RISK RANKING: LOW HAZARD ASSESSMENT: HAZARD 1. Improper use of tools or using faulty tools. 2. Physical strain. POTENTIAL EFFECTS 1. Worker could suffer personal injury if not using tools properly. 2. Back or muscle strain as a result of improper lifting technique. CONTROL 1. Use proper PPE and follow procedures on use of tools. 2. Use lifting equipment or use buddy system for two man lifts. SAFETY EQUIPMENT: Safety Glasses with side shields, hard hat, steel toe boots, FR Clothing, gloves, personal gas monitor and torque wrench. SAFETY NOTE: Hydrocarbon products are very susceptible to leaking through improperly fastened joints. Personnel shall adhere to the following instructions to determine all connections are properly fastened and free of leaks. These instructions are intended for all replacement work as well as new additions or constructions. PROCEDURE: 1. Flanges: all flanges shall be inspected for imperfections and damage such as lateral scores and dents across the gramophone finish. If any flanges are found to be damaged; they must be replaced, especially during new construction or additions. 2. Gaskets: shall be inspected for flattened area, tears, breaks and other imperfections that could cause leaking joints. Any gasket found damaged shall be rejected and a replacement provided. 3. Bolts, studs and nuts: Those require replacing or for any additions or new construction shall be as per the grade stipulated on drawings. All bolt and stud threads shall be inspected for imperfections such as flattened threads, broken threads, cross threads, etc. Nuts shall be similarly checked for thread damage. Ensure that the nuts run down the bolt or stud freely; replace any damaged or unfit pieces. 1 Date of Preparation: November 23, 2004
4. Lubricants: applied to the bolt or stud threads, nut threads and nut faces shall be of the proper and correct type. For NGL piping systems the recommended lubricant is Jet-Lube Nikal or equivalent. 5. Threaded fittings, nipples and valves: shall have all threads inspected for imperfections and damage such as scoring, flats, broken or cross threading, etc. Reject or replace all damaged fittings. Apply one wrap of Teflon tape to all male ends of any threaded connections (Loctite Teflon Thread Sealant #59231 or #59241 or equivalent is recommended). This is followed by applying SWAK or equivalent thread dope on top on the wrap of Teflon tape to the leading threads of the fittings prior to fastening the item in its intended location. Where certain valves are supplied with stainless steel bodies and threads, take due care and attention to ensure that threads or any adjoining carbon steel threaded connections are not damaged or scored by the stainless steel threads. The stainless steel connection does not require as much torque applied to make a tight leak free connection as the equivalent carbon steel threaded connection. 6. Assembly of flanged connections shall use the following sequence to make a tight leak free joint:. Ensure all flanges, gaskets, bolts, studs and nuts are free of dirt, mud, grit, etc.. Bring flanges together ensuring there is sufficient gap to install the gasket. Flanges shall be aligned so that there is not any hi-low between the mating flange faces.. Ensure that the bolts, studs and nuts have been lubricated.. Install two or three bolts near the bottom of the flange to receive and cradle the gasket.. Install gasket between the flanges.. Install remainder of the bolts and studs.. Tighten all nuts to finger tightness. Center the studs between the nuts so that an equal number of threads extend past the nut on each side of the connection.. Tighten bolts or studs starting first at the 12 o clock position, 6 o clock position, 3 o clock position, 9 o clock position. Then alternating out, remember when you tighten one bolt or stud you then must tighten the one directly across from it. Tighten bolts or studs in the 12, 6, 3 and 9 o clock positions using 25% of required torque. Tighten the remaining bolts or studs in sequence to 50% of required torque. Tighten all bolts or studs in sequence to 75% of required torque. Tighten all bolts or studs in sequence to 100% of required torque. Note: If the flanges are difficult to align and it becomes necessary to use the bolts or studs to bring the flanges together, all bolts or studs and nuts shall be replaced with new ones after the initial bolt-up has been made. Follow the same steps as previously detailed in this procedure to fasten the connection the second time. The following shows recommended bolt-up specifications and bolt or stud loadings. 7. Torque and Stretch Specifications for Flanged Joints Requirement: 40% ofyield unless otherwise specified. 2 Date of Preparation: November 23, 2004
Stud/bolt material L.7 10500 psi yield strength. To achieve correct torque, lubrication of studs/bolts, nuts must be done as per specifications. If nuts/bolts are inspected and lubricated, flanges and gaskets inspected and torque is re-checked for relaxation after 24 hours, leaking joints should be eliminated. Lubrication must be stressed as a most important phase of assembly. Non-lubricated joints can affect torque by as much as 50%. Stretch readings need only be used to verify torque calculations. Torque tolerance of plus 10% can be used on all joints. 150 lb. Flanges 8. Size Bolts Size Stretch Torque ft/lbs ¾ ½.0028 36 1 1/2.0028 36 1 ½ 1/2.0028 36 2 5/8.0036 74 6 3/4.0053 131 12 7/8.0061 212 300 Lb. Flanges Size Bolts Size Stretch Torque ft/lbs 1/2 5/8.0036 74 3/4 5/8.0036 74 1 5/8.0036 74 2 5/8.0036 74 3 3/4.0049 131 4 3/4.0053 131 6 3/4.0053 131 8 7/8.0061 212 3 Date of Preparation: November 23, 2004
10 1.0066 318 12 1 1/8.0073 466 14 1 1/8.0080 466 16 1 ¼.0090 656 18 1 ¼.0100 656 20 1 ¼.0100 656 24 1 1/2.0100 1174 600 lb. Flanges Size Bolts Size Stretch Torqueft/Ibs ¾ 5/8.0036 74 1 5/8.0036 74 1 1/2 3/4.0036 74 2 5/8.0049 131 4 7/8.0061 212 6 1.0066 318 8 1 1/8.0073 466 10 1 ¼.0090 656 12 1 ¼.0100 656 14 1 3/8.0100 890 16 1 1/2.0140 1174 18 1 5/8.0140 1514 20 1 5/8.0140 1514 4 Date of Preparation: November 23, 2004
24 1 7/8.0140 2376 5 Date of Preparation: November 23, 2004