BOLT TORQUING / TENSIONING PROCEDURE PDF

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Kuwait National Petroleum Company (K.S.C.) P6011MAA.000.10.51.044 Clean Fuels Project (CFP) REV F4 KNPC Contract No. CFP/EPC/0054-MAA Page 1 of 29 Contractor JOB CODE : 0-6798-20-0000 S-000-3160-0002V BOLT TORQUING / TENSIONING PROCEDURE Operation Center JOB CODE 0-6798-20-0000 Operation Center Doc ...

Description

P6011MAA.000.10.51.044

Kuwait National Petroleum Company (K.S.C.) Clean Fuels Project (CFP) KNPC Contract No.

REV

CFP/EPC/0054-MAA

F4

Page 1 of 29 S-000-3160-0002V

Contractor JOB CODE : 0-6798-20-0000

BOLT TORQUING / TENSIONING PROCEDURE

Operation Center JOB CODE

0-6798-20-0000

Operation Center Doc No.

S-000-3160-0002V

F4

19-Feb-17

Issued for Final

T. Okano

S. Hanada

K. Kawafuchi

F3

28-Jun-16

Issued for Final

T. Okano

S. Hanada

K. Kawafuchi

F2

29-Mar-16

Issued for Final

S. Mitsumoto

H. Suzuki

M. Sakaki

F1

26-DEC-15

Issued for Final

H. Suzuki

H. Kunifusa

M. Sakaki

A1

1-DEC-15

Issued for Design

H. Suzuki

H. Kunifusa

M. Sakaki

O1

8-NOV-15

Issued for Comment

H. Kunifusa

M. Sakaki

S. Hanada

Rev.

Date

Description

Orig.

Checked By

Approved By

Kuwait National Petroleum Company (K.S.C.) Clean Fuels Project (CFP) Kuwait JGC Corporation / GS Engineering & Construction / SK Engineering & Construction CONTRACT NO.

DOCUMENT NO.

REV NO.

CFP/EPC/0054-MAA

P6011MAA.000.10.51.044

F4

CONFIDENTIAL OR PROPRIETARY INFORMATION

Kuwait National Petroleum Company (K.S.C.) Clean Fuels Project (CFP) KNPC Contract No.

P6011MAA.000.10.51.044 REV

CFP/EPC/0054-MAA

Contractor JOB CODE : 0-6798-20-0000

F4

Page 2 of 29 S-000-3160-0002V

Record of Revisions Rev No

Date

Description

O1

8-NOV-15

Issued for Comment

A1

1-DEC-15

Issued for Design

F1

26-DEC-15

Issued for Final

F2

29-Mar-16

Issued for Final

F3

28-Jun-16

Issued for Final

F4

19-Feb-17

Issued for Final

CONFIDENTIAL OR PROPRIETARY INFORMATION

P6011MAA.000.10.51.044

Kuwait National Petroleum Company (K.S.C.) Clean Fuels Project (CFP)

REV

KNPC Contract No.

Page 3 of 29

CFP/EPC/0054-MAA

F4

S-000-3160-0002V

Contractor JOB CODE : 0-6798-20-0000

TABLE OF CONTENTS 1.0

INTRODUCTION .......................................................................................................................3

2.0

SCOPE......................................................................................................................................3

3.0

REFERENCE DOCUMENTS.....................................................................................................3

4.0

SCOPE OF APPLICATION .......................................................................................................4

5.0

TIMING OF APPLICATION .......................................................................................................5

6.0

PREPARATIONS ......................................................................................................................5

7.0

BOLT TIGHTENING..................................................................................................................5

8.0

THREAD LUBRICANTS ...........................................................................................................5

9.0

INSPECTION AND RECORD....................................................................................................6

ATTACHMENT Attachment- 1;Required Bolt Tightening Torque Value(1/10) ..................................................... 7 Attachment- 2;Required location of Bolt tensioner .................................................................... 18 Attachment- 3;Tightening sequence ......................................................................................... 28 Attachment- 4; Recommended tensioning values…………………………………………………...28

1.0

INTRODUCTION This document describes field procedures for flange bolting by using torque wrench and/or bolt tensioner to be applied to flanges installed at KNPC CFP Project site.

2.0

SCOPE The purpose of this procedure is to identify the detailed requirements, work sequence and methods in order to make sure field bolting works during construction and commissioning.

3.0

REFERENCE DOCUMENTS (1) ASME B31.3 – PROCESS PIPING (2) DEP 31.38.01.31 – SHOP AND FIELD FABRICATION OF PIPING (3) DEP 31.40.10.19 – GLASS-FIBER REINFORCED PLASTIC PIPELINE AND PIPING SYSYTEM (4) DEP 74.00.10.10 – SHOP AND FIELD PRESSURE TESTING OF PIPING SYSTEM CONFIDENTIAL OR PROPRIETARY INFORMATION

P6011MAA.000.10.51.044

Kuwait National Petroleum Company (K.S.C.) Clean Fuels Project (CFP)

REV

KNPC Contract No.

Page 4 of 29

CFP/EPC/0054-MAA

F4

S-000-3160-0002V

Contractor JOB CODE : 0-6798-20-0000

(5) S-000-1670-0305V - TYPICAL INSPECTION AND TEST PLAN FOR PIPING WORKS (6) S-000-1670-0401V - QC FORMS FOR CONSTRUCTION ACTIVITIES (7) S-000-3160-0001V CONSTRUCTION

-

GUIDELINE

FOR

CLEAN-BUILD

OF

PIPING

DURING

(8) S-000-3168-0001V - PIPING TEST PACKAGE PREPARATION AND HANDLING PROCEDURE (9) VV216A-109-A-808 - BOLT TIGHTENING PROCEDURE (10) DEP 70.08.10.11 – MECHANICAL MAINTENANCE EQUIPMENT AND TOOLS 4.0

SCOPE OF APPLICATION All the flange joints other than the following locations shall be tightened by torque wrench or torque machine in accordance with Required Bolt Tightening Torque Valve Table shown in Attachment-1. However regarding torque value of GRE, follow the vender document ‘VV216A-109-A-808’. Regarding the torque value for insulated gasket kits, follow the vendor document ‘VV216F191-A-808.’ The following flange locations shall be tightened by using bolt tensioner. The bolt diameter ranges which shall be tightened by bolt tensioner are specified for each piping class in Attachment-2. For bolt-tensioning equipment, see DEP 70.08.10.11 Appendix C para. C.6. However, torque wrench might be applied instead of bolt tensioner in case of the configuration or size limitations. (1) DEP 31.38.01.11 Appendix 16 (Construction class) - Class-1a or 1b (Category M): Hydraulic bolt tensioning: 1"" and above bolts - Class-2a: Hydraulic bolt tensioning: 1-1/2"" and above bolts - Class-3c or 3d: Hydraulic bolt tensioning: 2"" and above bolts - Class-4d: No hydraulic bolt tensioning is required. (Controlled flange tightening is required for size DN600 (NPS 24) and above.) (2) DEP 31.38.01.31 Sec. 3.12 c) - Category M: Hydraulic bolt tensioning: 1"" and above bolts - Hydrogen and CL600 and larger or All and CL1500 and larger: Hydraulic bolt tensioning: 11/2"" and above bolts - Other than above: Hydraulic bolt tensioning: 2"" and above bolts Note: In case recommendable torque is applicable for equipment by Vendor, that torque shall be applied at connection between Equipment and Piping and Manhole on Equipment Attachment-2 : Required location of bolt tensioner Flanges may be tightened by conventional spanners/wrenches on Construction class-4d below DN600, but not on GRP flanges.

CONFIDENTIAL OR PROPRIETARY INFORMATION

Kuwait National Petroleum Company (K.S.C.)

P6011MAA.000.10.51.044

Clean Fuels Project (CFP)

REV

KNPC Contract No.

Page 5 of 29

CFP/EPC/0054-MAA

S-000-3160-0002V

Contractor JOB CODE : 0-6798-20-0000

5.0

F4

TIMING OF APPLICATION This will be applied during piping construction, final reinstatement after piping pressure test, and commissioning phase until Mechanical Completion of the plant. All the flange joints shall be tightened before piping pressure test except the flanges where test limit of pressure test.

6.0

PREPARATIONS (1) (2) (3) (4) (5) (6)

To confirm flange face cleanliness and alignment and damage free. To confirm correct gasket in proper position. To confirm bolts and nuts are correct material, numbers, sizes and cleaned condition. To confirm anti-seize compound applied. To confirm sufficient working area around the flange to access. To confirm adequate torque wrench and tensioner with accessories are ready for use in position. (7) To confirm the validity of calibration certificate for torque wrench and bolt tensioner.

7.0

BOLT TIGHTENING (1) Torque Wrench Bolt tightening with torque wrench shall be proceeded with the following steps in order to avoid flange rotation and uneven tightening.

Step-1: Tighten by torque wrench with 30% of required torque value. Bolt Tightening Sequence shall be based on attachment-2. Step-2: Tighten by torque wrench with 60% of required torque value. Bolt Tightening Sequence shall be based on attachment-2. Step-3: Tighten by torque wrench with 100% of required torque value. Bolt Tightening Sequence shall be based on attachment-2. Step-4: Tighten by torque wrench with 100% of required torque value. Sequence shall be clockwise in this Step. (2) Hydraulic Tensioner Bolt tightening with tensioner shall be proceeded in accordance with method statement of Bolt Tensioning Contractor. Bolt information should be considered for bolt tensioning values on attachment-4.

8.0

THREAD LUBRICANTS As per shell DEP 31.38.01.31-Gen. paragraph 3.12 c) The use of lubricants containing molybdenum disulphide is not allowed for environmental CONFIDENTIAL OR PROPRIETARY INFORMATION

Kuwait National Petroleum Company (K.S.C.)

P6011MAA.000.10.51.044

Clean Fuels Project (CFP)

REV

KNPC Contract No.

Page 6 of 29

CFP/EPC/0054-MAA

Contractor JOB CODE : 0-6798-20-0000

F4

S-000-3160-0002V

reasons and because its application can result in sulphide stress corrosion in the bolt material. 9.0

INSPECTION AND RECORD In accordance with S-000-1670-0305V / TYPICAL INSPECTION AND TEST PLAN FOR PIPING WORKS, Contractor shall carry out inspection, and then the inspection report shall be controlled by Contractor. Bolt Torque & Tensioning report summary data shall be attached to relative piping test packages. Note: -

At test limit of pressure test, torque control will be applied, but no record will be taken because that flange will be tightened with torque control at reinstatement. Random check will be carried out including test limit at stage of piping re-instatement.

CONFIDENTIAL OR PROPRIETARY INFORMATION

P6011MAA.000.10.51.044

Kuwait National Petroleum Company (K.S.C.) Clean Fuels Project (CFP)

REV

KNPC Contract No.

Page 7 of 29

CFP/EPC/0054-MAA

F4

S-000-3160-0002V

Contractor JOB CODE : 0-6798-20-0000

Attachment- 1;Required Bolt Tightening Torque Value(1/110) Flange Rating : Flange Facing :

ASME Class 150 (ASME B16.5 / B16.47 Series A) RF

Flange Size [DN]

No. of Bolts [pcs]

15 20 25 40 50 80 100 150 200 250 300 350 400 450 500 600 650 700 750 800 900 1000 1050 1200 1250 1350 1400 1500 1600

Bolt Dia. [inch]

0.5 0.5 0.5 0.5 0.625 0.625 0.625 0.75 0.75 0.875 0.875 1 1 1.125 1.125 1.25 1.25 1.25 1.25 1.5 1.5 1.5 1.5 1.5 1.75 1.75 1.75 1.75 1.125

4 4 4 4 4 4 8 8 8 12 12 12 16 16 20 20 24 28 28 28 32 36 36 44 44 44 48 52 60

Recommended Bolt Tightening Torque (per bolt) [Nm] ASTM A193 Gr. B7 ASTM A193 ASTM A193 Gr. B16 Gr. B7M ASTM A320 Gr. L7 BS EN 10269 20CrMoVTiB4-10 ASME SA193 Gr. B7 ASTM A193 Gr. B8 Cl. 2

Min. 89 89 89 89 173 173 173 299 299 475 475 708 708 1008 1008 1383 1383 1383 1383 2390 2390 2390 2390 2390 3794 3794 3794 3794 1008

Max. 105 105 105 105 205 205 205 353 353 561 561 837 837 1192 1192 1634 1634 1634 1634 2824 2824 2824 2824 2824 4484 4484 4484 4484 1192

Min. 68 68 68 68 132 132 132 229 229 363 363 541 541 770 770 1056 1056 1056 1056 1825 1825 1825 1825 1825 2898 2898 2898 2898

Max. 81 81 81 81 158 158 158 272 272 432 432 644 644 917 917 1257 1257 1257 1257 2172 2172 2172 2172 2172 3449 3449 3449 3449

ASTM A453 Gr. 660 Cl. C Min. Max. 70 86 70 86 70 86 70 86 136 167 136 167 136 167 234 288 234 288 371 457 371 457 554 683 554 683 788 972 788 972 1081 1333 1081 1333 1081 1333 1081 1333 1868 2303 1868 2303 1868 2303 1868 2303 1868 2303 2967 3656 2967 3656 2967 3656 2967 3656

Notes: Note-1 : The recommended bolt tightening torque values in the table are applicable to metallic flanged connections except for construction class-4d below DN600. Note-2 : For non-metallic flanged connections, bolt tightening procedure and torque values shall be in accordance with the following vendor documents. ・GRE flanged connections in accordance with V-216A-109-A-808

CONFIDENTIAL OR PROPRIETARY INFORMATION

P6011MAA.000.10.51.044

Kuwait National Petroleum Company (K.S.C.) Clean Fuels Project (CFP)

REV

KNPC Contract No.

Page 8 of 29

CFP/EPC/0054-MAA

F4

S-000-3160-0002V

Contractor JOB CODE : 0-6798-20-0000

Attachment- 1;Required Bolt Tightening Torque Value(2/1011) Flange Rating : ASME Class 300 (ASME B16.5 / B16.47 Series A) Flange Facing : RF Flange Size [DN]

Bolt Dia. [inch]

No. of Bolts [pcs]

Recommended Bolt Tightening Torque (per bolt) [Nm] ASTM A193 Gr. B7

ASTM A193 Gr. B7M

ASTM A193 Gr. B16

ASTM A320 Gr. L7

BS EN 10269 20CrMoVTiB4-10

ASME SA193 Gr. B7 ASTM A193 Gr. B8 Cl. 2

15 20 25 40 50 80 100 150 200 250 300 350 400 450 500 600 650 700 750 800 900 1050 1200 1350 1400 1500

0.5 0.625 0.625 0.75 0.625 0.75 0.75 0.75 0.875 1 1.125 1.125 1.25 1.25 1.25 1.5 1.625 1.625 1.75 1.875 2 1.625 1.875 2.25 2.25 2.25

4 4 4 4 8 8 8 12 12 16 16 20 20 24 24 24 28 28 28 28 32 32 32 28 28 32

Min. 89 173 173 299 173 299 299 299 475 708 1008 1008 1383 1383 1383 2390 3038 3038 3794 4667 5663 3038 4667 8064 8064 8064

Max. 105 205 205 353 205 353 353 353 561 837 1192 1192 1634 1634 1634 2824 3590 3590 4484 5515 6693 3590 5515 9530 9530 9530

Min. 68 132 132 229 132 229 229 229 363 541 770 770 1056 1056 1056 1825 2320 2320 2898 3564 4325 2320 3564 6158 6158 6158

Max. 81 158 158 272 158 272 272 272 432 644 917 917 1257 1257 1257 2172 2762 2762 3449 4242 5149 2762 4242 7331 7331 7331

ASTM A453 Gr. 660 Cl. C Min. Max. 70 86 136 167 136 167 234 288 136 167 234 288 234 288 234 288 371 457 554 683 788 972 788 972 1081 1333 1081 1333 1081 1333 1868 2303 2375 2928 2375 2928 2967 3656 3649 4497 4428 5458 2375 2928 3649 4497 6304 7770 6304 7770 6304 7770

Notes: Note-1 : The recommended bolt tightening torque values in the table are applicable to metallic flanged connections in all hydrocarbon systems in all pressure classes, and utility systems in pressure classes 300 & higher. Note-2 : For non-metallic flanged connections, bolt tightening procedure and torque values shall be in accordance with the following vendor documents. ・GRE flanged connections in accordance with V-216A-109-A-808

CONFIDENTIAL OR PROPRIETARY INFORMATION

P6011MAA.000.10.51.044

Kuwait National Petroleum Company (K.S.C.) Clean Fuels Project (CFP)

REV

KNPC Contract No.

Page 9 of 29

CFP/EPC/0054-MAA

F4

S-000-3160-0002V

Contractor JOB CODE : 0-6798-20-0000

Attachment- 1;Required Bolt Tightening Torque Value(3/1011) Flange Rating : Flange Facing : Flange Size [DN]

Bolt Dia. [inch]

ASME Class 600 (ASME B16.5 / B16.47 Series A) RF No. of Bolts [pcs]

Recommended Bolt Tightening Torque (per bolt) [Nm] ASTM A193 Gr. B7

ASTM A193 Gr. B7M

ASTM A320 Gr. L7

ASTM A193 Gr. B16 BS EN 10269 20CrMoVTiB4-10

ASME SA193 Gr. B7 ASTM A193 Gr. B8 Cl. 2

15 20 25 40 50 80 100 150 200 250 300 350 400 450 500 600 650 700 750 800 850 900

0.5 0.625 0.625 0.75 0.625 0.75 0.875 1 1.125 1.25 1.25 1.375 1.5 1.625 1.625 1.875 1.875 2 2 2.25 2.25 2.5

4 4 4 4 8 8 8 12 12 16 20 20 20 20 24 24 28 28 28 28 28 28

Min. 89 173 173 299 173 299 475 708 1008 1383 1383 1841 2390 3038 3038 4667 4667 5663 5663 8064 8064 11061

Max. 105 205 205 353 205 353 561 837 1192 1634 1634 2175 2824 3590 3590 5515 5515 6693 6693 9530 9530 13072

Min. 68 132 132 229 132 229 363 541 770 1056 1056 1406 1825 2320 2320 3564 3564 4325 4325 6158 6158 8447

Max. 81 158 158 272 158 272 432 644 917 1257 1257 1673 2172 2762 2762 4242 4242 5149 5149 7331 7331 10055

ASTM A453 Gr. 660 Cl. C Min. Max. 70 86 136 167 136 167 234 288 136 167 234 288 371 457 554 683 788 972 1081 1333 1081 1333 1439 1774 1868 2303 2375 2928 2375 2928 3649 4497 3649 4497 4428 5458 4428 5458 6304 7770 6304 7770 8648 10659

Notes: Note-1 : The recommended bolt tightening torque values in the table are applicable to metallic flanged connections in all hydrocarbon systems in all pressure classes, and utility systems in pressure classes 300 & higher. Note-2 : For non-metallic flanged connections, bolt tightening procedure and torque values shall be in accordance with the following vendor documents. ・GRE flanged connections in accordance with V-216A-109-A-808

CONFIDENTIAL OR PROPRIETARY INFORMATION

P6011MAA.000.10.51.044

Kuwait National Petroleum Company (K.S.C.) Clean Fuels Project (CFP) KNPC Contract No.

REV

CFP/EPC/0054-MAA

F4

Page 10 of 29 S-000-3160-0002V

Contractor JOB CODE : 0-6798-20-0000

Attachment- 1;Required Bolt Tightening Torque Value(4/1011) Flange Rating : Flange Facing : Flange Size [DN]

Bolt Dia. [inch]

ASME Class 900 (ASME B16.5) RF No. of Bolts [pcs]

Recommended Bolt Tightening Torque (per bolt) [Nm] ASTM A193 Gr. B7

ASTM A193 Gr. B7M

ASTM A193 Gr. B16

ASTM A320 Gr. L7

BS EN 10269 20CrMoVTiB4-10

ASME SA193 Gr. B7 ASTM A193 Gr. B8 Cl. 2 ASTM A453 Gr. 660 Cl. C Min.

Max.

Min.

Max.

Min.

Max.

15

0.75

4

299

353

229

272

234

288

20

0.75

4

299

353

229

272

234

288

25

0.875

4

475

561

363

432

371

457

40

1...