installation procedure for misalignment flange. bolting sequence

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Oil States Industries, Inc. Houston Operations INSTALLATION PROCEDURE 42” CUSTOM BALL FLANGE CONNECTOR 0 05 JUL 2011 A. Tran A. Hinthorn L. Dolan Rev. Date Originator Checked Approved Document No. PRO-079277 Proprietary Rights Notice This document contains information proprietary to Oil States Industries, Inc. It shall not be reproduced nor shall the information contained herein be used by or disclosed to others except as expressly authorized by Oil States Industries,. Inc

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Page 1: Installation Procedure for Misalignment Flange. Bolting Sequence

Oil States Industries, Inc. Houston Operations

INSTALLATION PROCEDURE 42” CUSTOM BALL FLANGE CONNECTOR

0 05 JUL 2011 A. Tran A. Hinthorn L. Dolan

Rev. Date Originator Checked Approved

Document No.

PRO-079277

Proprietary Rights Notice This document contains information proprietary to Oil States Industries, Inc. It shall not be reproduced nor shall the information contained herein be used by or disclosed to others except as expressly authorized by Oil States Industries,. Inc

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Revision History

Rev. Date Description

0 05 JUL 2011 Issued for use

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Table of Contents 1.0 Scope ............................................................................................................................... 3

2.0 Job Information ............................................................................................................... 3

2.1 Customer Pipe Information ........................................................................................ 3

2.2 Connector Information ................................................................................................ 3

3.0 Description ...................................................................................................................... 4

3.1 Overview ...................................................................................................................... 4

3.2 Parts List ...................................................................................................................... 5

4.0 Handling and Storage ..................................................................................................... 6

4.1 General Precautions ................................................................................................... 6

4.2 Lifting ........................................................................................................................... 6

4.3 Storage ......................................................................................................................... 6

5.0 Welding ............................................................................................................................ 7

5.1 Material ......................................................................................................................... 7

5.2 Preparation .................................................................................................................. 7

6.0 Field Coating ................................................................................................................... 8

7.0 Installing Offshore .......................................................................................................... 9

7.1 Handling ....................................................................................................................... 9

7.2 Alignment ................................................................................................................... 10

7.3 Bolting ........................................................................................................................ 11

7.4 Adjustments to the Ball Flange ................................................................................ 11

8.0 Speed Load™ Bolting Option ...................................................................................... 12

9.0 Installation Bolting ........................................................................................................ 14

9.1 Materials ..................................................................................................................... 14

9.2 Methods and Equipment ........................................................................................... 14

9.3 Bolt Loads .................................................................................................................. 14

10.0 Annulus Testing & Installation Completion ................................................................ 17

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1.0 Scope This document outlines the installation for OilStates’ Ball Flange (BF) connectors.

2.0 Job Information All of the information required during the course of the installation can be determined prior to the installation and recorded here. Completion of this section ahead of time will help the Contractor complete the installation in a timely manner.

2.1 Customer Pipe Information Owner/Operator of pipeline: ............................................................... _______________ Nominal pipe size: ........................................................................................ 42” nominal Pipe wall thickness: ......................................................................... ._______________” Pipe material grade: .................................................................................... API 5L X___ Pipe coating: ................................................................................ __________________ MAOP (pipeline): ..................................................................................... _________ psi Location / Water depth: .......................................................................... _____________

2.2 Connector Information ANSI pressure class of BF: .............................................................................. 600 ANSI BF Serial Number ................................................................... ___________/_________ Operating temperature of BF: ....................................................................... 32 to 200°F Connector weight (see appropriate assembly drawing): ............ _______________ LBS Available rotational adjustment (angular): .................................................................. 10° Stud Data: ............................................................................... 2-1/2”-8UN (Quantity 32) Tension Pattern ...................................................................................... 100% coverage Bolt Tension: .............................................................................................. 233,000 LBS Max Annulus test pressure (may be reduced at request of customer): .............. 2250 psi

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3.0 Description

3.1 Overview The Ball Flange Connector is an articulated connector which provides a flange type connection for offshore pipelines. The patented configuration provides a weld end x RTJ flange connection. The device provides makeup to industry-standard flanges, adding four degrees of freedom for makeup flexibility. The bolt hole flange swivels 360o to accommodate rotational alignment with the mating flange. Additionally, the spherical components allow angular adjustment up to 10o from the tubular axis in any plane for flange face alignment. Upon installation, the unit is designed to form a rigid connection capable of withstanding bending moments in excess of pipeline yield for all common wall thicknesses and grades. The unit is furnished factory assembled requiring no special on-site or subsea assembly, and provides unmatched protection of the spherical sealing elements against handling damage and contamination.

The Ball Flange Connector incorporates metal-to-metal primary sealing which allows multiple ‘make and break’ operations without refurbishment. The spherical sealing surfaces are protected from grit contamination by the nose wiper and cup ‘O-ring’. Angular adjustment of the Ball Flange is facilitated by the use of a molydisulfide-impregnated nose wiper and an O-ring cup seal on the grip socket. Both of these prevent metal-to-metal contact prior to the application of bolt load.

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3.2 Parts List Figure 1 shows the component parts of a typical ball flange. Size and material specifications are listed for each Ball Flange on their respective Bill of Materials.

Figure 1 General Arrangement

TABLE 1 - BILL OF MATERIALS

ITEM DESCRIPTION ITEM DESCRIPTION

1 BALL 8 SHCS, 1-8UNC-2A X 11.50

2 CUP 9 SPRING

3 GRIP SOCKET 10 PLUG, ¼” NPT

4 NOSE WIPER 11 EXPANSION PLUG

5 NUT, MODIFIED HEAVY HEX 12 SWIVEL HOIST RING

6 STUD, 2.50-8UN-2A X 60.00 LG 13 SEAL, O-RING

7 NUT HEAVY HEX, 2.500-8UN-2B 14 RTJ RING

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4.0 Handling and Storage

4.1 General Precautions The sealing surface of the Ball Flange can be damaged by sharp objects or an accumulation of trash in the sealing area. Care should be taken to protect the finish of the ball until installation.

4.2 Lifting The preferred method of lifting the Ball Flange is using the lift eye, swivel hoist ring, or lifting through the stud holes. Plate dogs, if available, can also be used to lift at the weld end.

Never position the Forklift forks, chains, straps, of other lifting devices through the bore of the Ball Flange.

The lift eye is only designed to lift the weight of the Ball Flange itself. Do not use the lift eye to lift a Ball Flange once it has been attached to other piping.

4.3 Storage The standard external coating on the Ball Flange is a high build epoxy (Carboline 890). This coating is capable of long term exposure to sunlight and moisture.

The studs, nuts, and washers are coated with SP-1015. This coating is NOT rated for long term exposure to ultraviolet radiation (sunlight) or salt spray. After a few days of exposure to sunlight, the coating will begin to fade and chalk. The studs, nuts, and washers should be either stored inside or covered until they are to be used.

A light coating of grease has been applied to the sealing surfaces during assembly. No further lubrication or protective grease is required.

For long term storage of the Ball Flange, the component parts should be disassembled. This is only to be performed by qualified OSI technicians. Contact OSI for further information.

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MATERIALS

ITEM SIZE 42” BALL SV1B-00-003-8498 CUP SV1B-00-003-8498 GRIP SOCKET SV1B-00-003-8498

5.0 Welding

5.1 Material Each Ball Flange is supplied with a data book which contains the Material Certification. The Ball Flange materials are selected to allow field welding using procedures which are typically used in pipeline fabrication. Unless otherwise noted, the materials used on the Ball Flange is certified as:

5.2 Preparation (Numerical notes following statements in this section reference to figure 2 below) The most critical preparation for welding is the protection of the sealing area (1). The preferred method of protection is to pack the sealing area with a flame resistant material and seal with duct tape. An alternate, although less effective method is to install a dam of wet rags. The purpose is to protect the sealing area from weld beads and slag. The other two areas where damage may occur are between the Cup and Grip Socket (2) and between the Grip Socket and the Ball (3). Protection of area (2) and area (3) may be protected in the same manner as area (1). Upon completion of welding, all protective materials must be removed and the area washed with a stream of high-pressure water. Visually inspect the sealing area to ensure that all contaminants are removed and the sealing surface was not scratched or otherwise damaged.

The Ball Flange weld end is bored to match the inside diameter of the customer’s matching pipe. In order to provide equivalent physical strength to higher yield pipe materials, the outside diameter of the weld neck may be greater than that of the matching pipe. However, the wall thickness will not exceed 1.5 times the nominal wall thickness as typically allowed by MSS-SP44 and other applicable codes. No special procedures should be required for alignment to the pipe.

The weld end of the Ball Flange is left bare of coatings for approximately 2 inches. The standard external coating is Carboline 890. This coating will become discolored and burn in the presence of a direct flame.

If the welding procedure calls for a post weld heat treatment (PWHT), the preferred method is by local induction heating. The internal surfaces of the Ball Flange are coated with Xylan which has a maximum operating temperature of 450 degrees F. The nose wiper and cup seals have a maximum operating temperature of 200 degrees F. If any PWHT method will subject the coating or seals to temperatures above their rated operating ranges, contact OSI for further instruction.

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FIGURE 2: SENSITIVE AREAS

6.0 Field Coating Unless specified by the end user, the standard coating of the body of the Ball Flange is a high build epoxy (Carboline 890). No additional coating of the Ball Flange is required.

Do not coat the external surfaces of the Ball Flange with any field coatings such as coal tar epoxy or mastic. Application of these or other coatings can prevent the Ball Flange from operating properly.

The weld between the Ball Flange and the pipe may be coated. Any coating acceptable to the pipeline owner, using a hand applied method, can be used. When preparing the surface for coating, extreme caution should be used to ensure that the sand from sandblasting, debris, and/or surface preparation fluids cannot enter any of the areas shown on figure 2.

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7.0 Installing Offshore

7.1 Handling (Numerical notes following statements in this section reference to figure 3 below) The preferred location for lifting a spool and Ball Flange assembly is from a strap (6) behind the Ball Flange as shown in figure 3. By lifting the spool away from the Ball Flange, the connector is free to rotate and articulate. This gives the maximum advantage for ease of installation of the spool. The strap should be far enough away from the Ball Flange to allow the use of a pry bar (5). The lift eye (4) is not designed to lift the spool and should not be used as the lift point.

The Ball Flange should not contact the seabed at any point. Although the Ball Flange is designed with wipers and gaskets to protect the sealing area, excessive silt and debris may prevent a successful installation. The most critical areas to keep clean are the nose and cup area (1) in figure 2 or 3.

FIGURE 3: OFFSHORE HANDLING

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7.2 Alignment (Numerical notes following statements in this section reference to figure 4 below) The Ball Flange can be initially aligned to the mating flange using a variety of standard subsea tools, including air bags, tuggers, and/or lift lines. Final alignment can be assisted using drift pins, long threaded bolts, or pry bars as shown in Figure 4.

As the Ball Flange is brought into position, its housing should be adjusted until the face of the Ball Flange is parallel relative to the mating flange (7). The Ball Flange can be rotated using a pry bar (5) and the lift eye (4). It can be articulated using a pry bar (8) through a bolt hole in the Ball Flange. This process continues until the flange faces are parallel and the bolt holes are aligned.

The method used to install the studs varies depending on a number of criteria including field conditions, installation arrangement, intended method of tightening, and selection of the speed load option. The exact method is at the installation contractor’s option. Likewise, the installation of the gasket varies depending on the field conditions and whether it was pre-installed prior to deployment of the spool. Once the studs and gasket are installed, the load is applied to the studs to set the seals.

FIGURE 4: ALIGNMENT

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7.3 Bolting The RTJ gasket and the Ball Flange seals are both engaged with the flange studs. The load required is specified in section 9, “Installation Bolting”.

As the bolt load is applied, both the gap between the flanges and the gap between the Cup and Grip Socket will decrease slightly. In most cases, both gaps will remain parallel during the make up process. However, due to the spherical geometry of the Ball Flange, it is possible that the gap may close unevenly. The gap between the Cup and Grip Socket may close completely on larger size connectors. None of these irregular conditions should affect the strength or integrity of the Ball Flange. However, if the gap is not closing evenly or other anomalies are noted during the bolting process, OSI should be notified.

7.4 Adjustments to the Ball Flange The Ball Flange is inspected and assembled in the factory prior to shipping. No further adjustment is required. The cup and grip socket settings have been adjusted using the socket head cap screw and spring. This adjustment ensures that wiper seals are engaged, protecting the sealing surface while allowing rotation and articulation.

Access to the capture bolt and spring is protected by an expansion plug and covered with the following sticker. No field adjustment of the capture bolts is required or allowed. As stated on the sticker, attempting to access the capture bolts will void the warranty.

NOTICECAPTURE BOLTS ARE

PRESET AT THE FACTORY.ANY TAMPERING WITH

THESE BOLTS WILL VOIDOSI WARRANTY

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8.0 Speed Load™ Bolting Option Some of the larger sizes of Ball Flanges have been equipped with the Speed Load option. The purpose of this feature is to preload the bolts in the Ball Flange prior to deploying the piping spool subsea. This minimizes time and effort in handling of the studs and nuts. The retainer bolt is designed to remain in position with or without a stud in place. The retainer can be used several times prior to inspection or replacement.

The studs and nuts are installed as shown in figure 5. Both nuts are originally installed on one end of the stud. One or more of the bolt holes may initially be left empty to be used for alignment drift pins or other line up equipment.

FIGURE 5: SPEED LOAD™ OPTION

The retainer bolt is a three component device used to retain the stud during pipe spool deployment. A brass bushing is attached to the bolt using a drive rivet, but the bushing is allowed to rotate relative to the bolt.

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With the stud in position, the retainer bolt is tightened against the stud. The brass bushing deforms slightly into the threads of the stud and presses the stud against the bolt hole wall. This holds the stud in position.

Extreme caution must be taken whenever attempting to disengage the retainer bolt. The stud may become free to move at any time once the retainers are loosened.

In order to free the stud, the retainer bolt is rotated counter clockwise 2 full turns. This allows the brass bushing to fully disengage and allows the stud to move freely. At any time immediately after starting to loosen the retainer bolt, the stud may begin to move. Full disengagement is not necessary to allow release of the stud.

The retainer bolt torque required for proper operation is 50 ft-lbs minimum to 80 ft-lbs maximum. (The speed load retainer bolts have been tested to hold four times the stud weight when torqued in this range.) Torque in excess of 150 ft-lbs may damage the connection between the bushing and retainer bolt.

Prior to deploying the piping spool, the contractor must check to ensure that the retainer bolts have been properly torqued. Failure to properly torque the retainer bolts may result in the studs releasing prematurely and causing damage or injury to personnel.

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9.0 Installation Bolting

9.1 Materials The bolting of the Ball Flange to the weld neck flange is performed using studs and nuts. The material grade used is ASTM A540 Grade B21 Class 4 for the studs and ASTM A540 Grade B21 Class 4 for the nuts.

Both the studs and nuts are coated with SP-1015. This is a low friction coating which also provides some corrosion protection.

9.2 Methods and Equipment There are two typical methods of tightening the studs and nuts. These methods are either using torque by manual or hydraulic wrenches or by direct tensioning of the studs. The method of tightening is specified at the time of purchase.

When the studs are to be tightened by torque, the length of the stud is calculated using ANSI methods. Each stud is supplied with two nuts and two washers.

When the studs are to be tightened by direct tensioning, the length of the stud supplied is the ANSI length plus the additional length required by the tensioner. Half of the nuts supplied are drilled to accept a “tommy” bar. No washers are supplied or required when tensioning the studs.

9.3 Bolt Loads The Ball Flange is designed to operate with a stress in the studs between 40% and 50% of the specified minimum yield strength (SMYS) of the stud. The bolt load for this connector is 233,000 LBS. Figure 6 shows the recommended pattern for torque application. The same applies for tension applications although full coverage is preferred. For a torque application, multiple passes should be used until no nut rotation is observed. A minimum of two cross patterns as indicated followed by a ring pattern is required. For tensioning application, the tensioners should be bled off and pressure reapplied until once again no nut rotation is observed.

Information on the pressures required for bolt tensioning equipment is published by the manufacturers of the bolt tensioning equipment.

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FIGURE 6A: TORQUE/TENSION PATTERN

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FIGURE 6b TORQUE/TENSION PATTERN

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10.0 Annulus Testing & Installation Completion Unless otherwise noted and signed below, the maximum annulus test pressure is 2250 psi. Since this annulus pressure is never in contact with the pipeline, there is no need for the customer to be concerned regarding the magnitude of the pressure. Oil States does not guarantee correct functionality of the Ball Flange for any test pressure higher than that provided.

Company Representative has requested a test pressure of _________psi, which is a deviation from the above specified value.

____________________________ Company Rep. Signature

________________Date. Annulus Test Pressure: _________(+100-psi, -0) Follow the steps below to complete the annulus test:

1. Install annulus test fitting in Ball Flange and tighten it as required.

2. Prior to connection, a small amount of oil should be pumped through the test hose to purge any trapped air from the hose reel.

3. Connect the hose fitting mate for the pressure test hose to the annulus test port of the Ball Flange. Connect the pressure test hose to the Ball Flange. Plumb in the data recording equipment to the outlet provided at the test pump.

4. With the data recording equipment ready to record, pressurize the test port to the Annulus Test Pressure and hold for thirty (30) minutes, or as specified by Customer. Note that stabilization may take some time due to seal settlement.

5. Depressurize the Ball Flange annulus and shut down the data recording equipment. Disconnect the test hose from the Ball Flange. Remove the hose fitting from the Ball Flange test port and replace it with an annulus test port plug. The test port plug should be wrapped with fresh layers of TEFLON tape before it leaves the surface.

6. If chart recording is available, provide the Operator representative with a copy and retain the original for Owner and OilStates.

Sand bag or cover the installation location as required. Procedure Completed As Specified

_____________________ ______________________

OilStates Dive Contractor Supervisor