SAUDI ARAMCO TOTAL REFINING & PETROCHEMICAL COMPANY Bolted Flange Joints Assembly JERES-L-351 Bolted Flange Joints Assembly

SAUDI ARAMCO TOTAL REFINING & PETROCHEMICAL COMPANY

Bolted Flange Joints Assembly

Issuer: PMT May 2012 Rev: 1B JERES-L-351

JERES-L-351 Bolted Flange Joints Assembly

This procedure defines minimum mandatory requirements to assemble bolted flanged joints in pressure containing piping systems defined in JERES-L-100 as well as process equipment.

This document is the property of SATORP and shall not be reproduced in any form. Copies provided by SATORP shall only be disclosed or provided to third parties insofar as relevant for the operations of SATORP and the information provided in this document shall be used for no other purpose than these operations. The content of this document will be regularly updated by SATORP and the validated version will be published on its intranet site. Consequently, the validity of hard copies of this document must be verified prior to its use against the version on the SATORP intranet site. Only soft copies on the SATORP intranet site dedicated to SATORP QMS are considered controlled documents. Page 1 of 17




Name and Signature Rev

Date

Description

Prepared by

Approved by

Authorized by

1B

19-May-2012

Issued for Release 5A.

F. Lacanlale

N. Mosson, STC F. Silva, Eng. Mgr.

D. Grunemwald Project Director

1A

09-May-2012

New Template & Brief Scope added on the cover page.

F. Lacanlale



15-May-2008

Updating Issued for bid package Rev. 0 to incorporate technical comments.

J. Somoza



1





Revision Tracking

Revision

Revision Date

Scope of Revision

1B

19 May 2012

Issued for Release 5A.

1A

09-May-2012

New Template & Brief Scope added on the cover page.

1

15 May 2008

Updating Issued for bid package Rev. 0 to incorporate technical comments.

0

29 April 2008

Issued for bid package.

02

31 March 2008

Issued for bid package only for review.

01

06 April 2007

First official JERES-L-351 is issued.

00

27 February 2007

First draft issued is based on Saudi Aramco SAEP-351 “Bolted Flange Joints Assembly” issue date 7 November, 2006. Document was modified to incorporate amendments and modifications.





Table of Contents

Section

Contents

Page

1

Scope

5

2

Conflicts, Deviations and Clarifications

5

3

References

5

4

Definitions

6

5

Responsibilities

6

6

Pre-Assembly Inspection

7

7

Torquing

7

8

Torquing Tools

8

9

Stud Bolt Tightening Procedure

8

10

Stud Bolt Additional Tightening Procedure where Leaks Occur during Pressure Testing

9

11

Additional Requirements for PIKOTEK Gaskets

10

A

Table -1: Friction Factors for Different Lubricants

12

B

Table -2: Torque Value for Low–Alloy Steel Bolting

13

C

Table -3: Torque Value for Isolating Gaskets (PIKOTEK) on ASME B 16.5 and ASME B 16.47 Series A & B Class 150 Through Class 2500 Flanges

14

D

Figure JERES- 1 Stud Bolt Tightening Sequence

15

E

Figure JERES- 2 Stud Bolt Numbering

16

F

Table -4: Cross Pattern Tightening Sequence (36 to 68 Bolts) per (ASME PCC-1)

17

Appendixes





1

Scope

1.1

This procedure defines minimum mandatory requirements to assemble bolted flanged joints in pressure containing piping systems defined in JERES-L-100 as well as process equipment.

1.2

This installation procedure is applicable for both new and existing facilities.

2

Conflicts, Deviations and Clarifications

2.1

Any conflicts between this standard and other applicable Company Engineering Standards (JERES), Material Specifications (JERMS), Standard Drawings (JERSD), Engineering Procedures (JEREP), Company Forms or Industry standards, specifications, Codes and forms shall be brought to the attention of Company Representative by the Contractor for resolution. Until the resolution is officially made by the Company Representative, the most stringent requirement shall govern.

2.2

Where a licensor specification is more stringent than those of this standard, the Licensor’s specific requirement shall apply.

2.3

Where applicable Codes or Standards are not called by this standard or its requirements are not clear, it shall be brought to attention of Company Representative by Contractor for resolution.

2.4

Direct all requests for deviations or clarifications in writing to the Company or its Representative who shall follow internal Company procedure and provide final resolution.

3

References The selection of material and equipment, and the design, construction, maintenance, and repair of equipment and facilities covered by this standard shall comply with the latest edition of the references listed below as of the CUT-OFF DATE as specified in the Contract unless otherwise noted.

3.1

Company References Company Engineering Standards

3.2

JERES-L-100

Applicable Codes and Standards for Pressure Piping Systems

JERES-L-109

Selection of Pipe Flanges, Stud Bolts and Gaskets

Industry Codes and Standards American Petroleum Institute



Bolted Flange Joints Assembly API BULL 5A2


Bulletin on Thread Compounds for Casing, Tubing, and Line Pipe

American Society of Mechanical Engineers ASME B16.5

Pipe Flanges and Flanged Fittings NPS ½ through NPS 24

ASME B16.47

Large Diameter Steel Flanges NPS 26 through NPS 60

ASME B31.3

Process Piping

ASME B31.4

Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids

ASME B31.8

Gas Transmission and Distribution Piping Systems

ASME PCC-1

Guidelines for Pressure Boundary Bolted Flange Joint Assembly

4

Definitions

4.1

Definitions presented in this Standard and other SATORP documents have precedence over other definitions. Conflicts between various definitions shall be brought to the attention of Company Representative by the Contractor for resolution. Company: SATORP (formerly Jubail Export Refinery - JER) Company Representative: A designated person from the Company or an assigned third party representative. Company Inspector: A designated person or an agency responsible for conducting inspection activities on behalf of the Company.

4.2

List of Definitions Purposely left blank.

5

Responsibilities

5.1

For new capital program projects the following shall apply:

5.1.1

The Contractor is responsible for ensuring that this procedure is followed.

5.1.2

The contractor personnel executing the flange assembly shall adhere to flange assembly procedure. They shall have proper training and skills to conduct the job.

5.2

For existing facilities the following shall apply:

5.2.1

It is the responsibility of Company Representative to ensure that this procedure is adhered to during the maintenance activities within the facilities under his jurisdiction.





5.2.2

The maintenance personnel executing the flange assembly activities must be aware of this procedure and ASME PCC-1 Guideline and have the proper training to conduct the work.

6

Pre-Assembly Inspection

6.1

The gasket shall be verified for correct type, rating, dimension and compatibility with the flange facing. Also, it shall be free from any damage particularly in the seating element. Ensure that spiral wound gaskets are stored flat especially for large sizes, 24 inches and larger.

6.2

Bolts, nuts and washers shall be visually checked for proper size, grade, dimension and for any physical damage to shanks or threads which would affect the bolt assembly or performance. Also, check the suitability of the stud bolts and nuts material for the service temperature and the compatibility with the flange material.

6.3

The flange facing, particularly the seating area, shall be visually examined for cleanliness and ensure that no damage, such as scratches exist. For ring joint type flanges, the ring and the ring groove shall be free of damage and dirt.

6.4

Proper lubricant for bolts and nuts shall be used. Lubricant for bolts and nuts shall be Jet-Lube SS-30 or other acceptable lubricants listed in Table-1 of the Appendix.

6.5

Tightening tools shall be checked for adequacy, performance and calibration, if required.

6.6

Lubricant shall not be used in the gasket and the gasket seating area.

6.7

Flange shielding shall be available for installation / reinstallation when required. Commentary Note: Flange shielding is normally used for personnel protection against possible liquid splash or high temperature during operation.

7

Torquing

7.1

Torque values vary according to flange rating, bolt size, type of gasket, and friction factor of the thread lubricant.

7.2

The torque values are specified in Table -2 and Table -3.

7.3

Table -02 applies to all gaskets listed in JERES-L-109, except for insulating gaskets.

7.4

Table -03 applies to isolating gaskets (e.g., PIKOTEK), based on a friction factor of 0.16.





8

Torquing Tools

8.1

Selection of the proper tool depends on the stud bolt size, physical location of the flanged joint, and criticality of the flange. Identifying the proper tools shall be reviewed by the Company Representative and agreed on. Commentary Note: There exist various tools which will achieve the proper torque.

8.2

There are various types of tools available to achieve the proper torque value. The manufacturer's instructions shall be followed for the operation, limitation and maintenance of all torque wrenches used to perform flange bolts tightening.

8.3

Torque wrench calibration shall be performed in accordance with manufacturer's recommendations.

9

Stud Bolt Tightening Procedure Step 1

Align flanges and gasket. Forced tightening is not allowed to overcome non acceptable alignment tolerances. Clamp securely in place.

Step 2

Apply lubricants to stud threads over length and nut engagement and to face of nut which contacts flange. Ensure that the nuts run freely down the thread of the studs.

Step 3

Install all studs and nuts hand tight, ensure that studs pass freely through the flange holes. Position the nut on one end of the stud such that only the crown of the stud projects beyond the face of the nut. The excess stud length should project beyond the nut on the other side.

Commentary Note: By doing this, the nut that is installed nearly flush with the end of the stud can be easily removed since the threads are not coated, and normally have not been subjected to corrosion. The side of the stud with the flush nut should be chosen by taking into consideration factors such as whether one side has better access for maintenance personnel and/or tightening tools, e.g., torque wrench or impact wrench, etc.

Step 4

Number each stud according to its position in the flange as shown on Figure 1: Stud Bolt Tightening Sequence.

Step 5

For insulting gaskets like PIKOTEK, enough gap (½" of gap is recommended) should be available between flange faces to avoid any damage to seals during inserting the gaskets. If due to any reasons, seals are damaged, change the seal before installing PIKOTEK.





Step 6

Mating flange faces and the gaskets should be dry and free from grease, oil or water.

Step 7

Comply with the Following Stud Bolt Tightening Sequence:

Step 8

−

For 4 to 32 bolts use Figure -1 for bolts numbering and

−

For 36 to 68 bolts see Figure-2 for bolts numbering and Table-4 for the tightening sequence.

−

In all cases, the appropriate tool should be used such as an air impact wrench or equivalent.

Tightening Level Progression: Tighten the stud bolts in stages to obtain the final required torque from the appropriate torque Table- 2. The first stage should not be more than 30% of the final torque. Apply the torque evenly to each stud following the stud bolt tightening sequence. The final torque shall be within ±5% of the required torque value. In all cases, the appropriate tool should be used such as an air impact wrench or equivalent The final torque must be within ±5% of the required values per Section 7 above.

Step 9

10

For joints containing RTJ or Spiral Wound Gaskets, repeat step 7.

Stud Bolt Additional Tightening Procedure where Leaks Occur during Pressure Testing Step 1

Depressurize the piping system and re-torque stud bolts to maximum torque value shown on Table- 1 or Table-2 as appropriate.

Step 2

If leak does not stop after re-torquing has been performed, disassemble the flange joint and inspect as follows:

Step 3

a)

Inspect stud bolts and nuts for defects or damage to threads or improper cleaning of threads.

b)

Inspect flange faces for damage, misalignment.

c)

Inspect gasket for damage or defects.

After all defective and damaged items have been repaired or replaced, reassemble the flange joint using a new gasket and tighten the bolts using the appropriate sequence and maximum torque values.



Bolted Flange Joints Assembly 11


Additional Requirements for PIKOTEK Gaskets Step 1

The insulation kit found in the PIKOTEK package should check -out to the specifications as listed on the package label.

Step 2

Inspect all flange surfaces and ensure that large pits or defects will not cause leakage when the system is pressurized. Wipe sealing surfaces clean prior to installing the gasket.

Step 3

Align the flanges so that the bolt holes line up. Improper alignment could cause damage to the sleeve during installation by pinching the thread form through the plastic sleeve. When proper alignment has been achieved install all of the sleeves onto all of the bolt holes. All sleeves should slide easily into both mating flanges.

Step 4

Install one nut onto one end of each stud.. Be sure to lubricate the threads and nut surfaces with a suitable compound. From the opposite end of the stud nut assembly, install one steel washer and one plastic washer (in that order). Make sure all steel washers are butted against the nuts. DO NOT BUTT PLASTIC WASHER AGAINST NUTS. Remove the sleeves from the flange and slide them over the stud.

Step 5

Insert the stud, nut, steel washer and plastic washer assembly into the bolt holes around the lower half of the bolt pattern and install a plastic washer, steel washer and nut on the exposed end of the stud. Do not thread up studs to the point where the gasket cannot be installed. Be sure to leave enough space between the flanges to install the gasket Lubricate the appropriate surfaces before final make-up.

Step 6

Insert the gasket between the flanges and allow the gasket to rest on the sleeve and stud assemblies. Check the condition of the oring/Teflon seals making sure they are secure in each one’s respective groove. Install the remaining stud, nut, plastic washer and steel washer assemblies into the upper half of the bolt circle pattern.

Step 7

If a device was used to spread the flanges then remove it at this time. Thread all nuts onto all the remaining studs and in doing so bring the flanges into contact with the gasket. If misalignment exists between the flanges and gasket, tighten the nuts in such a way as to minimize pinching or point loading of the flange against the gasket

Step 8

Make sure that a sufficient number of threads are within the nut of each stud prior to torque-up. Torque the assembly to one-half of the





torque limit specified on the torque chart. Do this using an approved flange bolt tightening sequence pattern. Repeat the sequence this time torquing to the maximum torque limit as specified. Step 9

Test for shorts across the flange and then pressure test assembly. For safety reasons it is best to initiate the test pressures much lower than those normally encountered by the system. Work the pressure up to acceptable limits by stepping pressure 10% per pressure increments.




Bolted Flange Joints Assembly Appendix A Table-1 – Friction Factors for Different Lubricants Friction Factors

Torque Correction Factor

Moly Graphite

.06

0.67

Tool Joint Compound Graphite and Oil (used as the base line for torque values in Table-2)

.08

0.8

.10

1.0

Aerocote #4

.11

1.1

KOPR-KOTE

.11

1.1

EL-PRO C5A

.11

1.1

FEL-PRO C100 FEL-PRO C102 (commonly called Anti-Seize)

.11

1.1

.11

1.1

Jet Lube SS-30 API BULL 5A2 Thread Compound

.12

1.2

.125

1.3

Light Machine Oil as shipped

.15

1.5

Dry Bolts

.2

2

Lubricants





Appendix B Table-2 – Torque Values for Low-Alloy Steel Bolting Stud Bolt Size inch

Noncoated Bolts

Coated Bolts

1/2

60

45

5/8

120

90

3/4

210

160

7/8

350

250

1

500

400

1-1/8

750

550

1-1/4

1050

800

1-3/8

1400

1050

1-1/2

1800

1400

1-5/8

2350

1800

1-3/4

2950

2300

1-7/8

3650

2800

2

4500

3400

2-1/4

6500

4900

2-1/2

9000

6800

2-3/4

12000

9100

3

15700

11900

3-1/4

20100

15300

3-1/2

25300

19100

3-3/4

31200

23600

4

38000

28800

Torque Ft-Lb

Notes: 1)

Torque values are based on 50,000 psi prestress on stud bolts and Friction Factor of 0.16 for noncoated surfaces and 0.12 for new coated surfaces. A combination of various elements such as the conditions of the threads, the condition of the flange to the nut bearing surface and the type of lubricant used, makes up the friction factor which can vary from .04 to .20 or as much as 500%.

2)

Torque values for stainless steel or other alloy stud bolts can be obtained by multiplying the ratio of the specified minimum yield strength (SMYS) of stainless steel stud bolts to A193 B7 stud bolts, to the torque values in the Table-2. The SMYS values for all bolting materials are listed in ASME B31.3 code (Note: SMYS depends on grade, class and size).





Appendix C Table-3 – Torque Values for Isolating Gaskets (PIKOTEK) on ASME B16.5 and ASME B16.47 Series A & B, Class 150 Through Class 2500 Flanges

Note:

Stud Bolt Size inch

Torque Value Ft-Lb

1/2

30

9/16

45

5/8

60

3/4

100

7/8

160

1

245

1-1/8

355

1-1/4

500

1-3/8

680

1-1/2

800

1-5/8

1100

1-3/4

1500

1-7/8

2000

2

2200

2-1/4

3180

2-1/2

4400

2-3/4

5920

3

7720

3-1/4

8400

3-1/2

9000

3-3/4

9600

4

10000

Torque values based on 30,000 psi tension load and 0.16 Friction Factor from API BULL 5A2 thread compound. See Table-2 Note (1) for other factors.

Commentary Notes: a)

For ASME Class 900 through Class 2500, API-6B and API-6BX Class 2000 through Class 15000, and RTJ Flanges, the maximum compressive stresses induced during installation should not exceed 25,000 psi. Design to 12,500 psi when possible.

b)

Calculations for compressive stresses applied during torque-up procedures must account for ring joint grooves, gasket seal grooves, raised face diameters, and gasket inside diameter. (See PIKOTEK Gasket User's manual).

c)

Bolt tensioning equipment such as HYDRATIGHT may be used for class 900 and above resulting in a minimum residual bolt stress of 30000 psi and a maximum of 50,000 psi. Refer to PIKOTEK Gasket User's manual for specific bolting instructions.





Appendix D -Figure -1 – Stud Bolt Tightening Sequence (4 to 32 Bolts)





Appendix E Figure -2 – Stud Bolt Numbering (36 to 68 Bolts)

1 2 3 4 5 6 7 8 9 14

10 13

12

11




Bolted Flange Joints Assembly Appendix F Table-4 – Cross-Pattern Tightening Sequence (36 to 68 Bolts) per (ASME PCC-1) No. of bolts 36

Sequence 1-2-3 → 19-20-21 → 10-11-12 → 28-29-30 → 4-5-6 → 22-23-24 → 13-14-15

↵

31-32-33 → 7-8-9 → 25-26-27 → 16-17-18 → 34-35-36 40

1-2-3-4 → 21-22-23-24 → 13-14-15-16 → 33-34-35-36 → 5-6-7-8 → 25-26-27-28

↵

17-18-19-20 → 37-38-39-40 → 9-10-11-12 → 29-30-31-32 44

1-2-3-4 → 25-26-27-28 → 13-14-15-16 → 37-38-39-40 → 5-6-7-8 → 29-30-31-32

↵

17-18-19-20 → 41-42-43-44 → 9-10-11-12 → 33-34-35-36 → 21-22-23-24 48

1-2-3-4 → 25-26-27-28 → 13-14-15-16 → 37-38-39-40 → 5-6-7-8 → 29-30-31-32

↵

17-18-19-20 → 41-42-43-44 → 9-10-11-12 → 33-34-35-36 → 21-22-23-24 → 45-46-47-48 52

1-2-3-4 → 29-30-31-32 → 13-14-15-16 → 41-42-43-44 → 5-6-7-8 → 33-34-35-36 17-18-19-20 → 45-46-47-48 → 21-22-23-24 → 49-50-51-52 → 25-26-27-29

↵

↵

9-10-11-12 → 37-38-39-40 56

1-2-3-4 → 29-30-31-32 → 13-14-15-16 → 41-42-43-44 → 21-22-23-24 → 49-50-51-52 9-10-11-12 → 37-38-39-40 → 25-26-27-28 →

↵

↵

53-54-55-56 → 17-18-19-20

45-46-47-48 → 5-6-7-8 → 33-34-35-36 60

1-2-3-4 → 29-30-31-32 → 45-46-47-48 → 13-14-15-16 → 5-6-7-8 → 37-38-39-40 21-22-23-24 → 53-54-55-56 → 9-10-11-12 → 33-34-35-36 → 49-50-51-52

↵

↵

17-18-19-20 → 41-42-43-44 → 57-58-59-60 → 25-26-27-28 64

1-2-3-4 → 33-34-35-36 → 17-18-19-20 → 49-50-51-52 → 9-10-11-12 → 41-42-43-44 25-26-27-28 → 57-58-59-60 → 5-6-7-8 → 37-38-39-40 → 21-22-23-24

↵

↵

53-54-55-56 → 13-14-15-16 → 45-50-51-52 → 29-30-31-32 → 61-62-63-64 68

1-2-3-4 → 37-38-39-40 → 21-22-23-24 →

53-54-55-56

→ 9-10-11-12 → 45-46-47-49

↵

29-30-31-32 → 61-62-63-64 → 17-18-19-20 → 57-58-59-60 → 33-34-35-36 → 5-6-7-8

↵

41-42-43-44 → 13-14-15-16 → 49-50-51-52 → 25-26-27-28 → 65-66-67-68


SAUDI ARAMCO TOTAL REFINING & PETROCHEMICAL COMPANY Bolted Flange Joints Assembly JERES-L-351 Bolted Flange Joints Assembly

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