Total Flange Assurance (TFA) Trai ainnin for C Technic icia iann & Foreman 20 March 2012
2/28/2013
Topics covered 1) Purpose & goal TFA 2) Roles & Responsibilities 3) TFA Specification and Procedure 3) Bolt UT - Why Bolt UT? - Pr Prin incip ciple less of of Bol Boltt UT - Bo Boltlt UT ma mach chin inee - o t step- y-step - GM GMAX AX So Softftwa ware re Theory Test 4) Practical Practical Training Session Practical Test
Why TFA? – Purpose & Goals SHELL:
No leaks! No fire, no injury, no shutdowns, no pollution
Contractor:
No rework! More incentives No injury ess sco ng More time to do other things
TFA Procedure Procedure Work Process - Differences Roles and Responsibilities:
Authorized Foreman Foreman
QC Technician
SEPL TFA Inspector
TFA Organisation ZONE 1 FITTER
ZONE 2 / 3 / 4
FITTER
FITTER
FITTER
TFA TF A Authorize Authorizedd
TFA Authorized FOREMAN
FITTER
TFA TF A Authori Authorized zed
SEAL
TFA Executing Engineer
FITTER
TFA QC TECHNICIAN TFA Executing Engineer
SEAL
Definition
TFA TF A v5 Sc Scop ope e - Pi Pipi ping ng
Critical Service
Bolt Joints in following operating condition to be identified i dentified as a critical bolt Joints • Highl Highlyy hazardous hazardous chemical chemical service as defined defined in CFR 1910.119 1910.119 (OSHA (OSHA PSM PSM rule), • Lethal Service as defined defined in in the ASME Section Section VIII VIII Divisio Divisions ns 1 and 2 Codes Codes • Categ Category ory M Fluid Fluid Service Service as defi defined ned in in ASME ASME B31.3. B31.3. • Hydrog Hydrogen en Service above above 316 deg. C (600 (600 F), class class 600, size 10” 10” and greate greater r • Hy rocar on or So Souur Se Serv rviice 316 eg. C 600 F , c ass 900, si sizze 8” an greater • Hydroc Hydrocarbon arbon or Sour Sour Service 316 deg. deg. C (600 F), class class 1500, size size 6” and greater greater • Hydroc Hydrocarbon arbon or Sour Sour Service 316 deg. deg. C (600 F), class class 2500, size size 4” and greater greater • Joint Jointss subjec subjected ted to cyclic temp temperatu erature re
Definition (cont.) Standard Flanges • • •
Flanges that fo follow B1 B16.5 (flanges ≤24”) Flan Fl ange gess tha thatt fol follo low w B16 B16.4 .47 7 (f (fla lang nges es >2 >24” 4”)) Se Seri ries es A or or B Temperature at bolts <450°C Note: Temperature Temperature at bolts are typically >20% lower than process temperature unless flange is insulated
Non-standard Flanges • •
Fla lang nges es th thaat DO DO NOT NOT co conf nfoorm to B16 B16.5 .5 or B1 B16. 6.47 47 Temperature at bolts > 450°C
Selection of Bolt Tightening Method and QC Scope Flange Size
15 0 #
3 00#
60 0#
900 #
1 5 0 0#
2 5 0 0#
½” ¾” 1” 1 ½”
1
2” 3” 4” 6” 8” 10” 12”
2
14” 16” 18” 20” 24” 26”
4
28” 30” 32” 36” 40” 42” 48” 60”
3
Selection of Bolt Tightening Method and QC Scope (cont.) Zone
Rating
1.1
Dn < 20“, 150#
1
Service
Method
All Services
Torquing
Visual, Toque Sampling
Water, Compressed air , Steam, Nitrogen
Flogging
Visual, Spanner Sampling
Torquing
Visual, Toque Sampling
Torquing
Bolt-UT, 3 samples
1.2
Dn <12“, 300#
All Services
1.3
Dn < 6“, 600#
All Services
2.1
Dn ≥ 20“, 150#
2.2
10 < Dn < 36, 30 300#
2.3
4 < Dn < 26, 60 600#
All Services All Services, except critical
Dn <20“, 900#
3
Bolt-UT, 6 samples Bolt-UT, 3 samples Torquing
6 < Dn < 20, 900#
Critical services
2.5
Dn <6“, 1500# Dn <4“, 2500#
All Services, except critical
Torquing
2.6
All Services,
2-wrench Torquing
Critical se services
Tensioning
All Services, except critical
2-wrench Torquing
Critical se services
Tensioning
All Services, except critical
2-wrench Torquing
Critical se services
Tensioning
All Services
Tensioning
3.1
3.2
3.3
Authorized Foreman
Bolt-UT, 3 samples
All Services,
2.4
Sealed by
Torquing
Critical services 2
QC Scope
Dn > 32“, 300#
Dn > 24“, 600#
Dn >18“, 900#
4.1
Dn > 4“, 1500#
4.2
Dn > 3“, 2500#
4
Bolt-UT, 6 samples
Bolt-UT, 3 samples QC Technician
Bolt-UT, 6 samples
Flang e Size
15 0#
3 0 0#
600#
9 00 #
150 0#
250 0#
½” ¾” 1”
TFA Zone 1 Manual Tightening
1 ½”
1
2” 3” 4” 6” 8” 10”
2
12” 14” 16” 18” 20” 24”
4
26” 28” 30” 32”
3
36” 40” 42” 48” 60”
2 Fitters
2 Fitters
2 Fitters
2 Fitters
TFA Foremen
Seal
Seal
2 Fitters
2 Fitters
2 Fitters
TFA Foremen
Seal
Seal
Seal
2 Fitters
2 Fitters
TFA Foremen
Seal
Seal
Seal
Seal
Flang e Size
15 0#
3 0 0#
600#
9 00 #
150 0#
250 0#
½” ¾” 1”
TFA Zone 2
Tighteningg with Driven Wrenches Tightenin
1 ½”
1
2” 3” 4” 6” 8” 10”
2
12” 14” 16” 18” 20” 24”
4
26” 28” 30” 32”
3
36” 40” 42” 48” 60”
2 Fitters
2 Fitters
2 Fitters Seal
TFA Foremen
QC Technician
Seal
Seal
Bolt-UT database
Flang e Size
15 0#
3 0 0#
600#
9 00 #
150 0#
250 0#
½” ¾” 1”
TFA Zone 3
Tightening Tighteni ng with Driven Wrenches
1
1 ½” 2” 3” 4” 6” 8” 10”
2
12” 14” 16” 18” 20” 24”
4
26” 28” 30” 32”
3
36” 40” 42” 48” 60”
2 Fitters
2 Fitters
2 Fitters Seal
TFA Foremen
QC Technician
Seal
Seal
Bolt-UT database
Flang e Size
15 0#
3 0 0#
600#
9 00 #
150 0#
250 0#
½” ¾” 1”
TFA Zone 4
1
1 ½”
Bolt Tensioning
2” 3” 4” 6” 8” 10”
2
12” 14” 16” 18” 20” 24”
4
26” 28” 30” 32”
3
36” 40” 42” 48” 60”
Bolt-tensioning Crew
Bolt-UT database TFA Foremen
Special Services Provider
QC Technician
Seal
F.L.A.N.G.E. Every flange needs to be visually checked for:
Faces – No damage, no scratches, clean L ubricant ubricant – Suffici Sufficient ent Molykote Molykote 1000 on threads threads and nut faces faces A lignment lignment – Parallelism and OD alignment to spec uts o ts – Not corroded, cleaned, min. 2 threads protruding Gasket – Correct size, rating, material, not damaged Enough Bolt Load – Using QC method to determine adequate bolt tightness
Tightening Method Flogging Only for Zone 1: Utilities – Air Air,, Water Water,, N2, Steam Torquing For flanges in Zone 1 and Zone 2 Double Torquing Torquing (2 - Torque wrenches concurrently) concurrently) Tensioning For flanges in Zone 3: Critical and Zone 4 : All Service
QC Method Visual, spanner (By Authorized Authorized FOREMAN) FOREMAN) Visually check for F.L.A.N.G.E. F.L.A.N.G.E. Use spanner/hammer to test bolt tightness Only for Zone 1: Utilities – Air Air,, Water Water,, N2, Steam Torque wrench (By Authorized FOREMAN) Visually check for F.L.A.N.G.E. F.L.A.N.G.E. Use torque wrench (set at 90% of torque value) to check tightness Onll fo On forr Zo Zone ne 1 Al Alll se servic rvicee ex exce ce t Ut Utililititie iess Bolt UT, UT, 3 samples sa mples (By QC Techinici Techinician) an) Visually check for F.L.A.N.G.E. F.L.A.N.G.E. Reference reading : 3 bolts; Final Reading : 3 bolts for QC check For Zone 2 Non-Critical services Bolt UT, 6 Samples (By QC Techinician) Visually check for F.L.A.N.G.E. F.L.A.N.G.E. Reference reading : 6 bolts; Final Reading : 6 bolts for QC check For Zone 2 Critical services; Zone 3 & 4 : All Service
TFA Tagging &1-seal Approach #1
ZONE
#2/3/4
TFA 1-seal 1-seal approach
TFA 1-seal 1-seal approach
1 Seal Authorized TFA Foreman
Authorized TFA Foreman – execution under
-Execution -Responsible for the joint
1 Seal QC Technician – has proper tech to check for proper execution
SEPL TFA Inspector
SEPL TFA Inspector
– sign-off EQCC to accept
– sign-off EQCC to accept
TFA Roles and Responsibilit Responsibilities ies Fitter
(contractor)
Works W orks hand-in-hand hand-in-hand with TFA TFA Authorized Foreman Foreman ☞ Safely Break the Flange Joint ☞ Clean up the flange and prepare for inspection
, Flange and hand tighten tighten nuts ☞ Align Flange ☞ Prepare Bolts for Reference Reading ☞ Execute Flange tightening as instructed by Authorized Foreman
TFA Roles and Responsibilit Responsibilities ies Authorised TF TFA A Foreman (AF)
(contractor)
Works W orks hand-in-hand hand-in-hand with QC Technician Technician & Fitter Supervise saf safee brea breakin kingg of Fla Flange nge Joi Joint nt ☞ Supervise Inspec pectt Fla Flang ngee Faces Faces (rep (report ort defe defects cts to QCT) QCT) ☞ Ins Check ck Lubric Lubrication ation of Nuts Nuts and and Bolts Bolts ☞ Che Ensure ure fla flange nge face face checke checkedd ☞ Ens asse sed d ☞ QC Check and Apply SEAL for Zone 1 Flanges - QC pas
Flangee tightenin tighteningg as per given given spec Zone 2, 3 and 4 ☞ Execute Flang flanges for Zone 2 , 3 and 4 ☞ Assist QCT for QC check of flanges
TFA Roles and Responsibilit Responsibilities ies Authorised QC Technician Technician (QCT) (QCT)
(contractor)
Works W orks hand-in-hand hand-in-hand with TFA TFA Foremen
1:3 QCT vs. TFA Crew ratio
Ensure Ens ure fla flange nge face face check checked ed re
oremen on g ten ng scope an
scope
Ensure F.L.A. .L.A.N.G. N.G.E. E. check checked ed Take Bolt UT Referen Reference ce Reading Reading Re-set Reset tor torque que val value ue on the the 3rd pass based on 4 bolts Measure Measu re fina finall stress stress value value readin readingg Seall fla Sea flange nge (Zon (Zonee 2, 3 and and 4) – QC passed
TFA Roles and Responsibilit ies ies
SEPL TFA inspector
Project Engineer / Maintenance Engineer / Executing Engineer / Work Pack Leader
☞ Maintain Log of Off-spec flanges epor or -spe -s pecc an ange gess o eerr ng ea ee eam m ☞ ep Maintenance Manager / Construction Manager ☞ Organize execution of Discovery works ☞ Sign-off EQCC’s following Equipment handover protocol
Work Process : Zone 1 1. 2. 3. 4. 5. 6. 7. 8. 9.
Check flange faces Lubricate nuts an and bolts Check correct gasket – install Inst staall nuts and bolts – hand tight (max 15% of studs to hold flange) Tightening – 1st pass Tightening – 2nd pass Tightening – 3rd pass Tightening – Final pass QC – Seal flange
AF AF AF AF AF AF AF AF AF
Work W ork Process : Zone 2 & Zone 3 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.. 10 11.. 11 12.
Check flange faces Lubricate nuts an and bolts Check correct gasket – install Inst staall nuts and bolts – hand tight (max 15% of studs to hold flange) Prep Pr epar aree bol boltt end endss for for Bol Boltt UT UT – sa sand ndpa pape per/ r/ fililin ing: g: 3 / 6 bol bolts ts QC – Re Reffere renc ncee meas asur ureement (3 / 6 Bol olts ts)) Tightening – 1st pass Tightening – 2nd pass Tightening – 3rd pass Tigh ghtten eniing – Fin inaal pa pass QC – Ch Chec eckk appl applie ied d loa load d @ 3 / 6 bolt boltss QC – Seal flange
AF AF AF AF AF QCT AF AF AF AF QCT QCT
Work W ork Process : Zone 4 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Check flange faces Lubricate nuts an and bolts Check correct gasket – install Inst staall nuts and bolts – hand tight (max 15% of studs to hold flange) Prep Pr epar aree bol boltt end endss for for Bol Boltt UT UT – sa sand ndpa pape per/ r/ fililin ing: g: 6 bolt boltss QC – Reference me meas asuurement (6 (6 Bo Bolts) Tightening – for all Odd Studs Tightening – for all EVEN Studs QC – Check ap applied load @ 6 bolts QC – Seal flange
AF AF AF AF AF QCT AF AF QCT QCT
TFA TF A Bolt Boltstre stress ss Ultr Ultrason asonics ics What is Ultrasonics?
• • •
Usingg ult Usin ultra raso soun undd (s (sou ound nd ab abov ovee the the ra rang ngee of of hum human an he heari aring ng)) to measure distances – Ultr traasonics: 1,000, 0,0 000 - 5,000,000Hz (5 (5M Mhz) Ultrasound
Sound
Infrasound 20Hz
20,000Hz
TFA TF A Bolt Boltstre stress ss Ultr Ultrason asonics ics What is Bolt Ultrasonics?
• • •
Usingg ult Usin ultra raso soni nics cs to me meas asur uree the the le leng ngth th of bo boltltss in in a very very acc accur urat atee way Can me measure a ma maximum di distance of of 1. 1.5m
TFA TF A Bolt Boltstre stress ss Ultr Ultrason asonics ics Why do we use Bolt Bolt Ultrasonics?
• • •
By ta taki king ng a “re “refe fere renc nce” e” va valu luee of of the the bo boltlt le leng ngth th bef befor oree the the bo boltlt is tightened “ ” tightened Thee two Th two rea readi ding ngss can can be co comp mpar ared ed to de dete termi rmine ne “e “elo long ngat atio ion” n” of the bolt
Bolt before tightening “Reference” measurement Bolt after tightening “Final” measurement
elongation
TFA TF A Bolt Boltstre stress ss Ultr Ultrason asonics ics Why do we use Bolt Bolt Ultrasonics?
• •
A bo boltlt is lilike ke a spr sprin ingg – wh when en yo youu titigh ghte tenn the the bo boltlt,, itit str stret etch ches es Like Li ke a spr sprin ingg – ho how w muc muchh the the bo boltlt st stre retc tche hess or or “e “elo long ngat ates es”” is is
•
So,, ifif we So we kno know w the the el elon onga gatition on,, we we wil willl kno know w the the bo boltlt lo load ad
TFA TF A Bolt Boltstre stress ss Ultr Ultrason asonics ics What is the relationship between elongation elongation and bolt load?
Bolt Load = Spring constant x Elongation F = k x
∆L
Spring constant is dependent on material of bolt bol t
TFA TF A Bolt Boltstre stress ss Ultr Ultrason asonics ics What is the relationship between bolt load load and bolt stress?
Bolt Load
Bolt Stress = σ
Area of Bolt =
F A
Area of bolt is dependent on diameter diameter of bolt
A
TFA TF A Bolt Boltstre stress ss Ultr Ultrason asonics ics So, how do we use Bolt UT?
Measure reference (before tightening) Gives us elongation
Measure final (after tightening) Calculate Bolt Stress
Input Bolt Effective Area
Calculated by Bolt UT computer
Compare Bolt Stress with Required Bolt Stress Is it within –10%, +15% of required bolt load? If yes pass If no
retighten
TFA TF A Bolt Boltstre stress ss Ultr Ultrason asonics ics Why do we use bolt stress instead of bolt load?
Bolt Stress (MPa (M Pa / ps psi)i) •
vs
Bolt Load (N)
• size, so stress is the same across different bolt sizes
•
Failure point of bolts are dependent on material governed by stress
•
larger bolt = larger load
Unable to directly correlate failure point with load need to convert to stress first
TFA TF A Bolt Boltstre stress ss Ultr Ultrason asonics ics
Elastic Range
Plastic Range
Bolt Failure
Yield Point
Ultimate Tensile Strength
Tensile Point
s s e r t
S
Strain
TFA Procedure
100% Yield Stress Bolt material B7, L7, B16
psi (lbf/in2) 105,000
MPa (N/mm2) 724
B7M, L7M
80,000
551
B8 Class 1
29,000
200
B8 Class 2
80,000
551
TFA Procedure
Required Bolt Stress (MPa)
Bolt material
Standard Flanges
Non-standard Flanges
B7M, L7M
275
B8 Class 2
275
Depends on calculation
,
,
Based on 50% Yield Stress
Why Bolt UT? Bolt Tightening Methods Uncontrolled Flogging
Semi-controlled Torquing
Fully Co Controlled Bolt UT
Double Torquing Accuracy Method of Control Weakness W eakness
50-80% None ±
Highly inaccurate, no way to determining actual load or torque
ens on ng ± 20-40% Torque Conversion of torque into actual bolt load is affected friction, torquing method and lack of properr lubricat prope lubrication ion – eg. E9901 26”, E99
10% Actual Load
±
None – di None dire rect ct measurement of bolt load/stress ensures that bolt load is exactly correct c orrect as required.
Can we do better? What was not done well so far?
The tightening of Flanges were rejected due to INSUFFICIENT LUBRICATION
☹
MAKE SURE !
Stud/Nuts THREADS THREAD THR EADSS are in good good condi conditio tionn Lubricator MOLYKOTE 1000 Flange Surface is lubricated properly
Stud/Nuts THREAD is lubricated Nut’s FACE is lubricated February 28, 2013
37
Questions?
February 28, 2013
38
