bd0425a-57a1_bolt up procedure for critical flanges

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CRITICAL FLANGES

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  • JOB SPEC. BD0425A-57A1 BOLT-UP POCEDURE FOR Page: 1 of 22 CRITICAL FLANGES Rev.: I01

    Date: Dec. 11, 2008

    Hellenic Petroleum S.A. Thessaloniki Refinery Upgrading Project

    Thessaloniki Greece 1-BD-0425A

    REVISION INDEX

    PAGE REV DATE

    1 I01 11/12/08 2* I01 11/12/08 3 I01 11/12/08 4* I01 11/12/08 5* I01 11/12/08 6 I01 11/12/08 7 I01 11/12/08 8 I01 11/12/08 9 I01 11/12/08 10 I01 11/12/08 11 I01 11/12/08 12 I01 11/12/08 13 I01 11/12/08 14 I01 11/12/08 15 I01 11/12/08 16 I01 11/12/08 17 I01 11/12/08 18 I01 11/12/08 19 I01 11/12/08 20 I01 11/12/08 21 I01 11/12/08 22* I01 11/12/08 * Asterisk represents pages revised for this issue.

    Initial issue X Entire specification reissued Revised pages only attached

    Please replace revised pages with those now in your possession.

    Prepared by: E. De Rogatis Approved by: F. Chisoli

    Signature:

  • JOB SPEC. BD0425A-57A1 BOLT-UP POCEDURE FOR Page: 2 of 22 CRITICAL FLANGES Rev.: I01

    Date: Dec. 11, 2008

    CONTENTS

    PARA. SUBJECT

    I. INTRODUCTION II. FACTORS AFFECTING BOLT-UP RELIABILITY III. PREPARATION PROCEDURE IV. BOLT-UP PROCEDURE

    A. TORQUE WRENCH METHOD B. BOLT TENSIONING METHOD

    V. ASSEMBLY PROCEDURE QUALIFICATION VI. MAXIMUM BOLT STRESS VII. STAMPING/TAGGING OF FLANGED JOINTS VIII. INFORMATION FOR MATERIAL REQUISITION PREPARATION

    FIGURE "1" ALIGNMENT ALLOWANCES FOR PIPING FLANGES FIGURE "2" FLANGE MAKE-UP CHECK-LIST FIGURE "3" BOLT ELONGATION RECORD FOR CRITICAL FLANGES FIGURE 4" BOLT UP REPORT FOR FLANGED JOINTS

  • JOB SPEC. BD0425A-57A1 BOLT-UP POCEDURE FOR Page: 3 of 22 CRITICAL FLANGES Rev.: I01

    Date: Dec. 11, 2008

    I. INTRODUCTION

    A. This Job Specification is applicable for bolt-up of critical flanges of equipment and piping, as defined at below paragraph I.C, by means of adequate tools procedure.

    B.

    The information contained here is aimed to provide a controlled bolt-up procedure for critical flanges to achieve the plant delivery to the Owner with leakage free joints at any condition.

    This Job Specification does not cover "Post Start-up" operations.

    C. A recommended criteria for selecting critical joints requiring special treatment, including controlled bolt-up, is as follows:

    1. Equipment

    a. Flanged joints with bolt size 1-" and greater.

    b. Flanged joints with A-193 Grade B7M (when required by ExxonMobil GP 06-01-01, paragraph 8.1.1.1) and A-320 Grade L7M bolts, regardless the size.

    2. Piping system

    a. Flanged joints with nominal size 6" NPS and above and rating 900# and above.

    b. Flanged joints with bolt size 1- and greater.

    D. This Job Specification has to be considered a guideline for Vendors/Contractors rater than a series of mandatory requirements. Vendors/Contractors shall develop their own bolt-up procedure (to be issued for FW/HELPE review) based on the indication shown on their document. This Job Specification does not cover flange joint design that shall be in accordance with the applicable specifications, ASME code and standards.

    E. As "Vendor" it is intended the equipment (Vessel, exchanger etc.) manufacturer; as "Contractor" it is intended the organization in field that will supply the bolt-up services.

    F. Vendor is responsible for correct bolt up procedure of all critical flanges proper of his supply, whether performed by him in his shop or repeated by other in field.

    Vendor has to perform the bolt-up activity in his shop according to a.m. procedure, considering that a waive may be asked for critical joints to be reopened in field (such as Vessel manways).

  • JOB SPEC. BD0425A-57A1 BOLT-UP POCEDURE FOR Page: 4 of 22 CRITICAL FLANGES Rev.: I01

    Date: Dec. 11, 2008

    G. Contractor is responsible for correct bolt up procedure of all critical piping joints.

    He shall perform the bolt-up activity of:

    - Piping joint as per his own procedure - Equipment joint as per Vendor procedure (see F above)

    H. In particular, Vendor/Contractor shall define in his procedure the maximum bolt stress to be reached without damaging the gasket flange assembly, recognizing that the values given in TABLE 2 and para VI are indicative and referred to piping standardized flanges only. Appropriate calculation shall be submitted for FW/HELPE review in order to demonstrate the suitability of the gasket flanged assembly for the selected maximum bolt stress.

    I. Vendor/Contractor shall provide a Final Bolt up Report for any flanged joint using the form given in FIGURE N 4 of this Job Spe cification.

    II. FACTORS AFFECTING BOLT-UP RELIABILITY

    A.

    The major factors for successfully making up a bolted joint and eliminating leakage are:

    1. proper selection and design of the component, i.e. flanges, gaskets and bolts;

    2. proper preparation, inspection and installation;

    3. correct bolt-up procedure.

    III. PREPARATION PROCEDURE

    A. Prior to gasket insertion

    1. Clean gasket seating facing using wire brush (use stainless steel bristles on alloy components).

    2. Check conditions of flange faces for scratches, dirt, scale, remnant gasket and protrusions. Flange faces with coarse tool marks or scratches that form leakage paths should be refaced.

    3. Check that flange facing, gasket material, dimensions and type of bolting are in accordance with the general specifications.

  • JOB SPEC. BD0425A-57A1 BOLT-UP POCEDURE FOR Page: 5 of 22 CRITICAL FLANGES Rev.: I01

    Date: Dec. 11, 2008

    4. All gaskets should be replaced with new ones whenever an opened joint is to be closed again. This recommendation is mandatory for soft material gaskets and metalloplastic gasket (such as spirally wound or double jacketed gaskets).

    5. Visually examine gaskets prior to installation to assure they are free from defects. All damaged gaskets (including loose spiral windings) should be rejected.

    6. Use straight steel rule edge to check facing flatness. Flange shall have bearing surfaces for bolting that are parallel to the flange face within 1 (one) degree. Wrapped or badly corroded flanges should be replaced/repaired.

    7. Flanges at rest should be parallel. Alignment should be achieved by cutting and re-welding the pipe where possible. When trueing flanges, make sure that there are no residual stresses in the joint, particularly in machinery piping. Guidelines of alignment allowance are given in FIGURE N 1 of this Job Specification for pipe flan ges and 0,8 mm maximum out of parallel tolerance for exchanger girth flanges. Final alignment shall be filed and recorded for future reference using the form given in FIGURE N 2 of this Job Specification . The use of flame for the alignment of flanges is not permitted.

    NOTE: Alignment can be checked using a straight steel rule.

    8. Studs and nuts shall be cleaned using wire brush to remove any dirt on the threads. Visually examine studs and nuts after cleaning to ensure free from burrs. Nuts should turn freely on the studs for a distance equal to their in-service make-up. Lubricate the threads and nuts to flange contact surfaces with one of the anti-seeze products indicated in TABLE 1 of this Job Specification; lubrication aids in achieving required bolt tension uniformly for the flange.

    9. Align flange faces exactly, leaving just sufficient gap to insert the gasket. Once flanges have been aligned up, visually examine them to assure that an acceptable fit has been obtained. Use flange spreader instead of wedges for wedging.

    10. Prior to inserting slip-blind, it should be checked for protrusion or burrs at blind expecially at edges.

    B. Gaskets and bolts insertion

    1. Visually examine gaskets, prior to installation, to assure they are free from defects. Do not use sealing compound, grease or other paste or adhesive on gasket or flange faces. Holding gasket in place may

  • JOB SPEC. BD0425A-57A1 BOLT-UP POCEDURE FOR Page: 6 of 22 CRITICAL FLANGES Rev.: I01

    Date: Dec. 11, 2008

    present a problem, but use of greases, pastes or other substances to stick them in place should be avoided. If absolutely necessary to use something to hold gasket in place, the thin adhesive tapes such as surgical tapes or relatively stiff glazing type putty may be used in place along the outside edges of gasket.

    Tape/putty need to be located with care to avoid infringing on the flange face/gasket seating surfaces.

    2. Visually examine the flange alignment to ensure that an acceptable fit has been obtained. Studs inserted through the bolt holes of the flanges should guarantee the sustained alignment of the flanges without blocking insertion of the gasket.

    3. Insert the gasket between the flanges carefully to assure proper placement. Make certain that gasket is properly true in joint.

    4. Insert all remaining studs and nuts on hand-thight. Do not pull up studs in a manner that reaches uneven compression of the gasket.

    5. Ensure all bolts are installed with at least two threads protrusion through the nuts at both sides. Where bolt tensioner is to be used, protrusion shall be at least one bolt diameter on one of two sides.

    NOTE: Vendor/Contractor shall carefully complete the table given in FIGURE 2 of this Job Specification (Flange make-up check list).

  • JOB SPEC. BD0425A-57A1 BOLT-UP POCEDURE FOR Page: 7 of 22 CRITICAL FLANGES Rev.: I01

    Date: Dec. 11, 2008

    ANTI-SEEZE - PRODUCTS

    NAME COMPOSITION TEMPERATURE MANUFACTURER NOTES KEY Graphite and Oil Paste Maximum

    343 C (650 F) W.K.M.

    P.O. box 2117 - Houston, TX 770