014-MS For Bolt Tightening (Piping& Equipments).pdf

Pearl GTL Project Shell Project No: HP-3000-QAT Project Document Number: T- 4.250.955

Purchase Order Number:

2MH127

Tag/Item Number(s):

N/A

LINDE ENGINEERING

Contractor Project No: 5887

Project Rev.: A

Page 2 of 21

QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION

E

A

30.06.08

Ready for Constructions

BS

EO

AG

RFC

D

A

19.06.08

Ready for Constructions

FB

EO

AG

RFC

C

O

15.04. 08

Issued for Company comments

BR

UA

ZG

ICC

B

08.04.08

Issued for Review

BR

UA

ZG

IFR

A

06.04.08

Issued for Internal Review

BR

UA

ZG

IIR

Date

Description

GAMA Rev.

Project Rev

No.

No.

Prepared Checked Approved By By By ORIGINATOR ORIGINATOR

Status

Q A A T A A R

Doc. Title

:

Date

:

GAM-MTS-MEC-GTL-014 METHOD STATEMENT FOR BOLT TIGHTENING (PIPING & EQUIPMENTS)

30.06.2008 Rev-E

1.

TABLE OF CONTENTS PURPOSE PUR POSE _____________________ _________________________________ _______________________ ______________________ _______________________ ______________ __ 5

2.

SCOPE ______________________ __________________________________ _______________________ ______________________ _______________________ ________________ ____ 5

3.

H SSE SSE ______________________ _________________________________ ______________________ ______________________ _______________________ __________________ ______ 5

4.

REF RE F ERE N CES _____________________ ________________________________ ______________________ ______________________ ______________________ ___________ 5

5.

D EF I NI TI ONS ON S _____________ ________________________ _______________________ _______________________ ______________________ __________________ _______ 6

6.

EQUI EQ UI PM EN TS _____________________ ________________________________ ______________________ ______________________ ______________________ ___________ 6

7.

M AN POWE R _____________________ _________________________________ _______________________ ______________________ ______________________ ____________ _ 6

8.

RESP RE SPON ONSI SIBI BI L I TY ______________________ _________________________________ ______________________ ______________________ __________________ _______ 7

8.1.

SITE MANAGER ____________________________________________________________ __________________________________________________________________7 ______7

8.2. 8.3.

CONSTRUCTION CONSTRUCTION MANAGER _______________________________ ______________________________________________________7 _______________________7 EQUIPMENT MANAGER __________________________________________________________7

8.4.

SITE ENGINEER ____________________________________________ __________________________________________________________________7 ______________________7

8.5.

SITE SUPERVISOR _____________________________ _______________________________________________________________7 __________________________________7

8.6.

CREW LEADER/FOREMAN LEADER/FOREMAN __________________________________ _______________________________________________________7 _____________________7

8.7. 8.8.

STEEL ERECTOR_______________ ERECTOR________________________________________________ __________________________________________________7 _________________7 QC ENGINEER __________________________________ ___________________________________________________________________7 _________________________________7

8.9.

QC INSPECTOR _________________________________ __________________________________________________________________7 _________________________________7

8.10.

HSSE MANAGER _______________________________________________________________8 _______________________________________________________________8

8.11.

HSSE OFFICER ___________________________________________ _________________________________________________________________8 ______________________8

Q A A T A A R

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Date

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30.06.2008 Rev-E

1. PURPOSE The purpose of this method statement is to clarify the tightening & torque of high, ordinary strength bolts and inspection works at the Qatar Shell GTL Pearl Project by GAMA Qatar located inside the Ras Laffan Industrial City in Qatar.

2. SCOPE This method statement identifies the basic structure of the Tightening & torque of high, ordinary strength bolts works used for the successful completion of the Piping & Equipments works, by using the FSI Procedure stage by stages will be followed.

3. HSSE All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan Industrial City and International standards, codes, LINDE ENGINEERING AG and QSGTL and/or its PMC requirements and instructions. In addition all employees and GAMA subcontractor employees on site will have thorough QSGTL site safety induction, LINDE ENGINEERING AG Site Safety Induction and GAMA Qatar Safety induction for site safety, health, environmental and security prior to work activities. Other training courses will be attended as required by LINDE ENGINEERING AG or QSGTL and/or its PMC as required.

Q A A T A A R

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30.06.2008 Rev-E

DEP 31.38.01.11

:

T.4.096.689

:

Piping General Requirements (AmendmentsT.13.376.815E) Flange Tightening

T-13.377.454

:

Preservation of Old & New Equipment Standing Idle

T-4.250.930

:

QA/QC Procedure for Cleanliness

T-4.250.906

:

MS – MS – for for Piping Cleanliness

5. DEFINITIONS Company

: QSGTL/or its PMC

Contractor

: LINDE ENGINEERING AG

Sub Contractor

: GAMA QATAR

Contract

: QSGTL Pearl Plant - C2 ASU Project

ITP

: Inspection and Test Plan

QCP

: Quality Control Procedure

Q A A T A A R

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Date

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30.06.2008 Rev-E

8. RESPONSIBILITY 8.1.

SITE MANAGER

The site manager will provide inputs to the project execution plan to ensure that job strategies & philosophy are addressed.

8.2.

CONSTRUCTION MANAGER

The construction manager is responsible for the overall management of the project construction team to ensure that safe and effective operations are conducted and properly documented.

8.3.

EQUIPMENT MANAGER

The equipment manager will be responsible for the transporting equipments availability and good order.

8.4.

SITE ENGINEER

Shall report to Construction Manager Shall be responsible for planning, execution and implementation of all site activities related to this procedure Shall train the Bolt Tightening persons & assign them a unique number with a similar manner to the welder numbers, Bolt tightener certificates shall be issued and certificates will bear this number.

8.5.

SITE SUPERVISOR

Q A A T A A R

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30.06.2008 Rev-E

8.10. HSSE MANAGER Shall report to Project Manager and shall be responsible for over all control and Inspection of HSSE issues.

8.11. HSSE OFFICER Shall report to HSSE Manager Shall be responsible for monitoring monitoring all all safety aspects for this procedure.

8.12. BOLT TIGHTENER All the bolt tightening persons are to be trained and certified. They should have Knowledge about FSI.

9. PROJECT REQUIREMENTS This method statements deals with tightening of bolt for various type of bolts used in Flanges of vessel Piping and piping connection to rotary/static equipments Flanges of Equipment Piping & Flange connection

9.1.

MATERIAL:

Q A A T A A R

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30.06.2008 Rev-E

The gaskets gaskets are then to be centred between the flanges. flanges. Nuts shall be hand tightened to hold the gasket in place. When flanged joints are in horizontal lines gaskets without centring devices such as ring joints, shall be lowered to the bolts for retention and then raised into position. The remaining bolts and nuts shall be installed and hand tightened with the flange faces parallel. Care should be taken to assure proper seating and centring of the gasket within the allowable tolerances. Bolts shall be tightened by wrench and inspected for tightness in accordance with Sec 11. Stud bolts should have an equal protrusion through the nuts on both sides of the flanges of between 1 and 3 threads.

10.2. TORQUE WRENCHES Torque wrenches shall be calibrated as per calibration schedule schedule and have a valid certificate that must be revalidated after the wrench has been inspected and recalibrated on a monthly basis. A validation sticker confirming inspection and last date of calibration shall be attached to the torque wrench at all times. There are various types of tools available to achieve the proper torque value. The manufacturer's instructions shall be followed for the operation and maintenance of all Torque wrenches used to perform tightening procedure.

Q A A T A A R

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30.06.2008 Rev-E

Where applicable, applicable, any spectacle blind blind in the joint has been inspected to confirm that it is undamaged (no burrs or scratches on the gasket contact surface), and that the closed portion is coated with approved preservation material and a physical means of protection such as a timber cover. Temporary gaskets have been installed correctly rated to meet the expected test pressures.

11. JOINT TIGHTENING PROCEDURE The assembly drawings will indicate the bolt length, diameter and material type plus the gasket type and rating. Flange faces shall be thoroughly cleaned using a SHELL or its PMC approved solvent to remove preservatives and the gasket surfaces shall be inspected for defects. Any rust or burrs shall be removed using a hand wire brush and/or a hand file. Particular attention attention shall be paid paid to seating surfaces surfaces for ring type joints. (Appendix 1 includes acceptance criteria for flange imperfections) Bolts shall be checked for correct length, diameter and conformance with material specification. Except for those is oxygen service, all bolts will be coated with a SHELL or its PMC approved lubricant that shall be suitable for the expected temperatures and materials. NOTE: Once approved, a single lubricant type for each material (if necessary) shall be specified by LINDE for use by GAMA.

Q A A T A A R

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30.06.2008 Rev-E

Care shall be taken to prevent over-tightening one side of the flange and result in gasket crushing or flange distortion. Uniform Gap between flanges to be maintained before tightening begins. begins. Thereafter, two diametrically opposite bolts located 90° further round the circumference shall be tightened, again being careful not to distort the flanges. This procedure shall be repeated until all bolts have been tightened once. This sequence of tightening pairs of bolts is to be applied irrespective of whether the tightening is by torque or hand wrench/spanner. Once all the bolts in the flange have been initially tightened, the diametric tightening process shall be repeated starting at the first bolt pair. For flanges that are tightened with hand wrenches/spanners, the subsequent tightening should take them to a tightness where the bolts are uniformly tight and the gasket evenly compressed with the flange faces parallel. For torque wrench tightening, the bolts shall be tightened in wrench torque value steps that tighten the bolts to 80% then 100% of the bolt stress. stress. When performing the last two tightening sequences of all flange diameters, the pipe surface temperature is to be less that 40°C 40 °C.. This is to minimize stress relaxation relaxation in the bolts due to the high temperature gradients. Figure-1 for

flanges.

Q A A T A A R

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30.06.2008 Rev-E

13. TORQUE VALUES GAMA shall develop a table for each type of bolt specified for the project that indicates for every bolt size, the required torque value for each of the tightening steps. A typical torque table is shown below. When completed the tables shall be reduced r educed to pocket-size and issued to all pipe fitters, foremen and inspectors in a laminated format. WRENCH TORQUE VALUES (Sample Table)

TARGET TORQUE (N-m) Bolt Size (mm)

Initial Step (50% bolt stress)

Intermediate Step (80% bolt stress)

Final Step (100% bolt stress)

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30.06.2008 Rev-E

15. SUMMARY OF BOLTING TORQUES Table – 1 B8M BOLTS (CLASS 1) Lubr’d Bolts( u = 0.1) Torque Torque (N-m) (ft-lb)

Dry Bolts (u = 0.2) Torque Torque (N-m) (ft-lb)

35

25

44

Bolt Size (Inch) ½

Diameter (mm) 12.7

Bolt Load (KN) 12

Yield (Mpa)

%Yield

32

Bolt Stress (Mpa) 166

205

81%

5/8

15.9

21

70

50

90

66

159

205

77%

¾

19.1

32

125

90

164

121

159

205

77%

7/8

22.2

42

185

135

249

183

146

205

71%

1

25.4

58

280

205

381

281

146

205

71%

1-1/8

28.6

76

410

300

562

414

148

205

72%

1-1/4

31.8

98

580

425

800

590

151

205

74%

1-3/8

35.0

120

770

565

1069

789

149

205

73%

1-1/2

38.1

145

1005 1 005

740

1406

1037

150

205 20 5

73%

1-5/8

41.3

176

1300 1 300

960

1831

1351

152

205 20 5

74%

1-3/4

44.5

205

1630

1200

2296

1694

152

205

74%

Q A A T A A R

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30.06.2008 Rev-E

Table – 2 B8 B8M Bolts (Class 2) B8T Bolts (Class 2) Lubr’d Bolts (u= 0.1)

Dry Bolts (u= 0.2)

Torque (N-m)

Torque (ft-lb)

Torque (N-m)

Torque (ft-lb)

60

44

105

Bolt Size (Inch) ½

Diameter (mm) 12.7

Bolt Load (KN) 30

Yield (Mpa)

%Yield

77


690

58%

5/8

15.9

54

130

96

233

172

412

550

75%

¾

19.1

72

200

148

364

258

353

550

64%

7/8

22.2

110

350

258

644

475

379

550

69%

1

25.4

146

520

384

966

713

370

550

67%

1-1/8

28.6

162

640

472

1198

883

316

450

70%

1-1/4

31.8

199

860

634

1619

1194

306

450

68%

1-3/8

35.0

212

1000

738

1893

1396

264

345

77%

1-1/2

38.1

236

1200

885

2281

1682

244

345

71%

1-5/8

41.3

274

1500

1106

2861

2110

238

205

116%

1-3/4

44.5

316

1850

1364

3540

2611

234

205

114%

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30.06.2008 Rev-E

Table – 3 B7 & L7 Bolts Lubr’d Bolts (u = 0.1) Torque Torque (N-m) (ft-lb)

Dry Bolts (u= 0.2) Torque Torque (N-m) (ft-lb)

80

59

140

Bolt Size (Inch) ½

Diameter (mm) 12.7

Bolt Load (KN) 39

Yield (Mpa)

% Yield

103


720

74%

5/8

15.9

58

140

103

251

185

444

720

62%

¾

19.1 19. 1

107

300

221

546

403

529

720

73%

7/8

22.2

138

440

325

810

597

476

720

66%

1

25.4

177

630

465

1270

863

448

720

62%

1-1/8

28.6

218

860

634

1610

1187

424

720

59%

1-1/4

31.8

278

1200

885

2260

1667

427

720

59%

1-3/8

35.0

318

1500

1106

2839

2094

396

720

55%

1-1/2

38.1

374

1900

1401

3611

2663

386

720

54%

1-5/8

41.3

439

2400

1770

4578

3376

381

720

53%

1-3/4

44.5

513

3000

2213

5741

4234

380

720

53%

1-7/8

47.6

610

3800

2803

7292

5378

390

720

54%

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30.06.2008 Rev-E

16. QUALITY ASSURANCE The QA/QC management system for controlling the integrity of the joint shall be developed in detail during the activities, but shall include the following elements: ALL joints shall be signed off by a qualified qualified pipe fitter and checked checked by Inspectors. Bolt torque tightening tightening shall be applied to all bolts ≥ ¾” diameter . Recording of joint inspections and tightening will be kept for selected critical Services (oxygen, hydrogen, severe cyclic conditions, cryogenic, vacuum, Very toxic substances, high temperature [>350°C], high pressure), A helium test to be carried out for “super -critical” services, i.e. critical and can cause harm to people or the plant, eg very toxic service. A Quality Assurance System shall be operated conforming to related standards. Controls and checks shall be established and documented through relevant GAMQCR-QAC-GTL-041.

17. ATTACHMENTS 17.1. BOLT TIGHTENING INSPECTION REPORT

C2 ASU PEARL GTL PROJECT RASLA FFAN INDUSTRIAL INDUSTRIAL CITY

BOLT TIGHTENING INSPECTION REPORT

Subcontract Ref.:

Report No.:

Item Description:

Inspection Date:

Item Location / Area:

Test Code No.:

Subsystem:

ITP No.:

Ref. DWG / Docs: Used Measuring and test equipment ref. (if applicable): INSPECTIONS

Item No/Spool No

Mark No./Joint No

Bolting Grade

Size

Bolt Tightening (Torque Value)

Inspector’s Signature

C2 ASU PEARL GTL PROJECT RASLA FFAN INDUSTRIAL INDUSTRIAL CITY

FLANGE ALIGNMENT INSPECTION REPORT

Subcontract Ref.:

Report No.:

Item Description:

Inspection Date:

Item Location / Area:

Test Code No.:

Subsystem:

ITP No.:

Ref. DWG / Docs: Used Measuring and test equipment ref. (if applicable): INSPECTIONS

Item No/Spool No

Mark No./Joint No

Face Distance

Face parallelism

Centreline offset

Inspector’s Signature

Q Q A A T T A A R R

JOB SAFETY ANALYSIS / RISK ASSESSMENT

JSA Number: T.4.250.955

NEW

Page No: 1 of 3

REVISED

Job being analysed: METHOD STATEMENT FOR BOLT TIGHTENING (PIPING&EQUIPMENTS) Department/Section Department/Section doing JSA: HSSE & Mechanical Works JSA Members:Mr. Members:Mr. Syd Osborne, Mr. Ali E. TURKER Job Performers:Mr. Performers: Mr. Ali E. TURKER General job requirements / Common Normal Approvals: Name Signature Date Personnal Protective Equipment. JSA by: Mr. Atila Gtn, 18.03.08 Job Supervisor:

Muslim Topalogu

18.03.08

Additional Approvals (Determined (Determined by Job Supervisor Supervisor in correlation correlation with LINDE HSSE Manager). Manager). Name Signature Discipline Superindent (LINDE) HSSE Representative (LINDE) OTHERS(List Below):

Date

1. The following Personal Protective Equipment shall be worn while tightening & torqueing bolts in structural steel members: Approved coveralls, coveralls, safety safety glasses, glasses, safety helmet, safety shoes, safety gloves & safety harness. 2.Permit To Work.

Approval required for hazardous work detailed in the LINDE work permit procedure. Changing conditions and emergency procedures Stop work. Switch of equipment.Supervisor directs personnel to nearest and safest muster point considering wind direction. Supervisor counts all employees. Missing employees are reported reported to LINDE HSSE Dept. When all clear is given check with LINDE HSSE before returning to work. work. LINDE NDE EMER EME RGE GENC NCY Y TELEP ELEPHO HONE NE NO. NO.

H HS SSE SE MANA MANAGE GER R PEARL HOT LINE:

506 41 20 474 88 88

Note: 1) If any of the tasks i nvolves biological, physical or chemical hazards, then The LINDE Industrial Hygienist must also approve the work. 2) Use additional sheets as necessary. 3) Details on on safety (PPE,Hazard etc) and environmental requirements requirements can be found in LINDE and and SHELL Safety and and Environment Environment Procedures. Procedures.

JOB SAFETY ANALYSIS / RISK ASSESSMENT T.4.250.955

Q A A T A A R

SCOPE : METHOD STATEMENT FOR BOLT TIGHTENING(PIPING & EQUIPMENTS)

Initial Risk ITEM ACTIVITY

1

Bolts tightening for Piping and Flanges

HAZARD / POTENTIAL CONSEQUENCES 1.1

1.2

1.3

2

Bolts torqueing final 2.1 tightening after erection of structural steel members and Flanges

P

C

Hand and finger injury. B

2

B

2

B

2

Pinch point.

Improper use of tool.

ADDITIONAL CONTROLS

P

C

A

3

R

1.1.1 Do not use wrenches if the jaws are sprung. 1.1.2 Do not use tools with loose, LOW cracked, splintered. 1.1.3 Ensure all bolt holes shall be aligned during insertion of bo lts. 1.2.1 Ensure that all hand tools are in good condition. 1.2.2 Ensure qualified/ competent employee to carry out the task. LOW 1.2.3 Use the right tools for the job. 1.2.4 Keep away hand & finger from any pinch point hazard. 1.3.1 All tools shall be inspected & colour coded with the approved by LINDE. 1.3.2 Use the right tool for the job. 1.3.3 Operate tools according to manufacturers instruction. LOW 1.3.4 Use appropriate personnel protective equipment. 1.3.5 Perform maintenance on tools regularly. 1.3.6 Cheater bar are not allowed use as an e xtension for tightening bolts.

Falls of materials & tools.

B

Residual Risk

CURRENT CONTROLS

RISK RANK

2.1.1 2.1.1

Install Install barricade barricades s "exclusion "exclusion zone" 2.1.1.1 2.1.1.1 and secure the area with sign boards to prevent unauthorized entry.

2.1.2 2.1.2

All materi materials als shall be safety safety lowered from one level to the next either by hand-to-hand or by securily attaching a rope and hauling. Tools shall shall be be tied by a retai retaining ning rope attached to the harness.

3 LOW

2.1.3 2.1.3 2.1.4 2.1.4

Ensure Ensure to provide provide safety safety nets,toe boards.

LOW

Provide de adequate adequate working ng platforms

2

SCOPE : METHOD STATEMENT FOR BOLT TIGHTENING(PIPING & EQUIPMENTS)

JOB SAFETY ANALYSIS / RISK ASSESSMENT T.4.250.955

Q A A T A A R

Initial Risk ITEM ACTIVITY

HAZARD / POTENTIAL CONSEQUENCES 2.2

P

C

Residual Risk

CURRENT CONTROLS

RISK RANK

Fall of working personnel at height.

2.2.1

2.2.2 2.2.2

2.2.3 2.2.3 B

4

MED

2.2.4 2.2.4

2.2.5 2.2.5

2.3

Wind hazards.

2.3.1 2.3.1

B

2

LOW 2.3.2 2.3.2

Ensure all materials, tools,and equipment are kept secure at all times. Install Install lifting fting apparatuses apparatuses such as gin wheel and hoisting rope for lifting ng pieces of materials. Full body harness harness and and lanyards lanyards shall be inspected. All employees employees shall shall wear wear inspected full body harness fitted with twin lanyards with shock absorbers, each lanyard shall be fitted with dual action self-locking safety hook to a llow for 100% Tieoff. Ensure Ensure housekeepi housekeeping ng is done regularly to maintain walkway free of hazards. Monitor Monitor wind wind speed speed using ng Anemometer. Crane operations ons should be stopped if wind speed exceeds 25 knots or as stipulated by crane manufacturer, which ever is lower. Employees Employees should should be be aware aware of the the affect of weather conditions on the operation.

ADDITIONAL CONTROLS 2.2.1.1 2.2.1.2 2.2.1.3

P

C

R

A

4

LOW

Ensure 100% fall protection. Ensure that all employees working at height are properly trained. Discuss working at height hazards at daily TSTI.

3

014-MS For Bolt Tightening (Piping& Equipments).pdf

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