SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)

SATR NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO TEST REPORT
Flange Joint Tightening Inspection Report SATR-L-2001 25-May-05 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

EQUIPMENT ID NUMBER(S) or LINE NUMBER FLANGE JOINT NUMBER/S Test Pack No. SYSTEM ID. PLANT NO.

LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.

SCHEDULED TEST DATE & TIME ACTUAL TEST DATE & TIME QUANTITY INSP. MH's SPENT TRAVEL TIME
SAUDI ARAMCO USE ONLY
SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

ITEM
TEST PROCEDURE ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-TEST DATE
No.

A General Requirements

Tools for bolt tightening has been identified and resolved between
SAEP-351,
A1 Contractor, SAPMT, Proponent and Inspection prior to commencing the
Para. 6.1
erection of the piping.

Specific bolt tightening procedures in lieu of SAEP-351 is approved by

Proponent, SAPMT, Inspection and the Piping Standards Committee
Chairman or his representative. This includes Tensioning procedure by SAES-L-350,
A2
HYDRATIGHT. Para. 12.4
(NOTE: ASME PCC-1 could be used as a guideline to establish such
procedures. Use of SAEP-351 does not require pre-approval. )

Not more than one gasket is used between mating surfaces of the SAES-L-109,
A3
flanges. Para. 11.1

B Torque Wrench Method per SAEP-351

The contractor personnel executing the flange assembly have proper
training and skills to conduct the job. SAEP-351,
B1
(NOTE: This is verified by the submission of training certificates and Para. 3.2.2
work experience .)
The specific required torque value is identified and conforms with in
SAEP-351,
B2 Table-SAEP-351-02 and Table-SAEP-351-03. (Refer to Attachment 1
Para. 5.2
& 2)
Torque wrench calibrated. (Date of Calib:__________ / Due date for SAEP-351,
B3
Calibration __________) Para. 6.3

SAEP-351,
B4 Lubricant applied to stud threads an face of nut contacting the flange.
Sec. 7, Step 2
SAEP-351,
B5 All studs and nuts installed hand tight
Sec. 7, Step 3
SAEP-351,
B6 Each stud is numbered as shown in Attachment 3.
Sec. 7, Step 4

Stud are tightened, as numbered, with air impact wrench or equivalent SAEP-351,
B7
following the bolt tightening sequence. Sec. 7, Step 5

1st stage tightening done to not more than 30% of required Torque
SAEP-351,
B8 (Note: Required Torque Value and actual attained torque values to be
Sec. 7, Step 7
entered in the Bolt Tightening Report, Attachment 1 of this checklist. )

SAEP-351,
B9 Final Tightening to + 5% of Torque Required (Actual Torque _____ )
Sec. 7, Step 7

After tightening, all bolts have full thread engagement with the nut.
SAES-L-109,
B10 (NOTE: Lack of complete engagement by not more than one thread is
Sec. I
acceptable. ) -- (ASME B31.3, Para. 335.2.3)

Page 1 of 6
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SATR NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO TEST REPORT
Flange Joint Tightening Inspection Report SATR-L-2001 25-May-05 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
TEST PROCEDURE ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-TEST DATE
No.
Bolt Tensioning Method when approved. (i.e.: HYDRATIGHT - 50% Tensioning Method)
C
NOTE: Items listed below shall be verified against the project approved bolt tensioning procedure for conformance.
Sch. Q,
C1 Pressure gages in the tensioning machine are calibrated.
Att. IV, Para. 6.1
HYDRATIGHT
C2 Mark bolts in 2 Sets, Set 'A' & Set 'B', alternatively. Procedure or
Equivalent
HYDRATIGHT
C3 Tensioners are fitted to every other bolt of Set 'A'. Procedure or
Equivalent
HYDRATIGHT
Pressurize the tensioners to pre-determined "Pressure A" per the
C4 Procedure or
approved procedure. (This is repeated 2 more times.)
Equivalent
Transfer tensioners to Set 'B' bolts and pressurize to pre-determined HYDRATIGHT
C5 "Pressure B" and tighten nuts. This is repeated 2 more times. (NOTE: Procedure or
Pressure B is lower in value than Pressure 'A' ) Equivalent

After tensioning, Break Loose Pressure (BLP) is verified to be greater

than or equal to Pressure B by the following steps:
a) Fit tensioner to one of the tensioned bolts in Set 'A'.
HYDRATIGHT
b) Pressurize slowly until the nut is loosened using a Tommy Bar
C6 Procedure or
and socket.
Equivalent
c) Once the nut moves, stop pressurizing and record the
achieved pressure. This is the Break Loose Pressure.
(NOTE: If BLP < Pressure B, Tensioning is a Fail. )

Bolt Tensioning Method (i.e.: HYDRATIGHT-100% Tensioning Method)

D
NOTE: Items listed below shall be verified against the project approved bolt tensioning procedure for conformance.
Sch. Q,
D1 Pressure gages in the tensioning machine are calibrated.
Att. IV, Para. 6.1
HYDRATIGHT
D2 Tensioners are fitted to ALL bolts. Procedure or
Equivalent
HYDRATIGHT
Pressurize the tensioners to pre-determined "Pressure A" per the
D3 Procedure or
approved procedure. (This is repeated 2 more times.)
Equivalent

After tensioning, Break Loose Pressure (BLP) is verified to be greater

than or equal to Pressure A by the following steps:
a) Fit tensioner to one of the tensioned bolts in Set 'A'.
HYDRATIGHT
b) Pressurize slowly until the nut is loosened using a Tommy Bar
D4 Procedure or
and socket.
Equivalent
c) Once the nut moves, stop pressurizing and record the
achieved pressure. This is the Break Loose Pressure.
(NOTE: If BLP < Pressure A, Tensioning is a Fail. )

All findings are recorded in the Bolt Tightening Report Form SATR-L-
E
2001, Attachment 4.

REFERENCE DOCUMENTS:
1. SAES-L-350, Construction of Plant Piping, (30 September, 2003)
2. SAES-L-109, Selection of Flanges, Stud Bolts and Gaskets, (30 September, 2003)
2. SAEP-351, Bolted Flange Joints Assembly, (30 April, 2003)
4. ASME B31.3, Process Piping,
3. Schedule Q, Contractor's Quality Requirements, (November 2003)
4. Recommended Tensoning Procedure-By HYDRATIGHT

Page 2 of 6
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SATR NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO TEST REPORT
Flange Joint Tightening Inspection Report SATR-L-2001 25-May-05 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
TEST PROCEDURE ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-TEST DATE
No.

Contractor / Third-Party Saudi Aramco

Technician Performing Test*
Name, Title, Department,
Company, Initials and
Date:
QC Inspector
Name, Initials and Date:
PMT Representative
Test Performed Successfully and Results are Acceptable: T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date:
PID Representative
Witnessed Test Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date:

QC Supervisor Proponent and Others

Quality Record Approved: T&I Witnessed QC Record Reviewed Work Verified
Name, Organization,
Name, Sign and Date:
Initials and Date:

*Person Responsible for Implementation of Test and Analysis of Results Y = YES N = NO F = FAILED

Page 3 of 6
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SATR NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO TEST REPORT
Flange Joint Tightening Inspection Report SATR-L-2001 25-May-05 MECH-

Attachment 1

Notes:

Page 4 of 6
Attachment 2

Attachment 3

Page 5 of 6
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SATR NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO TEST REPORT
Flange Joint Inspection & Tightening Report
SATR-L-2001 25-May-05 MECH-
(Attachment 4)
EQUIPMENT ID NUMBER(S) or LINE NUMBER FLANGE JOINT NUMBER/S Test Pack No. SYSTEM ID. PLANT NO.

LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.

SCHEDULED TEST DATE & TIME ACTUAL TEST DATE & TIME QUANTITY INSP. MH's SPENT TRAVEL TIME
SAUDI ARAMCO USE ONLY
SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

Attachment 4 - FLANGE JOINT INSPECTION & TIGHTENING REPORT

YES
Pre-Inspection of Flange Joint Assembly Completed and Checklist, SAIC-L-2014, signed: QR # ______
NO
FLANGE JOINT INFORMATION:
Flange Size: Type: Rating: Material :

Outer Guide Ring: __________

Inner Guide Ring: __________
Gasket Size: Type: Material :
Ring Joint Gasket: __________
__________________________ Others: ___ _______
(Indicate number for Ring Gasket)

Bolt Size: Type: Material :

Required Torque or
Lubricant: Tightening Method:
Tension Values: _______________
Residual Bolt Load / Stress Required:

TORQUE METHOD BOLT TENSIONING METHOD

No. of Pass Torque Value Tensioning Stage Pressure Reading

1 30% of Reqd. Torque Pressure A

2 + 5% of Reqd. Torque Pressure B

Break Loose Pressure

RESULT:

REMARKS:

Contractor / Third-Party Saudi Aramco

Technician Performing Test*
Name, Title, Department,
Company, Initials and
Date:
QC Inspector
Name, Initials and Date:
PMT Representative
Test Performed Successfully and Results are Acceptable: T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date:
PID Representative
Witnessed Test Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date:

QC Supervisor Proponent and Others

Quality Record Approved: T&I Witnessed QC Record Reviewed Work Verified
Name, Organization,
Name, Sign and Date:
Initials and Date:

*Person Responsible for Implementation of Test and Analysis of Results Y = YES N = NO F = FAILED

Page 6 of 6