Service & Installation Instructions

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PETRONAS RAPID (Package 3)

BOLT TENSIONING & TIGHTENING PROCEDURE

This document replaces the document RAPID-P0003-TRSA-CON-PRC-0001-0530

OWNER Approval: Name: Date (DD-MMM-YY): Signature: Document Class: X

Pages modified under this revision:

2017.04.21 17:23:54 +08'00'

Alberto Rojas Espinosa 2017.04.21 18:31:57 +08'00'

Juan Manuel Tovar 2017.04.22 07:51:58 +08'00'

C

22-Apr-2017

IFR- Issued For Review

G.D. Carra

A. Rojas

J.M. Tovar

REV.

DATE DD-MMM-YY

STATUS-REVISION MEMO

WRITTEN BY (name & signature)

CHECKED BY (name & signature)

APPROVED BY (name & signature)

Sections changed in last revision are identified by a vertical line in the right margin

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BOLT TENSIONING & TIGHTENING PROCEDURE (Package 3)

HOLD´s HOLD No.

REF §

DESCRIPTION

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BOLT TENSIONING & TIGHTENING PROCEDURE (Package 3)

Table of Contents 1.

INTRODUCTION ............................................................................................................................................ 4

2.

SCOPE ........................................................................................................................................................... 4

3.

GLOSSARY..................................................................................................................................................... 4

4.

GENERAL SAFETY NOTES .............................................................................................................................. 5

5.

GENERAL REQUIREMENT ............................................................................................................................. 5 5.1

METHOD ............................................................................................................................................... 5

5.2

JOINT PREPARATION BEFORE TIGHTENING ......................................................................................... 6

5.3

REQUIRED TORQUE VALUE .................................................................................................................. 8

6.

BOLT TORQUEING ........................................................................................................................................ 8 6.1

GENERAL REQUIREMENTS ................................................................................................................... 8

6.2

TORQUEING PROCEDURE..................................................................................................................... 9

7.

BOLT TENSIONING........................................................................................................................................ 9 7.1

GENERAL REQUIREMENTS ................................................................................................................... 9

7.2

TENSIONING PROCEDURE .................................................................................................................. 10

8.

THREAD LUBRICANTS AND PRESERVATION FLUIDS ................................................................................... 11

9.

EXECUTION ................................................................................................................................................. 11 9.1

RESPONSIBILITIES ............................................................................................................................... 12

9.2

FLANGED JOINTS TAGGING ................................................................................................................ 12

9.2.1 9.3

TAGGING PROCEDURE ............................................................................................................... 12

FLANGE TIGHTENING REPORTS .......................................................................................................... 13

10.

REFERENCE DOCUMENTATION .............................................................................................................. 13

11.

ATTACHMENT......................................................................................................................................... 13

Attachment 01 – Recommended torque values for non-coated and coated bolts – (02 PAGES) ..................... 14 Attachment 02 – Flanged Joint Tightening Report – (01 PAGES) ...................................................................... 15 Attachment 03 – GASKETS Colour codes – (01 PAGES) ..................................................................................... 16 Attachment 04 – Multipart Tag Example – (01 PAGES) ..................................................................................... 17 Attachment 05 – List of applicable lubricants (01 PAGES)................................................................................. 18 Electronic filename: RAPID-P0003-TRSA-CON-PRC-0001-0529_C.pdf

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BOLT TENSIONING & TIGHTENING PROCEDURE (Package 3)

1. INTRODUCTION The purpose of this procedure is to specify requirements and methodologies for the tightening of flanges bolting using spanners, wrenches, torque wrenches (manual and hydraulic), and hydraulic bolt tensioning equipment where appropriate. The correct placement of gasket and proper tightening of bolts in a flanged joint will ensure a leak free joint. The following procedure describes how to achieve the same. 2. SCOPE This procedure is for use by TR and its nominated subcontractors and shall be applied to all piping flange bolting and bolting of connecting piping to flanged equipment, in all piping systems belonging to ISBL and OSBL units at PETRONAS refinery in Pengerang - Malaysia. 3. GLOSSARY Within the context of this procedure, the following words have the meanings stated: “shall"

indicates a mandatory requirement

"should"

indicates a preferred course of action

"may"

indicates an acceptable course of action

Client

PETRONAS

Contractor

Tecnicas Reunidas

Tightening

the making tight of a flanged joint by torqueing or tensioning the flange bolts

Torquing

the loading/stressing of flange bolts using manual or hydraulic torque wrenches

Tensioning

the loading/stressing of flange bolts using hydraulic jacking tools

Controlled

a method where the loading/stressing of flange bolts is measured to achieve a pre-determined value.

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4. GENERAL SAFETY NOTES The following notes apply to general safe joint assembly and bolting practices. They can only be considered as guidelines, since it is still essential that the operator remain alert for potential hazards and conduct the field operations in a manner that will prevent injury of personnel, or damage to equipment. Where specific precautions are advised with the relation to individual items of equipment, such safety notes are included in the text: A. Proper Eye protection must be worn when operating hydraulic or pneumatic bolting equipment. B. It is recommended that gloves be worn when operating or handling hydraulic equipment. Special precautions must be taken to avoid placing hands or fingers in pinch points, especially around the torque arms of the wrenches and is reaction points. C. Before operating any hydraulic bolting equipment, verify the maximum operating pressure for each equipment item and do not exceed the specified maximum levels in operation. D. Do not handle hydraulic tools by their hoses or hydraulic connections. E. Always remain alert to the positions and avoid standing in the line of any component that would become a projectile if a part were to break. F. Avoid kinking or running equipment over hoses to prevent damage. Inspect spray shields regularly and insure they are in place and in good condition before operating equipment. G. Tensioning: Do not exceed the maximum allowable stroke of the Hydraulic rams. Always insure that the rams are fully returned to the retracted position prior to pressurizing. Observe ram position often while pressurizing. H. Verify that all quick connect coupling are connected and fully engaged before pressurizing.

5. GENERAL REQUIREMENT 5.1 METHOD The method of flange tightening is dependent upon bolt size, system pressure rating and system service, and shall be as follows: Conventional Spanner/Wrenches: Flange bolts may be tightened by conventional manual spanners/wrenches on class 150 utility piping (bolts size 1” diameter and smaller) systems only, but not on GRP flanges, or steel flanges on GRP lap joints.

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BOLT TENSIONING & TIGHTENING PROCEDURE (Package 3)

Torque Wrenches: Flange bolts shall be tightened by torque wrenches on all hydrocarbon systems in all pressure ratings, and utility systems class 300 and above. The flogging of bolts in hydrocarbon systems is not permitted. Bolt torque values for flanges in GRP systems are not contained in this standard, and shall be obtained from the GRP system manufacturer. Hydraulic Jack 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 the following services and pressure ratings: 1) Bolt sizes 2 inches and larger in all services with pressure ratings up to and including class 900. 2) Bolt sizes 1½ inches and larger in all services with pressure ratings class 1500 and above. 3) Bolt sizes larger than 1 inch in critical applications. Critical applications are considered joints exposed to cyclic stress i.e. frequent changes of pressure and/or temperature. 4) For Hydrogen service with bolt size 1½ inches and larger and flange rating class 600 and larger.

5.2 JOINT PREPARATION BEFORE TIGHTENING Apart from the bolt tightening procedure there are several interdependent factors, which are essential to obtain good performance from a bolted flange connection. These are: Flanges 

Always visually inspect the surface finish of the flange, which should be clean, degreased and free of any defects, nicks or burrs. This is important for the back face of the flange where the nuts have to seat as well as the critical gasket face. Flanges should also be checked for flatness with a straightedge.



Check the phonographic or concentric groove on the face of RF flanges. For example, any radial defects will be virtually impossible to seal against. (For acceptance criteria, refer to ASME B16.5 or ASME b16.47 as applicable).



RTJ grooves must be kept scrupulously clean, corrosion free and undamaged.



When cleaning a flange face, never use a tool that may damage the surface finish. A soft wire brush is recommended.

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BOLT TENSIONING & TIGHTENING PROCEDURE (Package 3)



Do not use unnecessary force to bring together flanges which are clearly misaligned as this may over stress adjacent pipe work and make sealing of the flanged joint difficult and unreliable. Instead, this situation must be reported and rectified. The measured lateral misalignment shall not exceed the following values: DN ≤ 100 > 100

Maximum Misalignment 2 mm 3 mm

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

Do not mate flanges manufactured to different standards unless specified in an approved design.

Bolts 

Ensure that the correct size and material of bolting is used (refer to the piping class).



Allow for at least two threads to be exposed outside the nut once tightened, this is good practice. The only exception to this is when a flange requires Hydraulic Bolt Tensioning.



Only use clean, rust free nuts and stud bolts.



Coat the stud, the nut thread, the nut and the flange bearing surfaces with Molykote 1000



Ensure that the nut is free running ideally along the full length of the bolt, but especially around the area where the nut will be tightened.



Ensure that the flange area on which the nut will seat is clean and undamaged as unanticipated friction or compressible debris will adversely affect the Residual Bolt Load.



Do not use damaged or corroded stud bolts or nuts.



Do not use nuts or bolts that do not fit correctly together.



Does not use stud bolts or nuts that are not clearly marked with the correct material grade as a wrong assumption could have serious consequences. (e.g., stud bolts marked with B7 and nuts with 2H in sweet services and studs marked with B7M and nuts with 2HM in sour services in line with the pipe class).



Nuts should not be assembled with the identification marking against the flange. The identification marking should always point outwards.

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BOLT TENSIONING & TIGHTENING PROCEDURE (Package 3)

Gaskets 

Check the type, class, size and material specification of the gasket before using it. Check with the piping class to confirm that it is correct. (Applicable gaskets colour code is given in attachment 03)



Check the gasket for damage, nicks, etc. Ensure that it is clean and free from any contaminants before use.



Ensure the gasket fits correctly



Spiral Wound, and Ring Joint gaskets can only be used ones and shall not be re-used.



Do not use Spiral Wound, and Ring Joint gasket that have no identification. It may appear to fit the flange, but this is not a guarantee.



Do not cut or deform a gasket to fit a flange. If the gasket does not fit, the wrong one has been chosen.

5.3 REQUIRED TORQUE VALUE Recommended torque values for non-coated and coated bolts, both on SI and U.S. customary units are given in Attachment 01. These torque values will generate the bolt stresses necessary for gasket seating, design pressure and hydrostatic test pressures, differences in the coefficient of thermal expansion and bolt relaxation, but will not overstress the flange or crush the gasket. 6. BOLT TORQUEING 6.1 GENERAL REQUIREMENTS For all flange bolting on class 150 utility piping (bolts size 1” diameter and smaller) except flanges in GRP systems, tightening may be carried out by conventional spanners/wrenches. Bolt torques for flanges in GRP systems shall be obtained from the GRP system manufacturer. 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 the site personnel. When the bolt loading requires a torque figure of more than 500 Lbf.ft (678 Nm) to be applied, hydraulic torqueing is recommended, using hydraulic torque wrenches. (Note: calibration of torque wrenches remains critical, check certificate validity prior to use). Controlled torqueing shall be carried out on the following flanged connections:

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BOLT TENSIONING & TIGHTENING PROCEDURE (Package 3)

1) Bolt sizes less than 2 inches diameter for all service ratings up to and including class 900, except class 150 utility services (see above). 2) Bolt sizes less than 1½ inches diameter for all service ratings class 1500 and above. 3) Bolt diameters in excess of those stated in (1) and (2) when hydraulic jack tensioning is not practical. 6.2 TORQUEING PROCEDURE To achieve joint tightness it is important that the following procedure is adhered to: 

Check and ensure that the general requirements of Section 5 have been satisfied.



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 1. At each stage of tightening, bolts shall be tightened in a controlled sequence as follows (bolts numbered clockwise around the flange): 4 bolts flange

1,3,2,4.

8 bolts flange

1, 5, 3, 7, 2, 6, 4, 8.

12 bolts flange

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

16 bolts flange

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

20 bolts flange

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

24 bolts 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 bolts 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. 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.

32 bolts flange 

Finally, the bolts shall be chased round using the 100% torque value stated in Appendix 1, until no nut movement occurs.

7. BOLT TENSIONING 7.1 GENERAL REQUIREMENTS Controlled hydraulic jack bolt tensioning enables 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 bolts corresponds to the calculated load required to make the flanged joint.

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BOLT TENSIONING & TIGHTENING PROCEDURE (Package 3)

Whilst the bolts are elongated, the nuts can easily be run down the thread by hand, until they bear against the flange. When the hydraulic pressure is released virtually all of 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 lengths shall be protected against corrosion and damage to allow the nuts to be subsequently unscrewed. Grease filled rubber, plastic caps, or denso tape 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. The hydraulic pressure is supplied by a high-pressure oil pump via a distribution ring main to a number of jacking tools. Controlled hydraulic jack bolt tensioning shall be carried out on the following flanged connections (where inadequate space or availability of tooling restricts the use of tensioning, then controlled torqueing shall be used): 1) Bolt sizes 2 inches and larger in all services with ratings up to and including class 900. 2) Bolt sizes 1.5 inches and larger in all services with ratings class 1500 and above. 3) Bolt sizes larger than 1 inch in critical applications. 4) For Hydrogen service with bolt size 1½ inches and larger and flange rating class 600 and larger. 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 5 have been satisfied.



Before starting work, check that the tensioning tool is not too large to fit on the nuts and flange.



The application of hydraulic jack bolt tensioning equipment shall be in strict accordance with the manufacturer's instructions and safety procedures.



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

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BOLT TENSIONING & TIGHTENING PROCEDURE (Package 3)

8. THREAD LUBRICANTS AND PRESERVATION FLUIDS All bolts shall be treated with a preservative lubricant as per grade below, or equivalent: Molykote 1000 (combined friction coefficient for application nut face and threads = 0.11) Applicable list of lubricants is given in attachment 05. The use of lubricants with a lower coefficient of friction than that shown can lead to excessive bolt stress being applied by wrenches or torque wrenches, and yielding or failure of flanges or bolting may result. Molybdenum Disulphide greases shall not be used under any circumstances as this can result in stress corrosion cracking. Note that Molykote 1000 does not contain Molybdenum Disulphide. When the bolt tightening procedure is completed, to prevent corrosion a liberal coating of grease should 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. 9. EXECUTION Control of the competence of the people working with joints is the most important factor in preventing leaks. Only competent and qualified staffs are allowed to execute and supervise flange-fitting activities on all piping. The contractor shall keep training and competence records of the fitters and supervisors working under his responsibility. As a minimum fitters and supervisors, staff shall have knowledge/skills of: 

The behavior of nuts and bolts when tightened



Gasket/seal rings Types application and installation



Flange surface finish/join sealing face



Correct assembly of flange components



Flange alignment measurement and acceptance criteria.



Safe range of bolt loads and the importance of residual bolt load



Methods of tightening



Correct use of tools



Procedures and reporting.

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BOLT TENSIONING & TIGHTENING PROCEDURE (Package 3)

In addition, the operation of hydraulic bolt tensioning and torque equipment needs dedicated skills and training. 9.1 RESPONSIBILITIES It is the responsibility of TR area Supervisor and the executing subcontractor to ensure bolts are tightened in accordance with this Specification. It is the responsibility of the executing subcontractor to ensure that only qualified fitters are working on flange connections. 9.2 FLANGED JOINTS TAGGING All joints for which controlled tightening is to be applied (manually and hydraulic torque wrench and hydraulic jack bolt tensioning) shall be uniquely identified, tagged and details recorded. This requires all joints to be physically tagged so that their identity is clear and visible at the joints location, including unique joint ID number in order that it can be recognized in a joint database. A multi part tag will be used for this purpose. In the multipart tags, the status of the joint is indicated by the colour of the portion remaining of the tag. Joint status/conditions will be as follows: -

Joint to be broken out/Joint broken out,

-

Joint to be assembled/Joint assembled,

-

Joint to be controlled tightened/Joint tightened,

-

Joint to be tested/Joint tested.

An example of applicable colour multipart tag ID is given in Attachment 04.

9.2.1 TAGGING PROCEDURE  All joints that are to be made or disturbed during construction, Precommissioning and commissioning phase, shall be identified, recorded and tagged on a joint register. 

The tags shall be made of waterproof resistant material suitable for outdoor conditions.



The tags shall be fitted using a suitable tie and in a position adjacent to or on the joint.



The person who breaks the joint(s) will mark up the tag identification number on a copy of the relevant Isometric or P&ID and its correspondent register.

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BOLT TENSIONING & TIGHTENING PROCEDURE (Package 3) 

At the completion of each stage of the job (inspection, assembly, tightening and testing), the responsible person or the supervisor shall record its name against the stage.



Once the testing has been satisfactorily completed, the removable insert of the tag shall be returned to the TR area supervisor. The task completion shall be recorded in the relevant test pack when all joint tag bodies are returned, indicating that all works have been completed.



The relevant test pack and/or system final pressurization (start-up) shall be prevented until all the tag inserts are signed off and returned to allow sign-off of the job.

9.3 FLANGE TIGHTENING REPORTS A copy of the applicable flange tightening report is provided in Attachment 02.

10. REFERENCE DOCUMENTATION Doc. Number PTS 31.38.01.11 PTS 31.38.01.31 ASME-PCC-1-2013 ASME B16.20-2012 ASME B31.3-2014 ASME B16.5-2013 ASME B16.47 RAPID-P0003-TRSA-HSE-PLN-0001-0115

Description Piping – General Requirements Shop and Field Fabrication of Piping Guidelines for Pressure Boundary Bolted Flange Joint Assembly Metallic Gaskets for Pipe Flanges Process Piping Pipe Flanges and flanged fittings NPS 1/2 Through NPS 24 Large Diameter Steel Flanges NPS 26 Through NPS 60 (series B) Precommissioning & Commissioning HSE Plan

11. ATTACHMENT

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BOLT TENSIONING & TIGHTENING PROCEDURE (Package 3)

Attachments Attachment 01 – Recommended torque values for non-coated and coated bolts – (02 PAGES)

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ATTACHMENT 01 – RECOMMENDED TORQUE VALUES FOR NON-COATED AND COATED BOLTS

U.S. UNITS

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ATTACHMENT 01 – RECOMMENDED TORQUE VALUES FOR NON-COATED AND COATED BOLTS

SI UNITS

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Attachment 02 – Flanged Joint Tightening Report – (01 PAGES)

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No: 02260-CON-PIP-27 Rev.: 0 Date: 14/04/2016 Page: 1 of 1

TIGHTNESS REPORT FOR BOLTING (PIPING) PROJECT:

SUBCONTRACTOR:

SYSTEM/SUBSYSTEM:

DRAWING:

TAG NUMBER:

DESCRIPTION:

INCLUDED IN FOLDER:

REPORT NUMBER:

BAR CODE:

This certificate does not exempt the Subcontractor from the Terms of the Contract, Project Specifications or Quality Procedures but confirms that all these Tests have been performed according to them.

TYPE OF BOLTS 1

TYPE OF BOLTS 2

TYPE OF BOLTS 3

DIAMETER:

DIAMETER:

DIAMETER:

QUALITY:

QUALITY:

QUALITY:

QUANTITY:

QUANTITY:

QUANTITY:

FIRST TORQUING:

FIRST TORQUING:

FIRST TORQUING:

SECOND TORQUING:

SECOND TORQUING:

SECOND TORQUING: RANGE:

TORQUE WRENCH Nº:

CALIBRATION CERTIFICATE: FIRST TORQUING

ISOMETRIC

TYPE OF BOLTS

JOINT No

SECOND TORQUING

GASKET ACCORDING TO ISOMETRIC DRAWING

REMARK DATE

ACCEPTED

REJECTED

REMARKS:

WITNESSED/REVIEWED BY:

SIGNATURE:

PRINT NAME: DATE:

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SUBCONTRACTOR

TR QUALITY SUPERVISOR

CLIENT (If required)

DATE

ACCEPTED

REJECTED

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Attachment 03 – GASKETS Colour codes – (01 PAGES)

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ATTACHMENT 03 - GASKETS COLOUR CODE

In addition to the above, permanent Gaskets shall be marked for rating according to the instructions below:

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Attachment 04 – Multipart Tag Example – (01 PAGES)

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FRONT

REAR JOINT TESTING Joint No. Test Pack No.

JOINT

Joint

Joint

Size

Rating

Tech 1

Tech 2

Date

TIGHTENED JOINT TIGHTENED Joint No.

JOINT TO BE TIGHTENED

Test Pack No.

Torque Tech 1

Tension Tech 2

Date

JOINT ASSEMBLED Joint No. Test Pack No.

JOINT TO BE

Lubricant: Joint

Joint

Size

Rating

Tech 1

Tech 2

Date

ASSEMBLED JOINT BREAK DATA Joint No.

JOINT

TO BE BROKEN

Test Pack No.

Joint

Joint

Size

Rating

Tech 1

Example of a multi part tag

Electronic filename: RAPID-P0003-TRSA-CON-PRC-0001-0529_C-04.pdf

Tech 2

Date

Document Number Project

Package

Originator

Discipline

Doc. Type

Unit nº

Serial nº

RAPID

P0003

TRSA

CON

PRC

0001

0529

Rev.

C

BOLT TENSIONING & TIGHTENING PROCEDURE (Package 3)

Attachment 05 – List of applicable lubricants (01 PAGES)

Electronic filename: RAPID-P0003-TRSA-CON-PRC-0001-0529_C.pdf

Page

18 / 18

ATTACHMENT 05 – LIST OF APPLICABLE LUBRICANTS

Electronic filename: RAPID-P0003-TRSA-CON-PRC-0001-0529_C-05.pdf