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Al-Zour Refinery Project

(Contract No. : ZOR/EPC - 0045)


UNIT93 – SEA ISLAND
Page
Title FLANGE MANAGEMENT
2 of 30
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No. P4045ZOR-PR-CT-CM-512 Rev. O

Change Log
Rev. Section Change Description
First Issue for Approval
O All

Document Holds
Section Description

Unit93 – Sea Island Flange Management Procedure


P4045ZOR-PR-CT-CM-512_0
Al-Zour Refinery Project
(Contract No. : ZOR/EPC - 0045)
UNIT93 – SEA ISLAND
Page
Title FLANGE MANAGEMENT
3 of 30
PROCEDURE

No. P4045ZOR-PR-CT-CM-512 Rev. O

TABLE OF CONTENTS

1  INTRODUCTION ........................................................................................................................5 
1.1  PROJECT OVERVIEW......................................................................................................5 
1.2  PURPOSE OF THE DOCUMENT .....................................................................................5 
1.3  SCOPE OF THE DOCUMENT ..........................................................................................5 
1.4  REFERENCES ..................................................................................................................5 
1.4.1  PROJECT SPECIFICATIONS & DRAWINGS ......................................................5 
1.4.2  CODE & STANDARDS .........................................................................................8 
1.5  DEFINITIONS AND ABBREVIATIONS .............................................................................9 
1.5.1  DEFINITIONS .......................................................................................................9 
1.5.2  ABBREVIATIONS ...............................................................................................10 
2  HSE REQUIREMENT ...............................................................................................................11 
2.1  JSA & PERMIT TO WORK ..............................................................................................11 
2.2  WORK AREA ...................................................................................................................11 
2.3  EQUIPMENT ...................................................................................................................11 
2.4  PERSONNEL...................................................................................................................12 
3  FLANGE MANAGEMENT PROCEDURES ..............................................................................12 
3.1  FLANGES JOINT TYPE. .................................................................................................12 
3.2  FLANGES SURFACE ......................................................................................................12 
3.3  FLANGE ALIGNMENT ....................................................................................................12 
3.3.1  Lateral Alignment ................................................................................................12 
3.3.2  Parallelism...........................................................................................................13 
3.4  GASKET ..........................................................................................................................14 
3.5  BOLT & NUTS .................................................................................................................14 
3.6  BOLTS TIGHTENING METHOD .....................................................................................14 
3.6.1  Bolt Tensioning Method ......................................................................................14 
3.6.2  Bolt Torqueing Method ........................................................................................15 
3.6.3  Manual Tightening Method..................................................................................15 
3.7  JOINT LEAKING CONDITION .........................................................................................15 
4  RECORD AND REPORTING ...................................................................................................16 
4.1  FLANGE MANAGEMENT DATA BASE ..........................................................................16 
4.2  TEST PACK .....................................................................................................................16 
4.3  FIELD JOINT IDENTIFICATION ......................................................................................16 

Unit93 – Sea Island Flange Management Procedure


P4045ZOR-PR-CT-CM-512_0
Al-Zour Refinery Project
(Contract No. : ZOR/EPC - 0045)
UNIT93 – SEA ISLAND
Page
Title FLANGE MANAGEMENT
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No. P4045ZOR-PR-CT-CM-512 Rev. O

5  ATTACHMENT – A HSE TYPICAL DOCUMENT TEMPLATE................................................18 


6  ATTACHMENT – B TEST PACK & GOCOMPLETION CHECK SHEET BOLTING ...............19 
7  ATTACHMENT – C BOLT TIGHTENING METHOD & SCHEMATIC ......................................21 
8  ATTACHMENT – D BOLT TORQUEING VALUE REFERENCE (DEP SHELL
EXTRACT) ................................................................................................................................22 
9  ATTACHMENT – E TYPICAL FLANGE MANAGEMENT DATA BASE .................................30 

Unit93 – Sea Island Flange Management Procedure


P4045ZOR-PR-CT-CM-512_0
Al-Zour Refinery Project
(Contract No. : ZOR/EPC - 0045)
UNIT93 – SEA ISLAND
Page
Title FLANGE MANAGEMENT
5 of 30
PROCEDURE

No. P4045ZOR-PR-CT-CM-512 Rev. O

1 INTRODUCTION

1.1 PROJECT OVERVIEW

Kuwait Integrated Petroleum Industries Company (KIPIC) plans to build a new grassroots refinery, Al-
Zour Refinery Project (ZOR), with a refining capacity of 615,000 barrels per calendar day, located in
the southern coastal region of Kuwait, adjacent to the existing Al-Zour South Power (AZPS) Plant.

The HSSJV, also referenced as EPC Contractor “ZOR/EPC-0045” in Project documentation, is in


charge of the engineering, procurement, construction and pre-commissioning for the Package 5
consisting in the installation of a complete marine export terminal facility (MTF) for transfer and
exporting of solid and liquid products into bulk carriers and tankers.

1.2 PURPOSE OF THE DOCUMENT

The purposes of this document is to provide information and guidance, in performing flanges
management or bolting activity work, to complete the piping system installation process and ensure its
joint integrity.

1.3 SCOPE OF THE DOCUMENT

This procedure cover all flange management activity on Unit 93 – Sea Island facility, which including
piping interconnection;

 Between Steel piping flange to flange.

 Between Steel piping Flange to equipment nozzle interconnection.

The GRP / GRE piping interconnection are excluded from this procedures, and shall be referred to
dedicated manufacture standard or recommendation.

Bolts for structural work as well are not covered by this procedures, and shall be referred to the
dedicated manufacturer recommendation or relevant engineering design requirement.

1.4 REFERENCES

1.4.1 PROJECT SPECIFICATIONS & DRAWINGS

P4045ZOR-PR-CT-CM-019 GENERAL HOOK UP PHILOSOPHY


CONSTRUCTION PHILOSOPHY – UNIT 93 – SEA ISLAND
P4045ZOR-PR-CT-CM-018
UNDERDECK ACTIVITIES
MECHANICAL COMPLETION, PRECOMMISSIONING AND
P4045ZOR-PR-CO-CM-033
TURNOVER PLANS
P4045ZOR-PR-HS-CM-042 PPE - Personal Protective Equipment

P4045ZOR-PR-CO-CM-086 Piping Cleaning Pre-commissioning Procedure

Unit93 – Sea Island Flange Management Procedure


P4045ZOR-PR-CT-CM-512_0
Al-Zour Refinery Project
(Contract No. : ZOR/EPC - 0045)
UNIT93 – SEA ISLAND
Page
Title FLANGE MANAGEMENT
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No. P4045ZOR-PR-CT-CM-512 Rev. O

Piping & Equipment Tightness (Leak) Test


P4045ZOR-PR-CO-CM-041
Precommissioning Procedures
P4045ZOR-PR-HS-CM-043 Permit To Work

P4045ZOR-PR-HS-CM-067 HSE Signage and Barricading

P4045ZOR-PR-HS-CM-076 Lifting Operation and Lifting Equipment


Construction philosophy - UNIT 93 - Sea Island
P4045ZOR-PR-CT-CM-018
underdeck activities
P4045ZOR-00-40-4-N002 Standard Piping Assemblies
Mechanical Completion Pre-Commissioning and Turnover
P4045ZOR-PR-CO-CM-033
Plans
P4045ZOR-LI-CO-CM-001 Systemization – Sub-System List
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐026 
‐ WT30 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐027 
‐ UT30 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐028 
‐ EL30 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐034 
‐ SR30 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐039 
‐ PR41 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐040 
‐ PR42 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐041 
‐ PR43 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐042 
‐ PR44 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐043 
‐ PR45 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐047 
‐ PR49 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐050 
‐ PR31 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐051 
‐ PR32 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐052 
‐ PR33 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐053 
‐ PR34 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐054 
‐ PR35 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐055 
‐ PR36 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐056 
‐ PR37 

Unit93 – Sea Island Flange Management Procedure


P4045ZOR-PR-CT-CM-512_0
Al-Zour Refinery Project
(Contract No. : ZOR/EPC - 0045)
UNIT93 – SEA ISLAND
Page
Title FLANGE MANAGEMENT
7 of 30
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No. P4045ZOR-PR-CT-CM-512 Rev. O

PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐057 
‐ PR11 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐058 
‐ PL11 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐059 
‐ PL12 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐060 
‐ PR12 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐061 
‐ PR13 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐062 
‐ PR14 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐063 
‐ PR15 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐064 
‐ PR16 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐065 
‐ PR17 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐066 
‐ PR18 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐067 
‐ PR19 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐069 
– PR21 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 – OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐070 
– PL21 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐071 
‐ PL22 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 – OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐072 
– PR22 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐073 
‐ PR23 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐074 
‐ PR24 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐075 
‐ PR25 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐076 
‐ PR26 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐077 
‐ PR27 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐078 
‐ PR28 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐079 
‐ PR29 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐080 
‐ PR31A 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐081 
‐ P101 
P4045ZOR‐BK‐PI‐CM‐083  PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 

Unit93 – Sea Island Flange Management Procedure


P4045ZOR-PR-CT-CM-512_0
Al-Zour Refinery Project
(Contract No. : ZOR/EPC - 0045)
UNIT93 – SEA ISLAND
Page
Title FLANGE MANAGEMENT
8 of 30
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No. P4045ZOR-PR-CT-CM-512 Rev. O

‐ P102
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐084 
‐ P201 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐085 
‐ P202 
PREFABRICATION & ASSEMBLY ISOMETRICS ‐ UNIT 93 ‐ OFFSHORE 
P4045ZOR‐BK‐PI‐CM‐087 
‐ L101 
PIPING ARRANGEMENT DRAWING ‐ UNIT 93 ‐ ONSHORE MODULE 
P4045ZOR‐93‐40‐0‐X028 
‐ SL60 
PIPING ARRANGEMENT DRAWING ‐ UNIT 93 ‐ OFFSHORE MODULE 
P4045ZOR‐93‐40‐0‐X030 
‐ WT30 
PIPING ARRANGEMENT DRAWING ‐ UNIT 93 ‐ OFFSHORE MODULE 
P4045ZOR‐93‐40‐0‐X031 
‐ UT30 
PIPING ARRANGEMENT DRAWING ‐ UNIT 93 ‐ OFFSHORE MODULE 
P4045ZOR‐93‐40‐0‐X032 
‐ EL30 
PIPING ARRANGEMENT DRAWING ‐ UNIT 93 ‐ OFFSHORE MODULE 
P4045ZOR‐93‐40‐0‐X033 
‐ VR30 
PIPING ARRANGEMENT DRAWING ‐ UNIT 93 ‐ OFFSHORE MODULE 
P4045ZOR‐93‐40‐0‐X034 
‐ SR30 
PIPING ARRANGEMENT DRAWING ‐ UNIT 93 ‐ OFFSHORE MODULE 
P4045ZOR‐93‐40‐0‐X035 
‐ OF30 
PIPING ARRANGEMENT DRAWING ‐ UNIT 93 ‐ OFFSHORE MODULE 
P4045ZOR‐93‐40‐0‐X036 
‐ OB30 
PIPING ARRANGEMENT DRAWING ‐ UNIT 93 ‐ OFFSHORE MODULE 
P4045ZOR‐93‐40‐0‐X037 
‐ FW30 
PIPING ARRANGEMENT DRAWING ‐ UNIT 93 ‐ OFFSHORE MODULE 
P4045ZOR‐93‐40‐0‐X038 
‐ LC30 
PIPING ARRANGEMENT DRAWING ‐ UNIT 93 ‐ OFFSHORE ‐ PR31 & 
P4045ZOR‐93‐40‐0‐X039 
PR31A 
PIPING ARRANGEMENT DRAWING ‐ UNIT 93 ‐ OFFSHORE ‐ PR32 & 
P4045ZOR‐93‐40‐0‐X040 
PR33 
PIPING ARRANGEMENT DRAWING ‐ UNIT 93 ‐ OFFSHORE ‐ PR34 & 
P4045ZOR‐93‐40‐0‐X041 
PR35 
PIPING ARRANGEMENT DRAWING ‐ UNIT 93 ‐ OFFSHORE ‐ PR36 & 
P4045ZOR‐93‐40‐0‐X042 
PR37 
P4045ZOR‐93‐40‐0‐X043  PIPING ARRANGEMENT DRAWING ‐ UNIT 93 ‐ OFFSHORE ‐ PR46 
PIPING ARRANGEMENT DRAWING ‐ UNIT 93 ‐ OFFSHORE ‐ PR44 & 
P4045ZOR‐93‐40‐0‐X044 
PR45 

1.4.2 CODE & STANDARDS

Ref. Code Reference Title

DEP 31.38.01.12-Gen Piping Classes – Refining and Chemicals


DEP 31.38.01.31-Gen Shop and Field fabrication of piping
DEP 74.00.10.10-Gen Shop and field pressure testing of piping system
31.38.01.31-P4049NRP-00-PV Project Variation to DEP 31.38.01.31 – Shop and field
fabrication of piping

Unit93 – Sea Island Flange Management Procedure


P4045ZOR-PR-CT-CM-512_0
Al-Zour Refinery Project
(Contract No. : ZOR/EPC - 0045)
UNIT93 – SEA ISLAND
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Title FLANGE MANAGEMENT
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No. P4045ZOR-PR-CT-CM-512 Rev. O

74.00.10.10-P4049NRP-00-PV Project Variation to DEP 74.00.10.10 – Shop and field


fabrication of piping
P4045ZOR-WR-CT-CM-501 Approved Waiver Request for Painting before hydrotest

DEP-31.38.01.31-Gen – Shop and Field Fabrication of Piping


February 2012
DEP-31.38.01.11-Gen – Piping General Requirements
February 2012

1.5 DEFINITIONS AND ABBREVIATIONS

1.5.1 DEFINITIONS

Company “Company” and “Owner” are equivalent terms and mean KUWAIT
INTEGRATED PETROLEUM INDUSTRIES COMPANY (K.I.P.I.C.) and
Project Management Consultant (PMC) designated by Company

Contractor HDEC-SAIPEM-SKEC (HSS) Joint Venture contracted by Company to


manage all Vendor packages and scope of works.

Approved / Approval and like words mean Company's approval in writing.

EPC Contractor / mean those contractors other than the Contractor who are from time to
EPC Contractors time employed by the Owner in respect of the Project.

Project mean the Company’s New Refinery Project (NRP) [Renamed as Al-
Zour Refinery Project (ZOR)] as generally described in Section 4 -
Exhibit A Scope of Work.

Project Management mean the company or organization appointed by the Company to


Consultant / PMC perform project management services on behalf of the Company.
The “PMC” shall be AMEC Group Limited, U.K.

Project Variations mean a modification to Shell DEPs, Shell standard drawings, Shell
requisitions and Shell forms specific to the Project as more fully
described in Section 4 - Exhibit C, Technical Specifications.

Shell DEPs / DEPs mean Shell Design Engineering Practices as more fully described in
Section 4 - Exhibit C, Technical Specifications.

Shall / Will Used to indicate requirements strictly to be followed in order to conform


to the specification and accepted by all involved parties

Should Used to indicate that among several possibilities one is recommended


as particularly suitable without mentioning or excluding others, or that a
certain course of action is preferred but not necessarily required

Unit93 – Sea Island Flange Management Procedure


P4045ZOR-PR-CT-CM-512_0
Al-Zour Refinery Project
(Contract No. : ZOR/EPC - 0045)
UNIT93 – SEA ISLAND
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Title FLANGE MANAGEMENT
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May Used to indicate a course of action permissible within the limits of the
specification

1.5.2 ABBREVIATIONS

Abbreviation Complete Term


ATK/DPK Aviation Turbine Kerosene / Dual Purpose Kerosene
DCN Design Change Notice
DEP Design and Engineering Practice
EPC Engineering, Procurement and Construction
FEED Front End Engineering and Design
HSE Health, Safety and Environment
HSSJV Hyundai - Saipem - SKEC Joint-Venture
KEPA Kuwait Environmental Protection Authority
KIPIC Kuwait Integrated Petroleum Industries Company
LNGI Liquefied Natural Gas Import (Terminal)
LSFO Low Sulfur Fuel Oil
MESC Shell Material and Equipment Standards and Codes
MDO Marine Diesel Oil
MTF Marine Terminal Facilities
NRP New Refinery Project
PCN Petrochemical Naphta
PEFS Process Engineering Flow Scheme
PFS Process Flow Scheme
PMC Project Management Consultancy
PV Project Variation (to DEP Shell)
Rev. Revision
SI Unit 93 - Sea Island
SSP Unit 93 - Subsea Pipelines
ULSD Ultra-Low Sulfur Diesel
ZOR Al-Zour Refinery Project
JSA Job Safety Analysis
PTW Permit To Work
TBT Tool Box Talk

Note : additional abbreviations are listed in Contract Section 4 Exhibit A – Appendix G ‘Abbreviations’

Unit93 – Sea Island Flange Management Procedure


P4045ZOR-PR-CT-CM-512_0
Al-Zour Refinery Project
(Contract No. : ZOR/EPC - 0045)
UNIT93 – SEA ISLAND
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Title FLANGE MANAGEMENT
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2 HSE REQUIREMENT

2.1 JSA & Permit to Work

Prior to start any bolting activity, dedicated Job Safety Analysis review meeting shall be done, attended
by each responsible person to perform the work. This meeting shall discuss:

 All detail of activity planned to be done for bolting activity,

 Identify potential hazard or risk that may occurs, and

 Set recommended action to eliminate the risk.

The finalized and approved JSA shall be attached into Permit to Work, including work location plan,
work detail to be performed, and any other critical information related to the task.

JSA as well have to be communicated clearly to the entire task force member, at every beginning of
work to commence, during Tool Box Talk. Each of the task force is mandatory to attend the tool box
talk, or shall not be allowed to be part of team to execute the task.

2.2 Work Area

Cares shall be taken related to the work area surrounding where the bolting activity planned to be
performed.

Adequate and temporary scaffolding / raised platform, whereas necessary shall be available to be
used by the bolting team. It shall be completed with fall protection, inspected and approved to use by
certified scaffolding inspector on routine basis.

When Bolt torqueing or tensioning method selected, adequate barricade shall be installed surrounding
work area and the hydraulic power unit. Clear sign board shall be fitted, and standby watchman or
safety officer shall be present to prevent unauthorized access to working area.

2.3 Equipment

All equipment for bolting work shall be in compliance with below requirement:

 Proper use in accordance to its design purposes and application.

 Stored in good condition, when not in use for working purposes

 Inspected through prior to be use on site, from any sign of defect, malfunction, or failure.

 Having valid routine inspection / certification, as per manufacture standard recommendation or


approved third party body, to be used on the project.

 All pressurized hydraulic hoses, air supply hoses shall be equipped with whip check to avoid hazard
in the event of failures.

 All pressurized hydraulic equipment, prior to be used shall undergo and pass pressure test
qualification at their maximum working pressure rating.

Unit93 – Sea Island Flange Management Procedure


P4045ZOR-PR-CT-CM-512_0
Al-Zour Refinery Project
(Contract No. : ZOR/EPC - 0045)
UNIT93 – SEA ISLAND
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Title FLANGE MANAGEMENT
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2.4 Personnel

Flange Management or Bolting Work team shall be at least having previous project experience on
various bolting work, utilizing manual and hydraulic system tools.

Team supervisor in charge shall be ensure that each team member has adequate capability to work
with the related tools, and work methodology.

Proper training and familiarization on site shall be organized to ensuring proper knowledge from each
of team member, related to work requirement, equipment handling and work method.

Proper PPEs shall be worn at all time when performing the activity on shop or work site, as HSE site
requirements. This would mean appropriates Hard Hat, safety Glass, Gloves, Coverall, Safety shoes.

Additional PPEs shall be wear in accordance to the site condition, i.e. body harness when working at
height, etc.

3 FLANGE MANAGEMENT PROCEDURES

3.1 Flanges Joint Type.

In major, the flange management activity are divide in 2, based from the activity purposes:

 Permanent Joint: Bolting activity that done in final stage, with all permanent materials, required
all inspection and verification to be done and validated. Joint after recorded as completely done
on the progress report, with relevant check sheet and test sheet filled and sign as approved by
QA/QC and company representative.

 Temporary Joint: Bolting activity that done in temporary, example for the purpose of line or
equipment inspection, or hydro testing, or line cleaning activity. Utilize temporary or test material
i.e. gasket and bolt. No report required or produced for this type of joint since the joint shall be
break up again after completion of the intended activity.

3.2 Flanges Surface

The flanges surface condition shall meet below listed condition, at the date before joining activity
performed:

 Foreign materials and protective seal or grease shall be removed from the flanges faces prior to
assembly.

 Shall be inspected for pits and defect in the gasket contact face.

3.3 Flange Alignment

There is 2 (two) types of flanges alignment are recognized as common standard;

3.3.1 Lateral Alignment


Refer to the off-set of the aligned flanges centerlines. This is applicable to the complete flange set, as
well as the relative positioning of bolt holes.

Unit93 – Sea Island Flange Management Procedure


P4045ZOR-PR-CT-CM-512_0
Al-Zour Refinery Project
(Contract No. : ZOR/EPC - 0045)
UNIT93 – SEA ISLAND
Page
Title FLANGE MANAGEMENT
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The inspection can be done whereas;

 The flanges shall be lined up so that bolts can be inserted without force.

 Gasket and 25% of bolts (at least 4 bolts) shall be inserted. The bolts shall be uniformly fastened
using manual spanner to take out the free slack, to ensure the real miss-alignment will be
measured.

The acceptance criteria for lateral alignment check is that after measurement, the measured value
shall not be exceeding the values as given below:

3.3.2 Parallelism
Refer to the parallelism condition of the aligned flanges faces, sometimes referred to as Angular
Alignment.

The inspection shall be done or checked by:

 Measuring distance between mating flanges of the pre-assembled joint.

 The measurement shall be taken around the circumference at equal distance from the center line
of flanges (The outside of flanges rim will normally be the most convenient position).

The acceptance criteria is that, the value between each measurement point are not exceeding:

ASME B31.3 Flanges 05 mm/m

ASME B16.5 Flanges 02.5 mm/m

ASME B16.47 Flanges 1.75 mm

For flanges connection facing to the static equipment, i.e. Compressor, pumps, and else shall not be
exceed 0.05° in all direction, as value given on table below from DEP specification

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3.4 Gasket

Below requirement for the gasket shall be followed, both for permanent joint make up or for the piping
strength test purposes (hydrotest):

 Gasket shall be RF or spiral wound types.

 Gasket shall be new each time. Each flange joint whereas tightening activity has been performed
before, and for any reason the joint need to be re-opened, the existing gasket shall be replaced
with the new ones on the re-tightening process.

 Gasket shall be physically inspected for its condition, to be sure free from any deformation, scratch,
damage and else.

 Gasket selection shall be fit to the flange class sizing. No cross utilization are permitted either for
permanent or for temporary test purposes.

3.5 Bolt & Nuts

Bolt and nuts utilization shall be in accordance to below general requirement:

 Use only bolt and nuts as per project engineering design requirement.

 Undergo visual inspection, from any sign of rust, thread damage, or defect prior to be used on

 Utilization of more than 1 type or materials or size of bolt in same flanges tightening shall not be
permitted. Same materials type, class, model and size bolts only shall be provided in the event of
damaging bolts condition seen.

3.6 Bolts Tightening Method

Briefly described below are common of bolts tightening method use on the piping installation industry.

Typical configuration and example type of equipment are included on the Attachment – C of this
document for references.

3.6.1 Bolt Tensioning Method


Refer to bolt tightening process, by applied direct axial stretching to bolt, to achieve preload value.

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The tension commonly applied to several number of bolts at same time, recognized as the bolt
tensioning method (50% or 100% Bolt Tensioning method commonly selected).

Below are requirement to be taking into account from bolt tensioning method:

 Hydraulic bolt tensioners shall be used on flange stud bolts 50 mm (2 in.) in diameter and
larger.
 Bolts for use with bolt tensioners shall have increased length from normal length, formulated by 1
x Bolts Stud diameter.
 Bolt materials and properties vary within bolt types and this must be accounted when
using these methods.
 While doing the tightening care shall be taken to ensure sufficient clearance, particularly
when bolting in limited spaces in valves, compressor accessories, instruments, pumps, etc.
 Pre-tightening to ensure full contact of gasket face and subsequently tightening using torque
wrench or bolt tensioner.
 Bolt tensioning activity shall be done only by well experience, trained and qualified person
due to involving high pressure hydraulic equipment.
3.6.2 Bolt Torqueing Method
Refer to bolt tightening process, by twisting the nuts along the stud thread, until reaching pre-set force
value.

Below are requirement to be taking into account from bolt tensioning method:

 Hydraulic bolt torqueing shall be used on flange with stud bolt 25 mm (1 in.) and above (1” ≤ x <
2”).
 Bolt materials and properties vary within bolt types and this must be accounted for when
using these methods.
 Hand tight the nuts, ensuring correctly facing for the flange surface.
 First tightening should be set at 33% or 50% of the torque value.
 Tighten the stud bolts with “criss-cross” tightening sequence by operating the hydraulic torque
wrench.
 Continuing for the next tightening stage to 100%.
 Bolt tensioning activity shall be done only by well experience, trained and qualified person
due to involving high pressure hydraulic equipment.

3.6.3 Manual Tightening Method


Another method to do bolt tightening activity are by Manual torqueing, utilizing hand wrench.

 Practical only for bolts approximately below 25 mm (1 in.) in diameter.

 Tighten the stud bolts performed with “criss-cross” tightening sequence.

3.7 Joint Leaking Condition

Following step below are recommended initial action to be performed, on the event of leak condition
found on any of the flange joint for permanent or test installation:

a. Stop Piping Line Up or test pressurization activity.

b. Isolated the leaked joint, depressurized the pressure to atmospheric condition.

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c. Check and measure the outer flanges rims in circumference, for initial miss-alignment of the
flanges

d. Check each bolts torque values, apply 100% torque or tensioning value as applicable.

Re-pressurized the lines to check the joint integrity again after. Shall leakage condition still present:

 Re-depressurize and drain medium (if any) from internal system.

 Repeat all inspection as detailed on section 3 in this procedure accordingly.

 Replace all permanent gasket installed with the new set.

4 RECORD AND REPORTING

4.1 FLANGE MANAGEMENT DATA BASE

Simple data base, in excel spread sheet shall be populated and utilized as reference document
standard for all flange management activity progress follow up and reporting.

This data base shall be populated, by integrating all engineering details design data related to the
associated piping isometric drawing.

This data base shall contain all important data, as listed below;

 Reference Line ID, sizing, piping classification

 Isometric drawing reference number

 Flange data i.e. size, surface type, class

 Gasket data i.e. type, size, materials, class.

 Bolt data i.e. size, material, coated or non-coated type.

 Reference tightening method, torqueing or tensioning value.

 Reference of type of the tooling utilized for the activity, including certification.

4.2 TEST PACK

Relevant check sheet / test sheet called Go-Completion Sheet are available and included inside
standard piping Hydro testing Test Pack, i.e. bolt reference tightening value, materials data,
engineering design data, etc.

Typical Test Pack dossier including relevant form for bolting work as well included inside attachment
– B of this procedure for references.

4.3 FIELD JOINT IDENTIFICATION

Dedicated Labelling system shall be employed on field, for each of piping joint that has undergo and
completed the related inspection.

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With Purpose to ease joint status identification, the labels shall be;

 Only fitted to the joint whereas connection are final, has undergo through inspection and approved
by certified inspector.

 Prepared or filled by test engineer or test supervisor in charge.

 Checked and validated by certified inspector, during inspection of the piping joint. The inspector
then shall put his name, date of inspection and signature as required.

Below are typical of flange joint labelling system as example.

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5 ATTACHMENT – A HSE TYPICAL DOCUMENT TEMPLATE

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6 ATTACHMENT – B TEST PACK & GOCOMPLETION CHECK SHEET BOLTING

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7 ATTACHMENT – C BOLT TIGHTENING METHOD & SCHEMATIC

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8 ATTACHMENT – D BOLT TORQUEING VALUE REFERENCE (DEP SHELL EXTRACT)

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9 ATTACHMENT – E TYPICAL FLANGE MANAGEMENT DATA BASE

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