) while keeping the spacing between

the clamp halves approximately equal.




A5.17.3 Dismounting PCC’s

• Verify that the piping or flexible is de-pressurised. Be aware of potential residual stresses or

supporting forces, which could result in sudden dynamic movement of the piping or flexible during or after dismounting.

• Relieve the tension in the individual bolts in a cross pattern, but remain the full nut on the thread.

• Relieve the clamp parts from the hub gently using a hammer with a soft (rubber) head.

• Turn the nuts further and relieve the clamp segments further until they are released from the seal ring and the clamp segments are free to move / rotate.

• Finally remove the bolts, nuts, clamp halfs and seal ring completely.

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Appendix 6: Checklist for torquing / tensioning (Based on Shell Flawless approach) Tighteness "Q" ronde formulier Page 1 of 2

No. HSE Check

1 Is the work place accessible and is the flange connection accessible with the selected tools?

2 Is the permit to work available and communicated with all stakeholders?

DEMOUNTING

3 Are the flange labels filled in and attached to the right flanges?

4 Has the pipe work been sufficient supported by (temporary) supports (wood blocks, chains) and are spring hangers / supports locked?

5 Are drip pans available to catch any spills during opening of the flanges?

6 Are sealing surfaces checked for damage and cleaned from any contamination?

7 Are sealing surfaces protected against damage and are flanges covered to prevent ingress of foreign matter in to the pipeline?

8 Are stud bolts properly stored and protected?

9 Are stud bolts checked for damage before re-use?

MOUNTING

10 Check if the stud bolt material and gaskets material and type are per specification and/or work pack

11 Are stud bolds and friction surfaces properly greased with Molycote 1000?

12 Are stud bolts correctly mounted? For new studs: One side: max. 2 threads protruding outside the nut / other side: used for remaining thread length.)

13 Are new gaskets properly stored and protected to prevent damage before mounting?

14 Are sealing surfaces checked for damage and cleaned from any contamination?

15 Is the misalignment within the tolerances? (0,5 mm tot 4", 1 mm tot 8", 1,5 mm tot 16", 2 mm tot 20".)

16 When hydraulic torqueing or tensioning is performed: are the flange connections pre-assembled?

17 Are the right tools used and are the tools calibrated and well maintained?

COMPETENCY

24 Are the mechanics certified for the job they are performing?

25 Is there sufficiënt supervision?

26 Are sealing surfaces cleaned with the right tools?

COMPLIANCE / ACTIVITIES ACCORING PROCEDURE

28 Are the flange labels used and filled out after each step?

29 Is the bolt torque / Tensioning report available during disassembly of the flange (at the work place) and are all the steps registrated?

30 Is the bolt torque / Tensioning report available during assembly (at the work place) and are all the steps registrated?

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Tighteness "Q" ronde formulier Page 2 of 2

Use this box for remarks regarding the above check points

Which action have been taken and by whom?

Q-round executed by:

Date:

Distribution: Q-Captain / Project Manager / Site Coordinator / Supervisor

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Appendix 7: Checklist for bolting activities (work preparation)

CHECKLIST WORK PREPERATION / EXECUTION

No.

GENERAL

1 Location

2 PO. No. of Work Order No.

3 Work preparator

ACTIVITIES

1 Disassembly of flange connections Y/N

2 Tightening of stud bolts with manual torque wrench Y/N

3 Tightening of stud bolts with hydraulic torque wrench Y/N

4 Exchange of stud bolts by "Hot Bolting”: Y/N

WORK PREPERATION

5 Bolt torque registration form filled in correctly? Y/N

6 Permit to work requested? Y/N

7 Materials ordered? Y/N

8 Tools ordered? Y/N

9 Flange labels available and filled in? Y/N

EXCECUTION

10 Permit to work available? Y/N

11 Materials available? Y/N

12 Tools available and calibrated? Y/N

13 Certified Mechanics available? Y/N

14 Equipment available to execute the job (crane, scaffolding, etc) Y/N

Which action have been taken and by whom?

Q-round executed by:

Date:

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Appendix 8: Use of impact wrenches and pneumatic wrenches

• During tightening of stud bolts the use of hand wrenches such as open spanners or ring spanners is not allowed. Only in cases where the use of a mechanical torque wrench is not possible due to limited space available the use of alternative tools is permitted. See also appendix 5 for the correct tools for tightening.

• During dismounting of flanges the use of impact spanners should be avoided; where possible use an alternative such as a ring spanner, a pneumatic wrench or hydraulic equipment.

Specifically for dismounting of flanges the following instructions apply:

1. Only use a pneumatic wrench or hydraulic equipment if there is sufficient space available. Stay

away from the reaction arm. Reed the vendors instructions carefully and follow them. 2. To avoid rotation of the nut a backup wrench (see photo’s, also called ‘react back-up spanner’)

is a recommended tool to use. This can be applied for varying nut sizes. Use of this tool minimizes the risk of injuries to hands.

Examples of backup wrenches (various types / suppliers)

3. Incidentally, impact wrenches may be used when nuts cannot be dismounted using the

recommended tools. (corroded nuts or difficult to reach). However, it is not allowed to ‘flog’ these impact wrenches for a sustained period intensively. For those cases other alternatives should be considered to dismount the nuts from the studs (stronger tool, sawing, cutting or using a ‘nut splitter’).

4. During dismounting open impact wrenches (open impact spanner) are not allowed. Ring impact spanners are however permitted. Open impact spanners have a higher risk on spring back and a higher risk on getting loose suddenly. Only in exceptional cases, after approval of the HMI/LVP of the location, a deviation is allowed, but only when the additional instructions as mentioned below are followed and it is explicitly mentioned on the ‘Permit to Work’

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Additional instructions when using impact wrenches

If dismounting of bolts and nuts is only possible using impact wrenches, use the following precautions: 1. Ensure sufficient light and space is available on the working place. 2. Ensure the working place is clean and tidy (no risk on tripping / slipping). 3. Secure and mark the working place to avoid others getting hit. 4. If needed use a bucket to contain possible spills. 5. Check the impact wrenches:

a. No sharp metal pieces due to mechanical damage on the tool b. The impact wrench should not be greasy c. Use a finger-saver tool connected to the wrench which is properly d. The wrench should have the correct size to match the nut size 6. Execute the work with at least 2 persons. Hold the finger-saver tightened during hammering on the wrench and clearly indicate to the other person when starting to hammer. 7. Avoid body parts in de ‘line-of-fire’. 8. Take rest regularly to ease the muscles.

Open impact wrench/spanner Finger saver

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Appendix 9: CHECKLIST THREADED CONNECTIONS

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Appendix 10: LEAFLET RTJ ring Material

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Documents

01266239/Rev.A/01222008 - gltplusgoalzero.com · Table 5.2.1 Recommended bolt torque values for ASME B16.5 and/or API 6A flange connections Table 5.2.2 Recommended bolt torque values