Joint Integrity Procedure - GQP-ENG-014

ETHYLENE MALAYSIA SDN. BHD.
POLYETHYLENE MALAYSIA SDN. BHD.
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TITLE: JOINT INTEGRITY PROCEDURE PROCEDURE NO. : GQP-ENG-014
REVISION : 0
DATE : DECEMBER 2010
TABLE OF CONTENTS
INDEX PAGE NO.
TABLE OF CONTENTS 1
RECORD OF CHANGE 2
1. OBJECTIVE 3
2. SCOPE 3
3. REFERENCES 3
4. DEFINITION 3–4
5. PROCEDURE 4 - 13
6. APPENDICES 13 - 31
AUTHOR : REVIEWED BY : APPROVED BY :

Designation Executive Senior Manager, Mechanical Senior Manager, Maintenance
Signature
Date
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RECORD OF CHANGE
DATE OF
REVISION
AMENDMENT REASON FOR CHANGE
NO.
OR RE-ISSUE
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1. OBJECTIVE
1.1 This procedure established a system to control and record breaking and remaking of critical joints at
EPEMSB. Proper application of this procedure shall ensure the quality and integrity of joints for plant
startup.
1.2 Methods identified in joint making, are to eliminate joint leaks during start up by addressing the fol-
lowings:-
1.2.1 The correct method used.
1.2.2 The correct materials.
1.2.3 Validated joint makers.
1.2.4 Traceability of joint makers
2 SCOPE
2.1 This procedure shall be limited to all Critical Joints at EPEMSB.
2.2 This procedure applies to all joints using Manual Torque wrenches, Hydraulic Torquing and Hydrau-
lic Bolt Tensioning.
3 REFERENCES
3.1 GQP-HSE-015 Energy Lock Out Tag Out (LOTO) Procedure
3.2 GQP-ENG-015 Quality Procedure for Maintenance Activity
4 DEFINITION
4.1 Critical Joint - Joint such that the leak would cause HSE issue for the plant and inevitably delay the
plant startup as a result of remaking of these joints. (Refer to Table 1: Criteria of identifying Critical
Joint).
4.2 Bolts - Includes bolts, studs, nuts and washers
4.3 Bolt Tightening - Includes manual or machine assisted application of stress to stud bolts to close a
joint. Applications of stress on the stud bolts include torque tightening methods and tension tighten-
ing methods.
4.4 Leak - Passing through the remade joint when process fluid is introduced into the plant and repairing
the leak necessitate the shutting down of the plant.
4.5 EPEMSB - Ethylene/Polyethylene Malaysia Sdn. Bhd.
4.6 Executor - The party given the responsibility to execute the work of joints breaking and joints making.
4.7 Joint Maker – Appointed party responsible to execute the work of joint making.
4.8 Maintenance Engineer – Appointed Maintenance engineer for the area or work execution.
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4.9 Planner – Maintenance planner for daily maintenance work
4.10 Joint Integrity Team – Team appointed to ensure the joint breaking and joint making compliance.
The team can be from EPEMSB or Contractor.
4.11 Contractor Supervisor – Supervisor for the contractor appointed by EPEMSB to perform the main-
tenance work on behalf of EPEMSB.
5 PROCEDURE
5.1 Planning
5.1.1 During the Planning Phase (Daily planned maintenance or turnaround), the Planner will
summarize the gasket/joint requirements.
5.1.2 During the Preparation Phase, the Team Leader shall itemize and prepare Joint Integrity
Check Sheet as per EPEMSB JICS-rev0.
5.2 Preparation
5.2.1 Executor, engineering and operation personnel shall perform a Join site survey to identify
and tag the joints.
5.2.2 Parties involved shall observe LOTO Procedure requirement if joints are listed as part of
LOTO joints.
5.2.3 Executor shall ensure availability and correctness of Joint Integrity Check Sheet for each
joint as per EPEMSB JICS-rev0.
5.3 Material Selection and Handling
5.3.1 Flange / gasket arrangements:

Selection of the proper gasket material is important with regard to the flange finish
Never use fewer bolts than the number designed for the flange
5.3.2 When selecting bolts (bolts or studs):
Select bolts / studs with sufficient yield strength to ensure they are within their elastic
limit at the required load
Select bolts / studs with the same modulus of elasticity
Ensure there is no corrosion of the bolts / studs
5.3.3 When selecting nuts:
Select nuts with a proof load 20% greater than the ultimate tensile strength of the bolts
and nuts
5.3.4 When selecting washers:
Always use washers
Use the same material for the washers and the nuts
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5.3.5 Gasket selection:

Do not reuse gaskets
Always use a good quality gasket from a reputable supplier, because the cost of a
gasket is insignificant when compared to the cost of downtime or safety considera-
tions.
Ensure the gasket is as thin as possible without breaching the design requirement.
5.3.6 Cutting of soft gaskets:

Use a good cutter
Do not try to cut out a gasket by hammering material against the flange.
Ensure the gasket is the correct size
Cut the bolt holes slightly larger than the bolt shaft diameter
Ensure that the inside diameter of the gasket is not less than the inside diameter of
the process line
5.3.7 Storage of gaskets and gasket materials:
Store in a cool, dry place, away from direct sunlight, water, oil and chemicals
Store sheet materials flat
Avoid hanging gaskets. Store gaskets flat. Large diameter spiral wound gaskets
should be stored in a horizontal position
Gaskets should be kept clean and free from mechanical damage (ideally, store in
sealed poly bags)
5.3.8 Handling of gaskets and gasket materials:
Carry gaskets carefully, ideally with some form of protective cover
Do not bend or buckle
Do not damage the surface
For large diameter metallic and semi-metallic gaskets, always transport the gasket on
its mounting to the installation site
5.4 Approved Joint Makers
5.4.1 The Maintenance Engineer and Contractor’s Supervisor shall ensure that the personnel
identified for joint breaking and joint making understand the principles specified in this pro-
cedure by attending the Joint Integrity Training conducted by EPEMSB.
5.4.2 Joint makers shall comply with the stipulated requirement in Joint Integrity Procedure to
ensure all the joints are leak free. The executor shall guarantee the work.
5.4.3 The executor shall be allocated a set of joint tags, issued to the relevant Supervisor or
work leader.
5.4.4 All personnel attended Joint Integrity training shall automatically eligible to be a Joint Mak-
er during the execution of Joint Integrity activity.
5.4.5 No individual shall be allowed to make critical joint unless approved by the respective
Maintenance Engineer.
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5.5 Pre-Shutdown Activities
5.5.1 The Executor shall Tag all the Joints as described in the section 6.5 with designated tags
(to be done together by Maintenance, Operation, & Contractors).
5.5.2 To Check all spare parts and material and pack them separately according to Job Method
Sheet (JMS). Store them as to avoid any damage during handling and storing. This activity
shall be preferably done and completed prior to execution.
5.5.3 To erect work platforms, shades, equipment support, and other accessories required for
joint breaking and joint making.
5.5.4 To Conduct Job Safety Analysis (JSA) as required by JMS.
5.5.5 To check availability and functionality of special tools required in working the flanges.
5.5.6 Maintenance and contractor shall discuss work instruction to ensure contractor under-
stands the job steps. For hazardous and critical work, the precaution and special feature
of the jobs shall be highlighted during this discussion.
5.6 Critical Joint Tagging System
5.6.1 A batch of joint tags will be issued to by the respective Maintenance Engineers. Nomi-
nated joint makers will attach the tags to the allocated joint during the joint tagging exer-
cise. The joint tag provides a traceable route back to the executor. This activity shall be
preferably done and completed prior to execution.
5.6.2 The nominated Joint Maker shall request jointing materials from the stores and check that
they are as specified on the Material Control Sheet.
5.6.3 Tags shall be used to control and indicate the status of any joints. All tags shall be re-
turned and recorded in the Joint Integrity Check Sheet after serving their respective pur-
poses.
BREAKING OF CRITICAL JOINT (Orange) – Joint is identified as critical joint.
DETAIL INSPECTION REQUIRED (Blue) – Damage was detected on the joint. Detail
inspection required to be performed on the joint.
REPAIR REQUIRED (Red) – Damage detected and detail inspection found repair is
required.
SATISFACTORY (White) – Joint is in satisfactory condition. Joint does not need De-
tail Inspection or Repair performed and found satisfactory.
READY FOR JOINT MAKING (Yellow) – All relevant work have been completed and
joint is ready for tightening.
JOINT MAKING COMPLETED (Green) – Joint making was completed and ready for
pressure testing.
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5.6.4 Marking of Joint Tags.
Relevant portion of the tags shall be written with names and date for base on status and
finding. This shall also be reflected on the Joint Integrity Check Sheet.
The tag shall not be removed until:

The equipment or system has been pressure tested and accepted; or
The equipment or system has been handed over to Operations
NOTE: Box up certificates shall be approved before hand tightening may proceed.
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To be filled by the executor prior to tagging of the joints at

site.
SERIAL NO : 0001 The boxes to be marked as NOT APPLICABLE if the

steps are not required or relevant to the joint integrity
EQUIP NO: ___________ exercise.
FLANGE DESC: _______
FLANGE NO:
__________
SERIAL NO : 0001 To be filled by Joint maker Work Leader upon completion of

joint making work. Same person have to fill up the similar
JOINT MAKING box in the Joint Integrity Check Sheet.
COMPLETED
(GREEN)
BY :_________DATE:___
SERIAL NO : 0001 To be filled by relevant equipment overall work leader upon

readiness of the joints to be make. This needs to take con-
READY FOR JOINT sideration effects of the joints to the overall work, Same
MAKING person to fill up similar box in the Joint Integrity Check
(YELLOW) Sheet.
BY:_________DATE:____
To be filled by Inspector upon acceptance after detail in-
SERIAL NO : 0001 spection or after acceptance of Repair. If no detail inspec-
tion or repair required the Joint breaking work leader to fill
SATISFACTORY this portion upon satisfactory cleaning of the flanges and
(WHITE) bolts. Same person to fill up similar box in the Joint Integrity
BY:_________DATE:____ Check Sheet.
To be filled by Inspector if found repair is required after the
SERIAL NO : 0001 detail inspection. Same person to fill up similar box in the
Joint Integrity Check Sheet.
REPAIR REQUIRED
(RED)
BY:_________DATE:____
To be filled by joint breaking work leader if found detail in-
SERIAL NO : 0001 spection required after initial inspection of the joint, Same
person to fill up similar box in the Joint Integrity Check
DETAIL INSPECTION Sheet.
REQUIRED
(BLUE)
BY:_________DATE:____
To be filled by joint breaking work leader upon completion
SERIAL NO : 0001 of joint breaking and initial inspection of the joint. Same
person to fill up similar box in the Joint Integrity Check
BREAKING OF CRITICAL Sheet.
JOINT
(ORANGE)
BY:_________DATE:____
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5.7 Breaking of Critical Joint
5.7.1 Prior to commencing any work, the Executor shall ensure that the Permit to Work (PTW)
System has been implemented and that all safety requirements specified on the PTW
have been fully read and understood. The executor shall observe LOTO requirement if
applicable.
5.7.2 The executor shall work with planner to plan their jobs and arrange with the Maintenance
Engineer and Operations for the PTW by submitting the next day Job list in advance.
5.7.3 The executor shall perform only the Job scope as specified in the PTW.
5.7.4 All the PTW shall be returned when the Job is completed, stopped or canceled.
5.7.5 When Breaking the Joints:
Observe the material in the line and its hazards and comply with the recommended
precautions to be taken. Always assume there is partial pressure in the system
needed to be depressurized and drain.
Loosen adjacent bolts that are nearest to the bottom of the flange assembly, away
from harming any personnel. Ensure that they can be retightened quickly if necessary.
A fox wedge should be used to open the joint and drain the line completely at flange
location away from body.
Retighten the bolts quickly if excessive amount of pressure or gas or fluid escape from
the system.
DO NOT cut, drill, or grind any parts on flange, gasket, and bolts/nuts unless in-
structed in writing by Maintenance Engineer.
5.8 Examination of Joint Faces / Preparation for Joint Making
5.8.1 Joint Maker shall clean and examine the flange faces, ensuring the following points are
taken into consideration:
Use a steel wire brush to clean the flange sealing surfaces. If the space between the
flanges do not allow for the insertion of a wire brush, wind “steel wool” around a large
flat file to clean the surfaces.
Flange faces shall be free of indentations, scratches or corrosion. Conditions that are
detrimental to the potential joint tightness and subsequent repair shall be plan, ex-
ecuted and recorded.
Ensure the flange faces have the correct surface finish for the gasket type being fitted.
Check that the flange faces are parallel and aligned
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Note: When fitting isolation spades or blinds, it is imperative that the joint faces are inspected, and
any damage shall be informed to the Maintenance Engineer for remedial action to be taken, (e.g. in-
itiation of additional work).
5.8.2 Inspect the flange faces to establish flange faces condition against the acceptance criteria.
Where there is uncertainty of the condition of the joint faces, the joint maker shall contact
his supervisor to liaise with the Inspection to establish next action to be taken, (e.g. initia-
tion of extra work). Refer to Appendices (vi).
5.8.3 Bolts and nuts may be reused where practicable. However, the following must be adhered
to:
Bolts and Nuts shall be wire brushed until free from rust and debris.
Only approved lubricants must be applied to:
 Bolt threads
 Bolt nuts
 To the face of the nut to be tightened
Note: Do not apply lubricant to the bolt head face or face of nut which is expected to
remain stationary during tightening.
Do not lubricate stainless steel threads.
After cleaning, it should be possible to run the nut along the full length of the thread by
hand.
If in doubt, bolt and nuts should be replaced.
Bolts and nuts previously tightened more than three times using hydraulic bolt tension-
ing equipment should be replaced unless concession granted by Inspection Section.
In this case, the bolts must undergo a NDT test and certified for reuse by Inspection
Section.
Check that bolt/studs are the correct type and length, such that at least two (2) full
threads protrude from each nut when the joint is made. Nuts should be screwed in the
correct way round.
Note: No grease or oil bearing substance shall be used to lubricate bolts, nuts and
gaskets on the Ammonia or similar service.
5.9 Making the Joint
5.9.1 Holding the Gasket
Application of masking tape to hold the gasket in place must be avoided. In conse-
quence the reliability of the joint may be reduced.
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Note 1: No grease or oil bearing substance shall be used to lubricate bolts, nuts and
gaskets on the Oxygen or similar service.
Note 2: The Maintenance Engineer and Joint Integrity Team must ensure the above
instruction are complied with and must inspect/witness the joint making process by the
Joint Maker. Care must also be taken to ensure the correct gasket type, size and ma-
terial of construction of gasket before installation.
5.9.2 Align Mating Surfaces
Mating Flanges shall be aligned axially and radially without excessive force. Inability to
mate the flanges shall be reported to the Maintenance Engineer. Ensure that the
gasket is not misaligned or damaged when bringing the flanges together. Take extra
precaution with heavy equipment covers or flanges.
Insert the tapered end of a “Tommy-bar” into a hole where the flange bolts were re-
moved and re-align the two flanges until the blot hole are sufficiently aligned. Do not
insert the “Tommy-bar” too deep between the flanges to avoid damaging the flange
sealing surfaces.
Verify that two flange faces parallel to each other have the following maximum gap to-
lerance. Refer to Appendices (vii).
5.9.3 Bolts Insertion
Insert the bolts into bottom half of the flange assembly by hand forming a “cradle” for
accepting the gasket when inserted between the flanges.
Ensure all bolt and nut surfaces are sufficiently lubricated. Use the appropriate lubri-
cation on the threads on all COLD and NORMAL duty bolts.
For HOT duty bolts, use an approved high-temperature, lubrication compound.
All bolts must be thoroughly inspected for wear and damage. Replace damaged or
worn bolts.
Note: Do not lubricate stainless steel threads.
5.9.4 Bolting Sequence
Bolts positions are numbered in sequence in clockwise direction. Bolts shall be tigh-
tened in a diagonal sequence unless there are written instructions to the contrary.
Please refer to Joint Integrity Check Sheet for the diagonal sequence.
Tighten the flange to the required tightness following these steps. The bolts are to be
tightened in stages as follows:
 Finger tighten all nuts
 Tighten until faces are parallel but without gasket compression.
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 Torque to 30% of full torque value according to cross-bolting pattern on FIRST

50% of the bolts.
 Torque to 60% of full torque value according to cross-bolting pattern on SECOND

50% of the bolts.
 Torque to 100% torque value according to cross-bolting pattern on the FIRST 50%
of the bolts, followed by the SECOND 50% of the bolts.
 Tighten all the bolts at 100% torque value, moving around the flange bolts by bolt.
Repeat until no rotation of nuts observed and all bolts are uniformly torque.
Note: When tightening the nuts the whole nut and bolt assembly may turn, implying
interference between the nut and bolt thread. If this happens, the assembly
may be restrained using a hand held spanner, on the bolt head or stationary
nut.
o o
5.9.5 Untouched Critical Joints for Low Temperature Services (0 C to (-101) C).
Ensure that flange gap is uniform around the flange; record the gap at a minimum of
four locations (12.00, 3.00, 6.00, 9.00 o’clock positions).
Carry out brass hammer knocking on all bolts to ensure it is in tension.
Should there be any loose bolts, tightening of all bolts on the joint shall be carried out
according to the specified torque value.
Leave the identification tag attached to the flanged joint until the system has been
pressurized for operations.
5.10 Bolt Torque Value (Controlled)
5.10.1 Bolt torque value shall be identified based on the bolt s and flange specification.
5.10.2 Control Torque value and method shall be as per OEM recommendation. If no such rec-
ommendation from the OEM provided guide torque value shall be used. Application of the
torque value shall be as per step 5.9.4.
5.10.3 Control Bolt Tensioning shall also be based on the required bolt elongation derived from
the following formula:
Delta L = {[S (b) * L (eff)] / E} * {A (r) / A (ts)}
Where,
Delta L = Bolt elongation/stretch, inch (mm)
S (b) = Target Bolt stress root area, ksi (Mpa)
L (eff) = Effective stretch length, inch (mm)
E = Modulus of elasticity, ksi (Mpa)
A(r) = Root Area, square inch (square mm)
A (ts) = Tensile stress area, square inch (square mm)
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5.11 Completion of Joint
5.11.1 Upon completion of the joint, the Joint maker shall satisfy himself that he has made the
joint in accordance with the requirement.
5.11.2 When the joint has been made, the following checks and actions shall be made by the
Joint Maker:
Check that the flanges are parallel and aligned
Check that all threads are fully threaded
Fill up tag segment and update the Joint Integrity Check Sheet.
Remove all discarded items to the appropriate place
5.12 Traceability
5.12.1 Traceability is required for all Joint Making and this is achieved by filling the tag to the
Joint Integrity Check Sheet when it has been made by the authorized Joint Maker.
5.12.2 All personnel involved in the joint making shall be traceable from the tag and Joint Integrity
Check Sheet.
6 APPENDICES
6.1 Appendices (i) Criteria for Selection of Critical Joints and Bolt Tensioning.
6.2 Appendices (ii) Joint Integrity Work Flow.
6.3 Appendices (iii) Joint Integrity Check Sheet.
6.4 Appendices (iv) Bolts Torque Value Guides.
6.5 Appendices (v) General type of flange with their gasket’
6.6 Appendices (vi) Flange face finishing
6.7 Appendices (vii) Types of alignment
6.8 Appendices (viii) Product information: Molykote
6.9 Appendices (ix) Product information: Deacon
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6.1 APPENDICES (i)
CRITERIA FOR SELECTION OF CRITICAL JOINT AND BOLT TENSIONING
6.1.1 The definition of a critical joint is;

“All joints identified that require proper management during opening, inspection and closing ei-
ther by normal wrenches, hydraulic torque or hydraulic tensioner where applicable as per table
1”
6.1.2 All identified critical joint works shall be controlled by Joint Integrity Check Sheet. Joints faces
shall be inspected, repaired when required and close using correct tightening sequence, tor-
que or tension shall be applied during closing.
6.1.3 Anti-seize compound (Bolt Lubricant) must be applied to all bolts, where relevant. Preferably
the Bolt Lubricant for Critical Joints Bolts shall be Nickel based Compound (Molybdenum dis-
ulphide). Stainless steel bolts and nuts must not be lubricated. All high pressure rating flanges
bolts shall be tightened by hydraulic torque or tensioners with pullers to specified value and
the readings shall be recorded.
Table 1: Criteria of identifying Critical Joint.
Flange
Piping
Criteria Standard Sizes/ Closing Method
Class
Rating
1 Flammability Follow normal All All Sizes Torquing (Manual/Hydraulic)
flammable gas Hydraulic Bolt Tensioning
classification
2 Hazardous Follow normal All All Sizes Torquing (Manual/Hydraulic)
Chemicals /toxic Chemicals classifi- Hydraulic Bolt Tensioning
/Corrosive cation
3 Others Equipment that re- All All Torquing (Manual/Hydraulic)
quire shutdown. Hydraulic Bolt Tensioning
Equipment that
does not have by-
pass or backup.
Table 2: Criteria for Bolt Tensioning of Critical Joint.
Criteria Flange Sizes/ Rat- Piping Bolt Siz- Closing Method

ing Standard Class es
1 Process Pressure Any Size, 600 lb 600 lb and 1 1/4” Hydraulic Bolt Tensioner
and above above and
above
2 Package Equipment All Sizes & Rating All All Hydraulic Bolt Tensioner
designed for bolt
tensioning
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6.2 APPENDICES (ii)

JOINT INTEGRITY WORK FLOW
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6.3 APPENDICES (iii)

JOINT INTEGRITY CHECK SHEET
JOINT DESCRIPTION
Project Title Equipment No
Joint Description Joint identification
Joint Location Services

Yes No
LOTO Joint
Flange size Torque Multiplier Multiplier value

Yes No
Flange rating x
Bolt size (diameter) Torque Setting Actual value Torque Wrench value
No of bolts 30%
Bolt grade 60%
Nut A/F size 100%

Yes No
Bolts length Bolt Lubricant
Yes No
Gasket type Gasket Compound
Gasket Specification
Bolts location marked around the flange in clockwise direction.
FIRST 50% SECOND 50%
4 Bolts Flange 1,3 2,4
8 Bolts Flange 1,5,3,7 6,2,8,4
12 Bolts Flange 1,7,4,10,9,3 6,12,2,8,5,11
16 Bolts Flange 1,9,5,13,7,15,11,3 10,2,14,6,4,12,16,8
20 Bolts Flange 1,11,6,16,9,19,3,13,15,5 17,7,2,12,4,14,18,8,20,10
24 Bolts Flange 1,13,7,19,16,4,10,22,6,18,12,24, 2,14,8,20,21,9,3,15,11,23,17,5
28 Bolts Flange 1,15,8,22,18,4,11,25,26,12,5,19,7,21 28,14,9,23,2,16,27,13,6,20,24,10,3,17
Non Standard Flange
JOINT TAGS CUT SEGMENTS

BREAKING OF CRITICAL JOINT DETAIL INSPECTION REQUIRED REPAIR REQUIRED SATISFACTORY READY FOR JOINT MAKING
(ORANGE) (BLUE) (RED) (WHITE) (YELLOW)
(Attach segments here) (Attach segments here) (Attach segments here) (Attach segments here) (Attach segments here)
BY : BY : BY : BY : BY :
DATE : DATE : DATE : DATE : DATE :
Statement of Compliance.
I hereby confim that the abovementioned flange has been assembled and tightened correctly and is safe for plant operation.
JOINT MAKING COMPLETED
COMPLETED BY ACCEPTED BY
(GREEN)
NAME : NAME :
SIGNATURE : SIGNATURE : (Attach segments here)
BY :
DATE :
DATE : DATE :
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6.4 APPENDICES (iv)

BOLTS TORQUE VALUE GUIDES
150#-600# X Spiral wound (B7)

Diameter of Bolt Wrench Size 100% Torque
(mm) (inch) (mm) (Nm) (lb.ft)
1 13 1/2" 22 76 56
2 16 5/8" 27 148 109
3 19 3/4" 32 256 188
4 22 7/8" 36 407 299
5 25 1" 41 608 447
6 29 1 1/8" 46 865 636
7 32 1 1/4" 50 1187 873
8 35 1 3/8 55 1580 1161
9 38 1 1/2" 60 2051 1506
10 41 1 5/8" 65 2607 1917
11 44 1 3/4" 70 3256 2394
12 48 1 7/8 75 4005 2945
13 51 2 80 4861 3574
14 64 2 1/2 100 9494 6981
a. Bolt is at 50% min yield strength.

b. Coefficient of friction µ = 0.11 with DOW Molykote 1000.
c. Bolt material of SA193 Gr B7 / SA 193 Gr B16
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150# X Sheet Gasket (B7)

Flange Size Diameter of Wrench Size Quantity of Length of Torque
Bolt (mm) Bolt Bolt lbf.ft
(inch) 100%
1 1/2" 1/2" 22 4 1 3/4" 22

2 3/4" 1/2" 22 4 2" 26
3 1" 1/2" 22 4 2" 29
4 1 1/4" 1/2" 22 4 2 1/4" 44
5 1 1/2" 1/2" 22 4 2 1/4" 44
6 2" 5/8" 27 4 2 3/4" 86
7 2 1/2" 5/8" 27 4 3" 86
8 3" 5/8" 27 4 3" 86
9 3 1/2" 5/8" 27 8 3"
10 4" 5/8" 27 8 3" 69
11 5" 3/4" 32 8 3 1/4"
12 6" 3/4" 32 8 3 1/4" 137
13 8" 3/4" 32 8 3 1/2" 137
14 10" 7/8" 36 12 3 3/4" 194
15 12" 7/8" 36 12 4" 194
16 14" 1" 41 12 4 1/4" 296
17 16" 1" 41 16 4 1/2" 289
18 18" 1 1/8" 46 16 4 3/4" 421
19 20" 1 1/8" 46 20 5 1/4" 421
20 24" 1 1/4" 50 20 5 3/4" 588
21 26" 1 1/4" 50 24 6" 588
22 28" 1 1/4" 50 28 6 1/4" 588
23 30" 1 1/4" 50 28 6 1/4" 588
24 32" 1 1/2" 60 32 7" 1044
25 34" 1 1/2" 60 32 7" 1044
26 36" 1 1/2" 60 32 7" 1044
27 38" 1 1/2" 60 36 7 1/2" 1044
28 40" 1 1/2" 60 36 7 1/2" 1044
29 42" 1 5/8" 65 36 7 1/2" 1044
30 46" 1 3/4" 70 36 7 1/2" 1044
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(inch) 100%
1 1/2" 1/2" 22 4 2" 35

2 3/4" 5/8" 27 4 2 1/2" 69
3 1" 5/8" 27 4 2 1/2" 69
4 1 1/4" 5/8" 27 4 2 3/4" 69
5 1 1/2" 3/4" 32 4 3" 94
6 2" 5/8" 27 8 3" 64
7 2 1/2" 3/4" 32 8 3 1/4" 127
8 3" 3/4" 32 8 3 1/2" 127
9 3 1/2" 3/4" 32 8 3 3/4" 137
10 4" 3/4" 32 8 3 3/4" 137
11 5" 3/4" 32 8 4" 137
12 6" 3/4" 32 12 4 1/4" 137
13 8" 7/8" 36 12 4 3/4" 218
14 10" 1" 41 16 5 1/4" 325
15 12" 1 1/8" 46 16 5 3/4" 453
16 14" 1 1/8" 46 20 6" 474
17 16" 1 1/4" 50 20 6 1/2" 456
18 18" 1 1/4" 50 24 6 3/4" 500
19 20" 1 1/4" 50 24 7" 588
20 24" 1 1/2" 60 24 7 3/4" 809
21 26" 1 5/8" 65 28 8 3/4" 1044
22 28" 1 3/4" 70 28 10" 1899
23 30" 1 3/4" 70 28 10" 1899
24 32" 1 7/8" 75 28 10 3/4"
25 34" 1 7/8" 75 28 10 3/4"
26 36" 2" 80 32 11 1/4" 2555
27 42" 2" 80 36 13 1/2"
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(inch) 100%
1 1/2" 1/2" 22 4 3" 35

2 3/4" 5/8" 27 4 3 1/4" 69
3 1" 5/8" 27 4 3 1/2" 69
4 1 1/4" 5/8" 27 4 3 3/4" 69
5 1 1/2" 3/4" 32 4 4" 137
6 2" 5/8" 27 8 4" 86
7 2 1/2" 3/4" 32 8 4 1/2" 137
8 3" 3/4" 32 8 4 3/4" 137
9 3 1/2" 7/8" 36 8 5 1/4" 218
10 4" 7/8" 36 8 5 1/2" 218
11 5" 1" 41 8 6 1/4" 325
12 6" 1" 41 12 6 1/2" 325
13 8" 1 1/8" 46 12 7 1/2" 526
14 10" 1 1/4" 50 16 8 1/4" 662
15 12" 1 1/4" 50 20 8 1/2" 662
16 14" 1 3/8" 55 20 9" 894
17 16" 1 1/2" 60 20 9 3/4" 1175
18 18" 1 5/8" 65 20 10 1/2" 1507
19 20" 1 5/8" 65 24 11 1/4" 1507
20 24" 1 7/8" 75 24 12 3/4" 2354
21 26" 1 7/8" 75 28 13 1/4"
22 30" 2" 80 28 14" 3195
23 32" 2 1/4" 90 28 14 1/2"
24 34" 2 1/4" 90 28 15"
25 36" 2 1/2" 100 28 15 3/4" 5713
26 42" 2 3/4" 110 28 17 1/2"
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6.5 APPENDICES (v)
GENERAL TYPE OF FLANGE WITH THEIR GASKETS TYPES
The general type of flanges with their gasket types
Flat Face Unconfined Gasket

• Mating faces of both flanges are flat.
• Gasket may be ring type, or full face, which covers the entire face
both inside and outside the bolts.
Raised Face Unconfined Gasket

• Mating faces are flat, but the areas inside the bolt holes are raised
1/16" or 1/4".
• Gasket is usually ring type, entirely within bolts.
• Flanges may be disassembled without springing the flange.
Ring Type Joint (Also Called "API Joint“)

• Both flange faces have matching flat-bottomed grooves with sides
tapered from the vertical at 23 degrees.
• Gasket seats on flat section of flange between bore and ring joint
groove.
• Spiral Wound gaskets may replace solid metal ring gaskets.
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The general type of flanges with their gasket types (cont’d)
Male-Female Semi-confined Gasket

• Depth of female (recessed) face normally equal to or less than
height of male (raised) face, to prevent metal-to-metal contact dur-
ing gasket compression.
• Recessed OD normally is not more than 1/16" larger than the OD
of the male face.
• Joint must be pried apart for disassembly.
Tongue and Groove Fully Confined Gasket

• Groove depth is equal to or less than tongue height.
• Groove usually not over 1/16" wider than tongue.
• Gasket dimensions will match tongue dimensions.
• Joint must be pried apart for disassembly.
Groove to Flat Fully Confined Gasket

• One flange face is flat, the other is recessed.
• For applications requiring accurate control of gasket compression.
• Only resilient gaskets are recommended, such as Spiral Wound,
hollow metal O-ring, pressure-actuated, and metal-jacketed
gaskets.
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6.6 APPENDICES (vi)
FLANGE FACE FINISHING
Flange Face Finishing

There are limits on the degree of flange surface imperfection that can be sealed successfully with a
gasket. Large nicks, dents, or gouges must be avoided, since a gasket cannot properly seal
• Roughness
Roughness is the average of peaks and valleys measured from mid-line of flange surface (in mil-
lionths of an inch or meter). This is expressed as RMS (root mean square) or AA (Arithmetic Av-
erage) or AARH (Arithmetic Average Roughness Height).
Recommended Roughness Values
Spiral Wound Gaskets 125-250 rms

Jacketed or Metal Clad Gaskets 63-80 rms
Solid Metal Gaskets 63-80 rms
Note: - Typical roughness readings can be from 125 to 500 micro-inches

for serrated flanges and 125-250 micro-inches for non-serrated flanges.
Fine finishes, such as polished surfaces, should be avoided. Adequate
"bite" in the surface is required to develop enough friction to prevent the
gasket from being blown out or from extruding or creeping excessively.
Flange Face Finishing (cont’d)

• Lay
Lay is the direction of the predominant surface-roughness pattern. The lay of the finish should
follow the mid-line of the gasket. Every effort should be made to avoid lines across the face,
such as linear surface grinding, which at 180° points will cross the seal area at right angles to
the gasket, allowing a direct leak path.
• Waviness
Waviness is the departure from overall flatness. This is measured in thousandths or fractions of an
inch. Waviness is seldom a problem under normal conditions. If warpage is caused by heat or in-
ternal stresses, re-machining is generally sufficient. However, warpage due to excessive bolt loads
or insufficient flange thickness results in “Bowing”.
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Flange Facing Finish Imperfections (ASME B16.5)
Imperfections in the flange facing finish shall not exceed the dimensions shown in table below.
Permissible Imperfections in Flange Facing Finish for Raised

Face and Large Male and Female Flanges
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6.7 APPENDICES (vii)
TYPES OF ALIGNMENT
Types of alignment
Lateral Alignment
For standard flanges, the free insertion of the bolts is generally sufficient to demonstrate an accept-
able alignment. The Lateral Alignment may also be checked by positioning a straight edge along the
outside rim of the flange. Measurements should be taken at locations 90 degrees apart, around the
flange circumference. The measurements of lateral misalignment shall not exceed the following val-
ues:
NPS Tolerance “A”
Up to 4” 1.0 mm
6” to 10” 2.0 mm
10” to 24” 3.0 mm
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6.8 APPENDICES (viii)

PRODUCT INFORMATION - MOLYKOTE
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6.9 APPENDICES (ix)

PRODUCT INFORMATION - DEACON
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-END OF DOCUMENT-
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Joint Integrity Procedure - GQP-ENG-014

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ETHYLENE MALAYSIA SDN. BHD.

POLYETHYLENE MALAYSIA SDN. BHD.

AUTHOR : REVIEWED BY : APPROVED BY :

4.2 Bolts - Includes bolts, studs, nuts and washers

4.5 EPEMSB - Ethylene/Polyethylene Malaysia Sdn. Bhd.

4.9 Planner – Maintenance planner for daily maintenance work

5.3 Material Selection and Handling

5.3.1 Flange / gasket arrangements:

5.3.5 Gasket selection:

5.3.6 Cutting of soft gaskets:

5.4 Approved Joint Makers

5.5 Pre-Shutdown Activities

5.5.4 To Conduct Job Safety Analysis (JSA) as required by JMS.

5.6 Critical Joint Tagging System

BREAKING OF CRITICAL JOINT (Orange) – Joint is identified as critical joint.

5.6.4 Marking of Joint Tags.

The tag shall not be removed until:

To be filled by the executor prior to tagging of the joints at

SERIAL NO : 0001 The boxes to be marked as NOT APPLICABLE if the

SERIAL NO : 0001 To be filled by Joint maker Work Leader upon completion of

SERIAL NO : 0001 To be filled by relevant equipment overall work leader upon

5.7 Breaking of Critical Joint

5.7.5 When Breaking the Joints:

5.8 Examination of Joint Faces / Preparation for Joint Making

Check that the flange faces are parallel and aligned

Only approved lubricants must be applied to:

 To the face of the nut to be tightened

Do not lubricate stainless steel threads.

If in doubt, bolt and nuts should be replaced.

5.9 Making the Joint

5.9.1 Holding the Gasket

5.9.2 Align Mating Surfaces

5.9.3 Bolts Insertion

For HOT duty bolts, use an approved high-temperature, lubrication compound.

Note: Do not lubricate stainless steel threads.

5.9.4 Bolting Sequence

 Finger tighten all nuts

 Tighten until faces are parallel but without gasket compression.

 Torque to 30% of full torque value according to cross-bolting pattern on FIRST

 Torque to 60% of full torque value according to cross-bolting pattern on SECOND

Carry out brass hammer knocking on all bolts to ensure it is in tension.

5.10 Bolt Torque Value (Controlled)

Delta L = {[S (b) * L (eff)] / E} * {A (r) / A (ts)}

5.11 Completion of Joint

Check that the flanges are parallel and aligned

Check that all threads are fully threaded

Remove all discarded items to the appropriate place

6.1 APPENDICES (i)

CRITERIA FOR SELECTION OF CRITICAL JOINT AND BOLT TENSIONING

6.1.1 The definition of a critical joint is;

Table 1: Criteria of identifying Critical Joint.

Table 2: Criteria for Bolt Tensioning of Critical Joint.

Criteria Flange Sizes/ Rat- Piping Bolt Siz- Closing Method

6.2 APPENDICES (ii)

6.3 APPENDICES (iii)

Project Title Equipment No

Joint Description Joint identification

Joint Location Services

Flange size Torque Multiplier Multiplier value

Bolt grade 60%

Nut A/F size 100%

Bolts location marked around the flange in clockwise direction.

FIRST 50% SECOND 50%