oeup-int1000-sop-ops-0031 pe flange assembly bolt and nut tightening

PE Flange Assembly Bolt and Nut Tightening

Standard operating procedure – Level 1 OEUP-INT1000-SOP-OPS-003

PE Flange Assembly Bolt and Nut Tightening

Level 1 standard operating procedure

Review Record

Rev Date Reason for Issue Prepared Checked Approved

0 23/04/12 DRAFT CB MH

1 19/09/12 Final Version CB

Next Review Date: [23/04/2013]

*Please see Document Information and History section for more information.

For internal Origin use and distribution only. Subject to employee confidentiality obligations.

Once printed, this is an uncontrolled document unless issued and stamped Controlled Copy or issued under a transmittal.

OEUP-INT1000-SOP-OPS-003 [insert document number]

Released on 11/03/2012 – Revision 0 – Status: Draft Process Owner is: Chief Mechanical Engineer

Origin Energy Resources Limited: ABN 66 007 845 338 of 16

Once printed, this is an uncontrolled document unless issued and stamped Controlled Copy or issued under a transmittal. Template: Operations Excellence Manager_Revision 2_11/10/2010_OEUP-1000-TMP-BUS-001

Table of Contents

1. Purpose/ Scope 3

2. Responsibilities/Accountabilities 3

3. Definitions/Acronyms 3

4. Health Safety and Environment Error! Bookmark not defined.

4.1 Risk Identification Error! Bookmark not defined.

4.2 Required Tools/Equipment Error! Bookmark not defined.

4.3 Environmental Impact Error! Bookmark not defined.

5. Operating Steps 7

6. Troubleshooting 10

7. Record Keeping 10

8. References/Associated Documents 11

9. Document Information and History 12

Table of Figures

Figure 1 - Bolt Tightening Sequence 13

List of Tables

Table 5.1: Operating procedure - step tracking table. 7

Table 2 - Flange Bolt Torque Record Error! Bookmark not defined.

List of Appendices

Appendix A Bolt Tightening Sequence 13

Appendix B Torque record sheet Error! Bookmark not defined.

B.1. Torque Chart for Flanges with Non-metallic Gaskets 15





1. Purpose/ Scope

This Standard Operating Procedure provides the steps to tighten bolts for PE piping connections. The procedure shall be followed whenever PE piping connections are bolted up except for hot bolting or for the tightening of leaking joints. This procedure applies to all Origin Energy operations however a more specific procedure i.e. a site or equipment specific procedure may be used in lieu of this procedure. Apply this procedure to assemble flanges at ambient temperature only, as torques will not be accurate if the flange(s) or stud(s) are at abnormal temperatures. This procedure does not apply to flanged joints which are integral to specific equipment items such as heat exchanger end covers where Original Equipment Manufacturer (OEM) recommendations shall be followed.

Observance of this procedure will help ensure that gaskets provide an effective seal for all operating conditions.

2. Responsibilities/Accountabilities

All personnel undertaking flange assembly must be assessed by a competent Supervisor to ensure necessary competency skills are met with to execute the job. It is the responsibility of Maintenance / Construction Supervisor to ensure bolts are tightened in accordance with this procedure.

Roles Responsibilities / Accountabilities

Mechanical Engineer (Technical Function)

Responsible for the ongoing development of this document and its associated documents.

Provides technical advice and guidance regarding flange bolting procedure

Technical Authority Accountable to develop and maintain the Flange bolting procedure and Technical specifications

Responsible for the approval of any deviations from this procedure or associated documents

Project Manager/Engineer Responsible for ensuring this procedure is followed in its entirety to achieve flange integrity during new project commissioning

Ensures that the responsible person and all members of the work party are deemed competent to undertake the task, have read and understood this procedure, and its referenced documents

Correctly identify tasks covered in the scope of this document and ensures the procedure is distributed to the relevant personnel involved in the project

Correctly identify tasks that are not covered in the scope of work and seek either approval from technical authority for deviation, if necessary or enforce the exclusions in the procedure as applicable

Responsible for the implementation of safe work practices through the assessment and subsequent approval of Non-Routine tests as defined by this procedure

HSE advisor Responsible for ensuring the worksite safety during the execution of flange management tasks

Participate in JSA

Construction Manager / Superintendant

Responsible for implementation of the site Safety Management Plan

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Visually verify all documentation (i.e. FIC) associated with the integrity of the assembly including pressure test reports prior to start up of the asset. C1-C6 documentation is a mandatory process to be followed.

Field/Site Construction Supervisor

(Principal & Contractor)

Ensures that the responsible person and all members of the work party are deemed competent to undertake the task, have read and understood this procedure, and its referenced documents

Ensures that the requirements of this procedure and the site Safety Management Plan are implemented prior to the activity taking place

Acts as the Quality Assurance representative at site by the

o Verification of adherence to this procedure and control/assurance checklists of all documents, checklists, and forms

o Ensures all the documentation associated to the flange bolting task is attached in the FIC pack.

Site Maintenance Supervisor Ensures that the responsible person and all members of the work party are deemed competent to undertake the task, have read and understood this procedure, and its referenced documents

Ensures that the requirements of this procedure and the site Safety Management Plan are implemented prior to the execution of the activity

Participates in the pre-start up meeting and ensures the approved lubricant is selected with the correct torque values identified for the application.

Co-ordinates with Operations and Mechanical Engineers regarding any technical enquiries

Delegated Responsible Person at the work site

Responsible for the execution of the task in compliance with this procedure and its referenced documents

Immediately reports any incidents, near misses, suspicious behaviour, or new hazards

Stops the job immediately on identification of any new hazards not previously identified

Ensures that all members of the work party are satisfied that all identified risks are adequately managed prior to the test commencing

Responsible for installing information tags and/or completing the required information in the form in Appendix B (Torque record sheet).

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Work Party Ensures full understanding of this procedure and implements this procedure and its referenced documents to its entirety

Participates in and acknowledges the requirements of pre-start JSA

Immediately reports any incidents, near misses, suspicious behaviour, or new hazards

Stops the job immediately on identification of any new hazards not previously identified

Site Personnel Complies with all exclusion zoning, flagging, barricading and signage

Immediately reports any incidents, near misses, suspicious behaviour, or potential hazards

Initial/Sign the required documentation as specified in this procedure

3. Definitions/Acronyms

Term/Acronym Definition/Expansion

ABS Acrylonitrile butadiene styrene – Thermal plastic piping

Bolt Bolt as used herein is an all inclusive term for any type of threaded fastener that can be used in a pressure boundary bolted flange joint assembly such as bolt, stud bolt, cap screw, etc

Closure A part of equipment which requires bolting which is not a flange connection (e.g. manways, inspection ports, end caps, etc)

EMP Environmental Management Plan

FIC Field Installation Checklist

Hazard The potential for harm, such as injury, property damage or damage to the environment

Hot Bolting Is the sequential removal and replacement of bolts on flanged joints while under reduced operating pressure. It is carried out one bolt at a time in a predetermined cross pattern

Refer to OEUP-1000-PRO-PIP-035 for procedure

Insulating flange A flange equipped with plastic pieces to separate its metal parts, thus preventing the flow of electric current. Insulating flanges are often used in cathodic protection systems to prevent electrolytic corrosion and are sometimes installed when a flow line is being attached to a wellhead

JSA Job Safety Analysis is a process used to identify and control hazards associated with a job or task or scope of work that may cause health, safety or environmental harm

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PE Polyethylene

PPE Personal Protective Equipment

Proprietary Manufactured and sold only by the owner of the patent or brand name

PTW Permit to Work

Risk Event A function of both the likelihood and consequence of a specific hazard being realised

SMP Safety Management Plan

4. Health Safety and Environment

Personnel performing any site work must wear approved protective clothing i.e. long sleeve shirt, trousers made of natural fibers, safety footwear and the approved PPE for the work being performed i.e. hearing protection, hard hats as required, eye protection and gloves. Gas detectors are mandatory to be worn, where applicable. All personnel must comply with the relevant site Safety and Environmental management plans.

4.1 Required Tools/Equipment

PPE

Gas Detector

Spanners, Shifters

Pry bar

Bolt torque wrench

Bolt lubricant (approved for site use)

Wire brush

Hearing Protection

Eye Protection

4.2 Environmental Impact

All works shall be carried out in accordance with Project/Site EMP.

Fuel to be stored securely and in well ventilated areas.

Notification of environmental incidents shall be made to the Site Supervisor and/or Site Environmental Officer.





5. Operating Steps

Table 5.1: Operating procedure - step tracking table.

No. Task Step Task Step Notes Step Tracking 1, 2

1. Thoroughly clean all threads and bearing faces.

2. Check threads for damage or excessive roughness.

Reject studs and nuts that show thread damage. Clean up excessive roughness.

3. Check gasket type, specification, size, rating and condition.

Reject gaskets not to specification, damaged gaskets and asbestos gaskets.

4. Check nuts and studs for proper size, material spec and cleanliness.

5. Check flange faces for corrosion, damage, cleanliness and dryness.

Rectify prior to assembly.

6. Lubricate threads of non-coated bolts with a nickel-based lubricant paste or similar.

NOTE: do not contaminate the gasket or flange face with the anti-seize compound.

Following Origin policy no bolt should be used unless lubricant paste or bolt coating is in use.

7. Align flanges without using excessive force. A pry bar is generally required; manipulate the alignment by levering through mating flange bolt holes.

Ensure the flanges are parallel and that the bolt holes line up. Avoid using the bottom holes for leverage because bottom studs will hold the gasket in place.

8. Insert gasket and bolts ensuring full thread engagement.

Insert bottom bolts to help hold the gasket first.

Ensure gasket is not pinched.

Ensure there are a minimum of 2 threads protruding from each nut.

9. Number the bolts in the order they are to be tightened (as per Appendix A).

The bolts are tightened in a “criss-cross” pattern.

Numbers can be written beside the bolt on the flange with a paint pen.

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10. Determine the required torque.

Manufacturer or suppliers recommended torques should be applied when known.

or Appendix B.1 - Torque Chart for Flanges with Non-metallic Gaskets

or Appendix B.2 – Torque Chart for Steel Flanges with Non-metallic Gaskets

Please Note B.1 is for gaskets with 3mm thickness

B.2 is for gaskets with 1.5mm thickness

11. Tighten all nuts finger tight.

12. Tighten nuts in order of the numbering used in appendix A to 30% of the final torque value.

Continue the sequence until all nuts have been tightened to 30%.

Check that the gasket is centred in the flanges and bolts positioned with the head to the top.

Throughout the tightening sequence, check the gap around the flange - if it is not consistent, make appropriate adjustments by selective bolt tightening before proceeding.

13. After the nuts have been tightened to 30 % of their final torque value use some form of indication.

If the bolt size is adequate (approx > 5/8 inch) use a paint pen to add a stroke to the end of the stud

Example first stroke:

if the bolt size is too small the mark will smudge (approx <5/8 inch) use form in Appendix B – Torque Record sheet

14. Repeat step 12 to torque all nuts to 60% of the final torque value.



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15. After the Nuts have been tightened to 60% of their final torque value use some form of indication.


Example second stroke:

If the bolt size is too small the mark will smudge (approx <5/8 inch) use form in Appendix B – Torque Record sheet

16. Repeat step 12 to torque all nuts to 100% of the final torque value.

If the gasket begins to deform, the 100% torque value is too high. In this case, use the highest non-gasket-deforming torque for the final torque value.



17. After nuts have been tightened to 100% of their final torque value use some form of indication.


Example third and final stroke:

If the bolt size is too small the mark will smudge (approx <5/8 inch) use form in Appendix B – Torque Record sheet

18. Re-torque bolts to the final torque value:

Start at bolt number 1 and proceed clockwise around the flange and double check that each bolt is fully torqued.

19. Re-torque bolts to the final torque value a minimum of 4 hours after completing step 18:

Start at bolt number 1 and proceed clockwise around the flange and double check that each bolt is fully torqued.

If no documentation, either via tagging or torque record sheet.

Then it must be assumed that retorque has not been complete and step 19 must be completed prior to completing step 20

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20. When all bolts have been tensioned to the correct torque after minimum of 4 hours, attach an information tag to each flange with the details:

Flange Number

Date

Torque value

Lubricant used

Installer’s name

In some cases this will not be practical due to the time interval between completion of installation and commission. As well as other factors including weather, animals, etc.

Please keep a copy of this information in Appendix B – Torque Record sheet as backup information.

21. Prior to the system being de-isolated a FIC check must be completed post assembly

Operator to check for the appropriate markings on nuts/studs and that the appropriate information is on the tags attached

Form A-1000-50-AQ-008 is to be used for the FIC stage.

Example of completed symbol on stud if paint pen had been used:

If alternatives were used instead of visual markings the form in Appendix B – Torque Record sheet should have been used to store information

If no documentation exist to demonstrate retorque after a minimum of 4 hours then step 19 must be repeated prior to completion of FIC

22. After the System has been de-isolated:

Operations representative to remove tags and store in the Commissioning Pack.

6. Troubleshooting

1. Check that the correct gasket type has been used

2. Check that the lubricant is suitable

If both 1 and 2 are acceptable an alternative bolt coating may have been applied, reducing the friction such that torque values in Appendix C are too high. In this case use the highest non-gasket-deforming torque (check vendor torque requirements) as the final torque.

7. Record Keeping

For critical steps procedural completion sign-off may be required. The supporting documentation that outlines the critical step is to be signed both by the Operations Technician and the relevant Supervisor as having been completed correctly.

The Field Installation Checklist - Flange Bolt Testing (A-1000-50-AQ-008) is required to be completed by the Contractor and checked by the Origin Energy Construction Supervisor for all flanges post assembly and primarily used as a pre-commissioning check list.

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During assembly information tags and/or Flange Bolt Torque Record form found in Appendix B are to be used. The decision to use either or a combination of both will depend on the practicality of the situation, i.e. the length between completion of the assembly and commissioning checks.

Pre-start Toolbox meetings

Job Safety Analysis (JSA) if required

Field Installation Flange Bolt Testing (A-1000-50-AQ-008)

Information tags and/or Flange Bolt Torque Record

8. References/Associated Documents

ASME PCC-1-2010 Guidelines for pressure boundary bolted flange joint assembly

ASME B31.3-2010 Process Piping

A-10050-TS-1009 Technical Specification for Steel Pipe Flange Assembly

ASME B16.5-2009 Pipe Flanges and Flange Fittings

The Facilities Development Safety Management Plan

The Site Operations Safety Management Plan

Specific Development Safety Management Plan

Specific Development Environmental Management Plan

HSE-GDL-005 Origin Manual Handling Guideline

OEUP-1000-PRO-SAF-012 Job Safety Analysis – Performance of

OEUP-1000-PRO-OPS-001 Permit To Work Procedure

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OEUP-INT1000-SOP-OPS-003




9. Document Information and History

PROCESS OWNER

Position Name

Upstream Engineering Manager John Young

DOCUMENT HISTORY

Rev Date Detailed Changes made in Document

Prepared Checked Approved

0





Appendix A Bolt Tightening Sequence

Figure 1 - Bolt Tightening Sequence

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Appendix B Sample of Flange Bolting Torque Record Sheet

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B.1. Torque Chart for Flanges with Non-metallic Gaskets

Compressed Non-Asbestos Fibre (C.N.A.F.) gaskets are specified in Origin’s C150 piping spec rev 1 for class 150 piping. The following class 150 C.N.A.F gaskets can be used for class 150 piping under the listed service conditions:

Nominal PE pipe Size Flange Size

Bolt Diameter

Bolt Quantity Target Torque

(mm) (mm) (inch) (inch) (No.) (ft-Ib) (N.m)

125 100 4 5/8

8 105 145

160 150 6 3/4

8 185 250

200 200 8 3/4

8 185 250

225 200 8 3/4

8 185 250

250 250 10 7/8

12 290 395

315 300 12 7/8

12 290 395

355 300 12 7/8

12 290 395

400 400 16 1

16 435 590

450 450 18 1 1/8

16 615 835

500 500 20 1 1/8

20 615 835

560 600 24 1 1/4

20 860 1165

630 600 24 1 1/4

20 860 1165 General Notes:

(1) Installation at ambient temperature. (2) These specifications are for 3.0mm thick full faced gaskets. (3) Values based on coated bolts lubricated with anti seize paste or similar of friction factor 0.12, calculated using

KLINGERexpert software. (4) Use of non-metallic gaskets outside of these specifications is allowable but must be supported by vendor advice

including a recommended target bolt torque. Vendor advice on torque shall also be sought if coated bolts are used in conjunction with non-metallic gaskets.

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B.2. Torque Chart for Steel flanges with Non-metallic Gaskets

Compressed Non-Asbestos Fibre (C.N.A.F.) gaskets are specified in Origin’s C150 piping spec rev 1 for class 150 piping. The following class 150 C.N.A.F gaskets can be used for class 150 piping under the listed service conditions:

Cla

ss 1

50 o

nly

Nominal Pipe Size

Bolt Diam.

Target Torque Recommended Gaskets (Klingersil or equivalent)

Service Temperature

Service Pressure

(inch) (mm) (inch) (ft-lb) (N.m) (oC) (kPa)

½ 15 ½ 60 80 KlingersilC4509, KlingersilC4509L

-29 to 38 101.3 to1960

¾ 20 ½ 60 80

KlingersilC4430, KlingersilC4409, KlingersilC4409L, KlingersilC4509, KlingersilC4509L

-20 to 80 101.3 to1960

1 25 ½ 60 80

KlingersilC4430, KlingersilC4409, KlingersilC4409L, KlingersilC4500, KlingersilC4509L, KlingersilC4509

-20 to 80 101.3 to1960

1 ½ 40 ½ 60 80

KlingersilC4400, KlingersilC4400L, KlingersilC4300, KlingersilC6307

-20 to 80 101.3 to1960

2 50 5/8 120 165

KlingersilC4400, KlingersilC4400L, KlingersilC4300, KlingersilC6307, KlingersilC8200, KlingersilC4808

-20 to 80 101.3 to1960

3 80 5/8 120 165 KlingersilC4106 -20 to 80 101.3 to1960

4 100 5/8 120 165

KlingersilC4324, Klingersiltop-chem2003,

KlingersilC4300, KlingersilC6307

-20 to 80 101.3 to1960

6 150 ¾ 210 285 KlingersilC4324, KlingersilC4300

-20 to 80 101.3 to1960

8 200 ¾ 210 285

KlingersilC4106, KlingersilC4324,

Klingersiltop-chem2005, Klingersiltop-chem2006

-20 to 80 101.3 to1960

General Notes: (5) Installation at ambient temperature. (6) These specifications are for 1.5mm thick circular ring type gaskets, not full faced gaskets. (7) Values based on non-coated bolts lubricated with anti seize paste or similar, calculated using KLINGERexpert

software. (8) Use of non-metallic gaskets outside of these specifications is allowable but must be supported by vendor advice

including a recommended target bolt torque. Vendor advice on torque shall also be sought if coated bolts are used in conjunction with non-metallic gaskets.