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ASSEMBLING FLANGED JOINTS PROCEDURE

ORIGINAL SIGNED
Rev. Status Rev. Date Revision Memo Issued by Checked by Approved by

01

IFC

30-Aug-2011

Issued for Approval

R. BALA

C. KUSIOLEK

T. RODRIGUEZ

00 D0

IFC

22-Oct-2010

Issued for Approval

R. BALA

C. KUSIOLEK

T. RODRIGUEZ

IFA

14-Sept-2010

Issued for Approval

R. BALA

C. KUSIOLEK

T. RODRIGUEZ

C0

IFR

04-June-2010

Issued for Review

R. BALA

C. KUSIOLEK

T. RODRIGUEZ

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REVISION DESCRIPTION

Rev. index C0 D0 00 01

Revision Description Issued For Review Issued For Approval Issued For Construction Issued For Construction

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INDEX INDEX 1. 2. 3. 4. 5. 6. 7. SCOPE AND PURPOSE 1.1. 2.1. GENERAL 3 5 5 5 5 5 5 6 6 6 6 6 8 8 9 9 9 9 9 9 10 10 10 10 12 12 12 13 13 13 14 14 14 15 16 16 16 17 18


NG22-280-CST-SPD-002101-011.doc

REFERENCE DOCUMENTATION DEFINITIONS

SCOPE RESPONSIBILITY PERSONNEL QUALIFICATION MATERIAL ASSEMBLING EXECUTION 7.1. 7.2. 7.3. 7.4. GENERAL CHECKLIST BEFORE ERECTION ASSEMBLY CHECKLIST AFTER ASSEMBLY

8.

TIGHTENING 8.1. 8.2. CHOICE OF THE METHOD MANUAL TIGHTENING

9.

BOLT TORQUING 9.1. 9.2. 9.3. GENERAL PREPARATION TORQUE TIGHTENING SEQUENCE BOLT TENSIONING GENERAL BOLT TENSIONING PROCEDURE

10.

10.1. 10.2. 11. 11.1. 11.2. 12. 12.1. 12.2. 13. 13.1. 13.2. 13.3. 14. 15.

MAXIMUM BOLT STRESS CORRESPONDENCES CHECK OF FINAL BOLT STRESS

ASSEMBLY PROCEDURE QUALIFICATION MOCK-UP QUALIFICATION PROCEDURE BOLT ELONGATION PROCEDURE

BOLT TENSIONING CALCULATION NOTE DETERMINING THE LTF(LOAD TRANSFER FACTOR) DETERMINING THE TOOL PRESSURE DESIGN CHECK

DISASSEMBLING IDENTIFICATION AND FOLLOW UP COLOR CODE LABEL

15.1. 15.2.

APPENDIX A: TIGHTENING SEQUENCE: CRISS-CROSS METHOD


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APPENDIX B: ANOMALY REPORT CARD APPENDIX C: SECURITY INSTRUCTION C.90 APPENDIX D: SECURITY INSTRUCTION C.91 A & APPENDIX E: SECURITY INSTRUCTION C.91 B APPENDIX F: SECURITY INSTRUCTION C.39 APPENDIX G: RECOMMEND TORQUES AND TENSIONS FOR FLANGE BOLTING APPENDIX H: FLANGE ASSEMBLY CHECK LIST APPENDIX I: BOLT MARKING FOR BOLT TENSIONING APPENDIX J: BOLT TENSIONING CHECKLIST APPENDIX K: BOLT TENSIONING TOOLS

19 20 21 23 24 28 30 31 33

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1. SCOPE AND PURPOSE


1.1. General
OML58 Block, operated by TOTAL E&P Nigeria Ltd, is located in Nigeria, at some 75km North-West from Port Harcourt, close to the villages of OBITE and OGBOGU. The project is composed of five main parts: OGBOGU FS (Flow Station), which is an existing oil treatment plant, OBITE TC Treatment Center which is an existing gas treatment plant OGBOGU CLUSTER (Production Center), which is an existing gas production cluster, IPP-GSU (Gas Supply Unit for the Independent Power Plant), which is a new unit (grass root) dedicated to the future IPP (not in current Contractor SOW), Interconnecting pipelines and cables.

TOTAL E&P Nigeria Ltd, intend to upgrade the OML 58 facilities and mainly increase the gas export capacity from 9.5 to 15.65 MMSCMD (Million Metric Standard Cubic Meter per Day) of marketable gas.

2. REFERENCE DOCUMENTATION
TOTAL General specification GS PVV 171 Contract UPG-D100 Exhibit A Appendix 10 Specific pre-commissioning / commissioning requirements and explain the chapter on this document. GS EP COR 350 & 354 painting requirements. ANSI B31

2.1. Definitions
The following terms are used in this Procedure: COMPANY CONTRACTOR PROJECT PNL TOTAL E&P NIGERIA LIMITED The Consortium made of SAIPON SNC, SCNL, PNL & DESICON Engineering OML 58 UPGRADE PHASE 1 PONTICELLI Nigeria Limited

3. SCOPE
This procedure is applicable for all lines on the OML58 Upgrade Phase1 Project.

4. RESPONSIBILITY
. This procedure is managed by the CONTRACTOR QUALITY MANAGER and he is responsible for the approval and issue of all revisions to this document.
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In accordance with project Codes and Standards, CONTRACTOR is responsible on applying correct bolt up procedure on all piping and equipment assembly. He will perform the bolt-up activity of: - Piping assembly as per CONTRACTOR procedure and if necessary API6A / ISO 10423 recommended torques or tensions, - Equipment assembly as per Vendor procedure Vendor is responsible for correct bolt up procedure of Package Equipment critical flanges. Flange assembling is carried out under responsibility of the Pipe Fitter Foreman. He is responsible to monitor staff competence in term of Quality and Safety for the assembling work achievement. The Pipe Fitter FOREMAN is, consequently, responsible for applying this procedure.

5. PERSONNEL QUALIFICATION
The personnel carrying out assembling operations shall be qualified. This qualification is obtained through internal CONTRACTOR training or from a training given by an external company.

6. MATERIAL
The Pipe Fitter FOREMAN must check that the material is adapted for the work: - Individual and collective adapted tools (bronze tools on high explosive risks zone, anti-deflagrant material), - Adapted individual protections (gloves, screen, glasses, evacuation mask ), - Adapted security, insulation or test spades, - Insulation gasket in conformity with the specifications, - Adapted tightening tools.

7. ASSEMBLING EXECUTION
7.1. General
The major factors for successfully sealing a bolted assembly and eliminating leakage are: - proper selection and design of the components, i.e. flanges, gaskets and bolts; - proper preparation, inspection and installation; - correct bolt-up procedure All gasket sealing surfaces shall be protected from damage (shock, stripe, corrosion, sanding) by installation of hardwood blanks and shall be inspected after prefabrication, lifting, offshore transfer and final installation.

7.2. Checklist before erection


1. Review potential risks for damage from surround area or activities. 2. Confirm correct type, size and rating to be installed or dismantled. Check the location of the gasket to be erected or dismantled (refer to the assembling drawings and associated documents) 3. Inspect gasket sealing area and confirm it is free from defects or damage such as: o scores, o erosion/corrosion, o Deformation. 4. Flange faces with coarse tool marks or scratches that may cause the joint to leak should be rejected and where necessary remachined if required.
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5. Check that flange facing, dimensions and type of bolting are in accordance with the general specifications. 6. Use straight steel rule edge to check facing flatness. Flange shall have bearing surfaces for bolting that are parallel to the flange face within 1 degree. Damaged or badly corroded flanges should be repaired or replaced. 7. Flanges at rest should be parallel, in case of misalignment; corrective measure will defined will be defined with COMPANY and witnessed by COMPANY. Completed flanged connections shall be free of residual stresses during assembly, particularly in machinery piping and shall not be force fit to achieve fit-up. Guidelines of alignment allowance are given in figure n 1 for pipe flanges. Any anomaly shall be filed and reported using the Assembly anomaly report card given in Appendix B which is then transmitted to COMPANY for decision.

Fig. 1: ALIGNMENT RAISED FACE ALLOWANCES FOR PIPING FLANGES

A = 1 mm / 200 mm MAXIMUM OUT OF PARALLEL ALIGNMENT OF FLANGES MEASURED ACROSS ANY DIAMETER B = 3 mm MAXIMUM TRANSLATION OF BRANCHES OR CONNECTIONS 8. All gaskets shall be new and unused whenever an opened assembly is to be closed again. Check conformity of the gasket (material, dimensions, series, thickness, type) to ensure that it is in compliance with the piping specification, class, pressure rating or the dismantled gasket. 9. Check the general aspect of the gasket: coating,
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geometry, crushing, spiral windings,

traces of corrosion or erosion. All damaged gasket (including loose spiral winding) shall be rejected. 10. Check studs and nuts : grade coating damage threading, bolts, nut, Dimensions.

If necessary, stud bolts shall be cleaned using wire brush to remove any dirt on the threads. Visually examine studs and nuts to ensure it is free from burrs. Nuts should turn freely on the studs for a distance equal to their in-service distance. In the case of existing stud bolts re-assembly, wires brush them before greasing. 11. Check the supporting quality of the line and report any anomaly.

7.3. Assembly
1. 2. The gasket is now under responsibility of pipe fitter foreman (final or temporary) If required, grease RTJ seating face and if necessary seal the gasket.

CAUTION: Some services such as Oxygen or Hydrogen are not compatible with the use of grease.
3. Center the flange faces using appropriate tool (pin, centering device,). Align flange faces exactly, leaving just enough space to insert a gasket. Once flanges have been aligned up, visually examine them to assure that an acceptable fit has been obtained. 4. Install the first stud bolts.

Note: For a gasket in vertical plane, it is necessary to start the assembly by placing the lower stud bolts which will be used as support for the gasket before tightening,
5. 6. 7. 8. Install the gasket. Center the gasket. Insert all remaining studs and nuts on hand-tight. Do not pull up studs in a manner that reaches uneven compression of the gasket. Ensure all bolts are tensioned evenly and in sequence with at least two threads protrusion through the nuts at both sides. Otherwise, distribute protrusion equally from the sealing facing Note: If bolt tensioner is to be used, over length bolt are required (protrusion shall be at least one bolt diameter on one of the two sides). Attention is to be paid for allowance for tensioning equipment access. 9. Tighten the stud bolts with manual wrench to obtain the parallelism of the flange faces.

7.4. Checklist after assembly


The PIPE FITTER FOREMAN (or a person whom he designates), checks by surveying:
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1. 2. 3.

The parallelism of the flanges The remaining length of stud bolt The correct torque values have been applied and recorded.

8. TIGHTENING
Bolts shall be of sufficient length to leave minimum of three threads at the end of tightening activity.

8.1. Choice of the method


The method of tightening commonly used is the manual tightening method. The use of bolt torquing or pre-tensioning (bolt tensioning) is determined by COMPANY piping specifications.

8.2. Manual Tightening


1. 2. Tighten with "CRISS-CROSS" method (sketch in Appendix A) with the suitable wrench keys while controlling parallelism. Ensure the tightening of all the bolts is sufficient. (interaction between various tightening) See NOTE section from paragraph 10. 2 for RTJ flanges.

9. BOLT TORQUING
9.1. General
Hydraulic, pneumatic or beam type torque wrenches are commonly used in bolt torquing. The hydraulic wrenches are normally preferred. Reference to the tensioning equipment manufactures hydraulic pressure/tensioning values shall be used for guidance. The pressure to be applied is indicated in the equipment pressure / torque conversion specific chart.

9.2. Preparation
1. Using Appendix G table, determine the torque values necessary to achieve the desired bolt stress. 2. Bring all nuts up snug-tight with a short wrench using the "CRISS-CROSS" pattern shown in Appendix A. Do not tighten the bolts using impact force. 3. All torque wrenches shall be of adequate capacity and recently calibrated. Certificates of torque wrenches calibration shall be available. 4. In the event that seizure of the nut being torqued is encountered, back the nut off until seizure is eliminated and torque again. Apply lubricant if necessary and replace the nut and/or bolt if seizure reoccurs.

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9.3. Torque tightening sequence


1. Torque bolts and nuts in a "CRISS-CROSS" pattern as shown in Appendix A using a minimum of three torquing stages and recommended final torque as defined in Appendix G. STAGE 1 Torque to a maximum of 50% of the final torque value and in accordance with the CRISSCROSS sequence. Check that the flange is bearing uniformly on the gasket. Then tighten with 40% of the final torque value in clockwise circular sequence. STAGE 2 Torque to the final torque value with the CRISS-CROSS method. 1. After these three basic torque stages completed, repeat torquing the nuts at least once using the final torque in a "CRISS-CROSS" sequence until no further rotation of the nut is observed. 2. Continue torquing with the final torque in a circular sequence to ensure no further rotation. 3. All torque readings and sequences of tightening shall be filed and recorded for future reference using the form given in Appendix H.

10. BOLT TENSIONING


10.1. General

The advantage of this method lies mainly in the homogeneity of tightening. It requires stud bolts over lengths are equals to one bolt diameter. However, its implementation shall be carried out strictly in accordance with the equipment manufacturers recommendations. The hydraulic pressure to be applied is function of the bolt diameter and the type of tool; it is indicated in the equipment specific tables as shown in table 5 in paragraph 13.3. The tensioning of bolts shall be performed by trained personnel with appropriate equipment (bridges, pullers, hydraulic pumps, connection pipes, manometers, etc.). Tools are shown in Appendix L. Ideally all bolts should be tensioned in one operation to ensure even loading on the bolts and gaskets. It may not be practical to tension all bolts in one operation, but at least 2 bolts diametrically opposed should be tightened in one operation to ensure an acceptable degree of uniformity in loading. CAUTION: Bolt tensioning should not be carried out on equipment or systems which are in service. The trained personnel selected to perform the controlled bolt tensioning shall develop in the preliminary operation a diagram correlating the required pressure to be reached in the hydraulic circuit connected to the tensioners and the required load in each bolt.

10.2.

Bolt tensioning procedure

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The following procedure provides an example of 20" - 900# flange and 4 bolts tightened at the same time. In case the quantity of tensioner is different, each group below will have the same quantity as quantity of tensioner. 1. Group the 20 bolts into five groups (quantity of tensionners is the quantity of each group, 4 A's, 4 B's, 4 C's, 4 D's and 4 E's) as shown in Appendix I and then mark them accordingly on the flange. 2. Mount the 4 hydraulic tensionners on the first 4 bolts A's group of bolts. 3. Check the hydraulic system if there is any pressure problem. 4. Check that the specified hydraulic pressure is applied to the tensioner before running the nut down on each stud. 5. Apply equivalent hydraulic pressure by operating the hydraulic pump to give a bolt load equal to 40% of the maximum bolt stress (see paragraph 11). Note: It is often advisable to continuously re-apply the bolt stress, especially with Ring Type Joints, until no further movement of the flange nuts can be obtained. Also, it may be beneficial to allow a few minutes between each pressurization to allow the gasket to bed in. 6. Shift the tensionners to the next group and repeat the steps 3 to 5 until all group are 40% tightened. 7. Repeat the steps 2 to 5 with 70% of the maximum bolt stress 8. Shift the tensionners to the next group and repeat the steps 3 to 5, but applying a bolt load equal to 70% of the maximum bolt stress. 9. Repeat the steps 2 to 5 with 100% of the maximum bolt stress 10. Shift the tensionners to the next group and repeat the steps 3 to 5, but applying a bolt load equal to 100% of the maximum bolt stress. 11. Repeat steps 3 to 5 on all group of bolts to check if the hydraulic pressure required is enough to obtain the required bolt stress. Note: As a check to see if an excessive load has been lost in the initial groups, assemble two tensioning tools to randomly select but diametrically opposite group bolts. Apply 100% final hydraulic pressure and attempt to further tighten the flange nuts. If the nuts cannot be further tightened, then tensioning is complete and the tensioners may be removed. If the flange nuts can be further tightened, then repeat steps 2 to 5 by increasing the hydraulic pressure to 100% of final hydraulic pressure, on the bolts of each group. 12. The bolt tensioners may now be removed. 13. As a final check, use a hammer and ring each bolt to ensure no loose bolts remain 14. The PIPE FITTER FOREMAN and the trained personnel selected to perform the bolt tensioning shall fill the forms given in Appendix J, K stating the procedures adopted during the operations and the parameters adopted (pressure in the hydraulic circuit, temperature of flanged joints, etc). The form shows also the original length of bolts (unstressed conditions) and the final length of bolts (stressed conditions). As the hydraulic operating pressure varies according to the type and size of tools used, reference shall be made to the equipment's manufacturer specifications. CAUTION: Never exceed the tensioner maximum working pressure
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Never exceed the tensioner maximum piston/ram stroke

11. MAXIMUM BOLT STRESS

11.1.

Correspondences

The bolt-up procedure with torque wrench method is based, as an example, on the bolt stress of A-193 Grade B7 or A-320 Grade L7 in making up the flange, while the bolt tensioning method is referred to a generic maximum bolt stress. Table n 3 indicates the maximum bolt stress values recommended, it is important to notice that there are some flanges where lower bolt stress values are appropriate depending on the flange rating, and/or type bolting. In case of the Ring Joint Flanges, lower maximum bolt stress values are recommended for the higher flange ratings to avoid excessive bolt loads which can lead to undesiderable deformations to ring gasket and flange groove seating surfaces. Unlike raised face flanges, there is a little difference in gasket seating area with ring joint flanges as flange ratings increase so bolting loads are more concentrated in narrow zones of the ring groove. The remaining situations are all governed by the material strength of the specific bolt indicated. See Appendix G for correspondence between bolt load and bolt diameter depending on flange class and face type.

11.2.

Check of final bolt stress

The check of final bolt stress shall be performed for critical flange by means of the bolt elongation method described at the paragraph 12.2. The check will be spot, 10% of flanged joint (for piping) and at least 4 bolts of every joint for equipment tightened by each crew, and it shall be performed as follows: 1. measure with caliper the bolt elongation of the four bolts diametrically opposite; 2. check the correspondence of the specified bolt stress in the range of 10% of the bolt elongation measured; 3. if the above tolerance is not achieved in one bolt, then all the bolting of the joint will be checked and, in case of no compliance, retensioned; in case of no compliance of all 4 bolts for more than two joints in the same sampling, all the flanged joint tensioned by the crew who performed the bolt-up during that working day, will be completely checked.

MAXIMUM BOLT STRESS

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BOLT MATERIAL MAX. BOLT STRESS, A-193 Grade B7 A-193 Grade B8 A-193 Grade B8M A-193 Grade B16 A-320 Grade L7 A-453 Grade 660 360 360 360 360 360 360

max

(Mpa)

Table n 3

12. ASSEMBLY PROCEDURE QUALIFICATION


Each size of bolts for flange shall be submitted to a qualification procedure. The qualification shall be carried out on mock-up flange and elongation of each bolt shall be measured to ensure uniform bolt tension. For the finished joint, bolt elongation should correspond to maximum bolt stress value determined as per Appendix G 10%.

12.1.

Mock-up qualification procedure


1. Prepare the stud bolt ends to improve accuracy of stretch measurement. The stretch measurement will be tenths of millimeters accurate. 2. Using Appendix J form, number each bolt 3. Measure and record the initial length of each bolt. 4. Tighten the bolts, measure and record the final length of each bolt. 5. Record the desired stretch and also the recommended tool setting (torque value). 6. The crew is considered "qualified" after having assembling two sets of bolted flanges with the maximum bolt stress 10%.

12.2.

Bolt elongation procedure


A suitable device for measuring bolt elongation is the use of a caliper. The formula derived from the basic stress-strain relationship is:

Where L is the effective bolt length measured from center of nuts (as shown in Appendix J). And A is the elongation coefficient.
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Bolt Material A-193 Grade B7 A-193 Grade B8 A-193 Grade B8M A-193 Grade B16 A-320 Grade L7 A-453 Grade 660

E (Gpa)
205 205 205 205 205 195

A (no unit) 0.001756 0.001756 0.001756 0.001756 0.001756 0.001846

Table n 4

13. BOLT TENSIONING CALCULATION NOTE


Before any bolt tensioning, it is necessary to calculate the correlation between required pressure to be reached in the hydraulic circuit connected to the tensioners and the required stress in each bolt.

Load Transfer Factor = 1.01 + (Bolt Dia / Clamp Length) Tool Pressure = (Reqd Bolt Load x LTF) / Tool Hydraulic Pressure Area

13.1.

Determining the LTF(Load Transfer Factor)

Any stretch Bolt Tensioner regardless of make, exhibits a Load Transfer Loss as the bolt load is transferred from the Tensioner to the joints hexagon or round nuts. The Bolt load loss is a direct loss of stud elongation, this is due to many different factors, such as thread deflections, radial expansion of the nut and bedding in of the nut into the joint reaction surface. Because of this phenomenon it is essential that a load allowance is made when calculating the required operating pressure of a Tensioner, to achieve a known residual bolt load, extra load must be applied so the bolt will relax down to the required load on transfer. The load transfer factor can be accurately calculated and is a direct function of joint clamp length and the nominal diameter of the stud :

Load Transfer Factor = 1.01 + (Bolt Dia / Clamp Length) Units: D = Nominal Thread Diameter (mm or In) C = Bolt Clamp Length (mm or In) Note: If the calculated LTF is less than 1.1, then use a 1.1 LTF
CAUTION: Applying the Load Transfer Factor to the required bolt Stress will Increase the % of yield being generated on the bolt this value must be checked again

13.2. Determining the Tool Pressure


Tool Pressure = (Required Bolt Load x Load Transfer Factor) / Tool Hydraulic Pressure Area Units:
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Tool Pressure = (N/mm2 or Ton/In2) Required Bolt Load = (N or Ton) LTF = (No Units) Tool Hydraulic Pressure Area = (mm2 or In2) *To convert N/mm2 to bar: Multiply by 10 * To Convert Ton/In2 to psi: Multiply by 2240
CAUTION: Check that the calculated tool pressure does not exceed the Maximum Working Pressure of the tool. This value is hard stamped on all tools and is documented on the tool technical data sheet which came with the tools.

13.3. Design Check


It is always good practice to determine the % of bolt yield applied, if the final bolt stress exceeds 75% of the bolt yield strength, then it may be necessary to consider the fatigue characteristics of the bolt and joint. CAUTION: NEVER EXCEED 95% OF THE BOLT YIELD STRENGH

% of Yield = (Bolt Stress Required / Yield Strength of bolt) x 100 Units: Bolt Stress Required = (N/mm2 or Ton/In2) Yield Strength of Bolt = (N/mm2 or Ton/In2) Step 2: Example: Bolt Clamp Length = 144mm Bolt Diameter M36 x 4 Bolt Yield Strength = 720 N/mm2 Tool Hydraulic Pressure Area = 2955mm2 (Tool data) Required Bolt Load = 299kN LTF= 1.01 + (Bolt Dia / Clamp Length) = 1.01 + (36/144) = 1.26 % Yield Check = (Reqd Bolt Stress / Bolt Yield Strength) x LTF x 100 = (365.8 / 720)x 1.26 x 100 = 64.01% Tool Pressure = (Reqd Bolt Load x LTF) / Tool Hydraulic Pressure Area = (298858 x 1.26) / 2955 = 127.43 N/mm2 = 1274.3 bar

Tools Pressure / Tension correspondance table : Step 4:

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Tool reference Pressure Area (mm) Max Pressure (bar) Max Load (kN) Max Piston Stroke (mm) Dia (in) 1 1/2 1 1/2 2 2 2 2 1/2 2 1/2 2 1/2 2 3/4 Dia (mm) M39 M39 M52 M52 M52 M64 M64 M64 M70 L (in) 10 1/2 12 3/4 14 1/4 15 3/4 20 3/4 20 1/4 20 1/4 30 1/2 22 1/4 L (mm) 219 276 298 337 464 435 435 695 478 LTF 1,15 1,13 1,15 1,14 1,11 1,13 1,13 1,09 1,13 Tension (kN) 346 346 644 644 644 1032 1032 1032 1146 40% 553 541

Tool T22 2,884 1500 433 15 Pressure (bar) 70% 968 947 100% 1383 1353 40% 303 296 562 556 541

Tool T23 5,271 1500 791 15 Pressure (bar) 70% 530 518 984 972 946 100% 757 740 1405 1389 1352 40% 189 185 351 347 337 554 554 534 615

Tool T24 8,445 1500 1267 15 Pressure (bar) 70% 331 323 614 607 591 970 970 934 1077 100% 472 462 877 867 844 1385 1385 1334 1538 40% 131 128 243 240 234 384 384 370 426

Tool T25 12,197 1500 1830 12 Pressure (bar) 70% 229 224 425 420 409 671 671 647 746 100% 327 320 607 600 584 959 959 924 1065

Table n 5

14. DISASSEMBLING
1. 2. 3. 4. 5. 6. 7. Respect security instructions C.39 in Appendix F, and C90-C91A-C91B in Appendix C,D if asbestos or ceramic fibers are sealing the flanged assembly. Chock the flanged assembly to be dismantled with wood chocks and/or hoist and sling. Loosen the bolts without removing them, Use flange spreader instead of wedges. Space the flanges, facing the flanged assembly which will be in the direction of the wind (wind in the back), Clean the gasket seating facings (calamine, grease, products, varnish), Inspect the supports, gaskets, stud bolts and line. In the event of an anomaly the PIPE FITTER FOREMAN fills the anomaly report card (Appendix B) which is then transmitted to COMPANY for decision, If necessary, grease the nuts, bolts, stud bolts.

15. IDENTIFICATION AND FOLLOW UP


According to the Quality requirements required by COMPANY, the flanged assembly can be identified by a color code or/and a label. A register will be maintain by Quality Control Manager.

15.1. Color code


A color code can be used to identify: provisional gaskets : none tested final gaskets : RED painting on one bolt on one flange only After this RED marking, no gasket replacement will be possible without approval of COMPANY. in the case of systems for which the leak test is not required, the flange edge is directly painted in red after tightening. If COMPANY found no anomalies after inspection, COMPANY will mark in green the closest bolt (next to the RED marked one) with a GREEN paint.
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The colors being specific to each production site, PIPE FITTER FOREMAN will take care of giving information to the assembling affected personnel on each working site.

15.2. Label
The label ensures the traceability of the executants for each assembly. Labels shall include specific valve / equipment tag numbers, where necessary. It is fixed by a wire to one of the stud bolts and at least includes the following indications: PONTICELLI NIGERIA LTD Executants name Execution date

The figure 2 shows CONTRACTOR label:

PNL
Name : .. Dat

Fig.2

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APPENDIX A: TIGHTENING SEQUENCE: CRISS-CROSS METHOD

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APPENDIX B: ANOMALY REPORT CARD

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APPENDIX C: SECURITY INSTRUCTION C.90

C.90
03/02/98

MEASURES TO BE TAKEN FOR HANDLING MATERIAL CONTAINING FIREPROOF CERAMIC FIBERS

1)

FIELDS OF APPLICATION:

The refractory ceramic fibers (RCF), just as the glass, rock fibers, etc belong to the group of vitreous artificial mineral fibers. They are used for the insulation at high temperature in the following fields: - Industrial furnaces and boilers, - Heat shields, - Expansion gaskets, - Anti fire protection systems and fire wall.

2)

INCURRED RISKS:

The exposure to ceramic fibers can cause momentary irritations of the eyes, skin and respiratory tracts. To date, no other significant effect was observed. Nevertheless, the International Research Cancer Center has classified ceramic fibers as being possible carcinogens on the man after studies undertaken on the animal.

3)

RECOMMENDED METHOD TO LIMIT EXPOSURE:

- Always maintain the level of dust contamination at minimum level, - Use personal protection equipments, - Wear integral safety goggles - Wear mask or standard half-mask P3 type. - Wear clothing with long sleeves or better a disposable combination. - Do not clean personal clothing by blowing on it, - Do not eat or drink at the working station.

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APPENDIX D: SECURITY INSTRUCTION C.91 A & APPENDIX E: SECURITY INSTRUCTION C.91 B

C.91 A
REV.1 APRIL 17, 1997

MEASURES TO BE TAKEN DURING INTERVENTIONS (EXCEPT CAPACITES) ON GASKETS, CORDS OR BRAIDS CONTAINING ASBESTOS.

1)

INCURRED RISKS:

The inhalation of asbestos dust can cause affections of the respiratory tracts of which most serious are: - Asbestose, noncancerous lung disease, - Bronchopulmonary cancer, - Mesothelioma, pleura, pericardium or peritoneum severe tumour.

2)

EQUIPMENT FOR THE PERSONNEL: - Mask or half-mask with P3 filter, - Elastomer Gloves, - Disposable Combination.

3)

PROCESS :

Pulverization of a fixing product - for the braids and cords, - for the gaskets (requiring a scraping by manual tools). Manual removal of the gasket, braids or cord Installation of the element (joined, braid, cord) in an identified plastic bag. Deposit of the bag in an identified dustbin (in charge of client). FOOT-NOTE: Gaskets, cords or braids not identified are to be treated as containing asbestos.

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C.91 B
REV.1 APRIL 17, 1997

MEASURES TO BE TAKEN DURING INTERVENTIONS IN CAPACITES ON CORDS OR BRAIDS CONTAINING OF ASBESTOS.


1) INCURRED RISKS:

The inhalation of asbestos dust can cause affections of the respiratory tracts of which most serious are: - - Asbestose, noncancerous lung disease, - Bronchopulmonary cancer, - Mesothelioma, pleura, pericardium or peritoneum severe tumour.

2)

EQUIPMENT OF THE INTERVENING PERSONNEL: - Mask or half-mask with P3 filter, - Elastomer Gloves, - Disposable combination, - Washable safety boots.

3)

EQUIPMENT OF SUPERVISING PERSONNEL: - Identical to the intervening personnel.

4)

METHOD UTILISEE:

Ground protection by a polyane film, Pulverization of a fixing product on the braid or cord, Manual removal of the braid or cord, Deposit of the element (braid or cord) in an identified plastic bag, During every exit from the capacity, removal of the combination in the protected zone by polyane film and put in a plastic bag, Dispose the polyane film in a plastic bag, Plastic deposit of the bags in an identified dustbin (in charge of the client).

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APPENDIX F: SECURITY INSTRUCTION C.39

C.39
JANUARY 92

DISASSEMBLING OF THE VALVE BONNETS DISASSEMBLING FLANGED VALVES, FLANGES, OR BLIND SPADES ON FLANGES

1) Ask the authorization to your FOREMAN in order to disassemble or receive the order. 2) Before any work begin, a task pack corresponding to the work is required. Start only when this you are authorized to work. 3) Wear the necessary safety material planned for the work, as detailed hereafter: Masks with cartridge, breathing insulating apparatuses, protect faces, glasses, gloves, boots, special clothing, etc. 4) Check that the working station ensures your safety: ground continuity and handrail. If the working environment do not have this continuity, systematically use your tether and your harness of which you must attach your tether. 5) Open the cover of the valve completely so that it is free of air. THEN CARRY OUT DISASSEMBLING 6) Think of what will arrive when the bonnet will be unbolted and fix it to the environment or use lifting equipment if necessary. 7) Choose 2 bolts diametrically opposite fixing the bonnet to the body of valve and unbolt them only partially. 8) Unbolt the other bolts completely. 9) Make oscillate the valve from the body of valve to break the gasket. 10) The gasket being broken and the bonnet dismantled from the body of the valve, you will be able to unbolt the last 2 bolts completely and lift the bonnet with precautions due to its weight. For valve disassembling, apply all the rules above to remove the valve of its FLANGE instead of removing the bonnet from the body of the valve. 11) Place yourself on the wind each time it is possible so that possible emanations move away from you, carried by the wind.
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APPENDIX G: RECOMMEND TORQUES AND TENSIONS FOR FLANGE BOLTING

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APPENDIX H: FLANGE ASSEMBLY CHECK LIST

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FLANGE ASSEMBLY CHECK LIST


PipingArea: TestPackNumber: TorquingDeviceref.: IsometricNumber Flange Number Project:OML58UpgPh1OBAGISite PipingClass: ReportNumber: BOLTDiam Torque Value TighteningComplete (inches) (N.m)

SEQUENCE CONFORM SHORTWRENCHTIGHTENING STAGE1:50%FINALTORQUEVALUE STAGE2:FINALTORQUEVALUE BLOCKING(nofurtherrotation) TIGHTENINGCOMPLETE Others ReferenceAcceptableTable


DIA BOLT (inches) DIA BOLT ISO NUT SIZE (mm) Tension F kN

COMMENTS

Torque value f = 0.07 N.m

Torque value f = 0.13 N.m

0,5 0,625 0,75 0,875 1 1,125 1,25 1,375 1,5 1,625 1,875 2 2,5
Name : Date : Signature :

M14 M16 M20 M24 M27 M30 M33 M36 M39 M42 M48 M52 M64

21 24 30 36 41 46 50 55 60 65 75 80 95

33 52 78 107 141 184 232 288 346 412 561 644 1032

48 92 160 253 376 540 745 996 1297 1653 2549 3097 6068

80 155 270 429 639 925 1285 1727 2261 2894 4493 5476 10828

SPD CST

SPD QAQC

CLIENT

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APPENDIX I: BOLT MARKING FOR BOLT TENSIONING

The 5 groups are marked respecting criss cross method from Appendix A: for 4 tensionners, group A is number 1 to 4, B is 5 to 8,

12 BOLTS FLANGE 2 TENSIONNERS

. The 6 groups are marked respecting criss cross method from Appendix A: for 2 tensionners, group A is number 1 and 2, B is 3 and 4, ...

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APPENDIX J: BOLT TENSIONING CHECKLIST

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APPENDIX K: BOLT TENSIONING TOOLS

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