000.200.0780 Establishing Flange Assembly Requirements

1/14/2019 000.200.0780 Establishing Flange Assembly Requirements.
pdf
Practice 000.200.0780
Date 14Jan2019
Engineering Management
Full Practice Printed from Quality Requirement System Global Library
ESTABLISHING FLANGE ASSEMBLY REQUIREMENTS
1.0 PURPOSE
The purpose of this practice is to outline the requirements for establishing flange assembly and
tightening requirements on a project. Flange assembly requirements are developed for flanged
connections on both piping systems and mechanical equipment.
2.0 APPLICATION
This practice applies to all Fluor projects and entities. Refer to Attachment 01 for clarification of roles
and responsibilities and workflow while reading this practice.
Note: Target stress bolt load or torque tables are provided by a 3rd Party Bolting Contractor or the
Client. Fluor does not provide this information. The requirements in this practice are limited to the
creation of a flange assembly procedure, along with identification of flange criticality.
3.0 INTERFACING DISCIPLINES

Piping Engineering
Mechanical Engineering
Construction
4.0 DEFINITIONS
See glossary at the end of this practice
5.0 This section has been left intentionally blank
6.0 REQUIREMENTS
6.1 The Project Engineering Manager will review the prime contract to determine the party
responsible for defining the flange assembly procedure.
Note: If Fluor is not performing Engineering, the Client is responsible for requirements 6.2 and
6.3. See Attachment 01.
© 2019, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission.
http://localhost:8082/PDF/000.200.0780%20Establishing%20Flange%20Assembly%20Requirements.pdf 1/15
1/14/2019 000.200.0780 Establishing Flange Assembly Requirements.pdf
Practice 000.200.0780
Date 14Jan2019
6.2 The Lead Piping Materials Engineer will identify all flanges for assembly in the field with
input from Mechanical Engineering.
This includes all flanges associated with each line class and piping system and flanges
associated with equipment, including body flanges. The extent of this effort is identified per
project and Client requirements.
6.3 The Lead Piping Materials Engineer will identify any flanges for special consideration.
Please see Attachment 03 for more information on assessing flange criticality.
6.4 The Lead Piping Materials Engineer will engage a 3rd Party Bolting Contractor to create
a flange assembly procedure.
Note: If the Client provides a flange assembly procedure, the above requirement can be
waived.
Flange assembly procedures take into consideration the requirements of one of the following
publications depending on the design code used on the project:
ASME PCC-1 – Guidelines for Pressure Boundary Bolted Flange Joint Assembly
European Nation Standard EN 1591-1 – Flanges and their joints, Part 1, 2, and 4.
Note: All codes and specification referenced herein, but not dated, will be of the latest
revision. The terminology “latest revision” is interpreted as the revision and addenda in effect
at the date of the purchase order or contract. Where local jurisdictional authorities have
requirements exceeding or in conflict with these standards, such requirements will supersede
the requirements in this practice.
6.4.1 The Lead Piping Materials Engineer will provide information to the 3rd Party
Bolting Contractor on the flanges or systems that require special consideration.
The 3rd Party Bolting Contractor provides Fluor with a flange assembly
procedure, which is then issued for Client Review.
See Attachment 02 for more information on considerations when reviewing

flange assembly procedures.
6.5 The Lead Piping Materials Engineer will maintain Flange Management documentation
with input from the Client and 3rd Party Bolting Contractor.
6.6 The Project Engineering Manager will issue the final flange assembly procedure along
with any Flange Management documentation to Fluor Construction or the Construction
Contractor.
Practice 000.200.0780
Date 14Jan2019
7.0 SUPPORTING RESOURCES

Attachment
Attachment 01 Roles and Responsibilities Chart and Workflow
Attachment 02 Considerations when Reviewing a Flange Assembly Procedure
Attachment 03 Identification of Critical Flanges for Special Consideration
Refer to Section 9 for more information.
8.0 SUPPORTING KNOWLEDGE
9.0 ATTACHMENTS, ADDENDA, WORK INSTRUCTIONS

Addenda
Not Used
Attachment
Attachment 01 Roles and Responsibilities Chart and Workflow
Attachment 02 Considerations when Reviewing a Flange Assembly Procedure
Attachment 03 Identification of Critical Flanges for Special Consideration
Work Instructions
Not Used
Practice 000.200.0780
Date 14Jan2019
Attachment 01
01 ROLES AND RESPONSIBILITIES CHART AND WORKFLOW
Note: reference to “Fluor Construction” also includes Fluor Fabrication
Practice 000.200.0780
Date 14Jan2019
Attachment 01
01 ROLES AND RESPONSIBILITIES CHART AND WORKFLOW
Practice 000.200.0780
Date 14Jan2019
Attachment 02
02 CONSIDERATIONS WHEN REVIEWING A FLANGE ASSEMBLY PROCEDURE

CRITICALITY ASSESSMENT
Flange Criticality defines the level of workmanship required to assemble and tighten a flange to insure that it will function as
required to minimize leakage, fires, explosions, personal harm and environmental damage. Also, the criticality ensures that
non-standard or specially designed connections are given the necessary attention.
PRE BOLTING INSPECTION

Inspection of the surface finishes and flange components (flanges, bolting, washers, gasket, bolt tightening, lubrication,
materials).
FLANGE AND GASKET ASSEMBLY

Flange alignment, proper lubrication, gasket handling & centering and stud tightening pattern
FLANGE MANAGEMENT DOCUMENTATION

Establish which assembled joints require proper documentation and tracking.
INSTALLATION BOLT LOAD

a. The required bolt load for initial installation of flanged connections shall be established to assure a leak tight connection
based on an acceptable methodology.
b. The following methodology shall be considered in establishing the bolt tightening procedure.
1. ASME PCC-1
Simple Method (Bolt target Stress Joint Component Approach)
2. EN 1591 1&2
3. ASME Section VIII Division 2 (proposed new section of Division 2 to include “PVRC” bolt load calculation method)
BOLT TIGHTENING METHODS

The method of applying the bolt load will be in accordance with the Field Flange Assembly Procedure. Some of the methods
are listed below.
1. Wrench (Examples: Turn-of-the-nut, hand tight, snug tight, etc.).
2. Calibrated torque wrench.
3. Hydraulic torque wrench.
4. Bolt tensioning tool.
QUALITY ASSURANCE
Tool calibration, frequency of inspection, remedial action and documentation.
Practice 000.200.0780
Date 14Jan2019
Attachment 03
03 IDENTIFICATION OF CRITICAL FLANGES FOR SPECIAL CONSIDERATION

Many Clients have their own requirements with respect to bolt tightening and criticality requirements. This information is
provided as a guide to establish a criticality for flange assembly sometimes referred to as a criticality rating. The criticality
can be defined by Engineering or in conjunction with a 3rd Party Bolting Contractor. Any agreed to rationale method for
determining flange criticality is permitted.
Flange Criticality defines the level of workmanship required to assemble and tighten a flange to insure that it will function as
required to minimize fires, explosions, personal harm and environmental damage. Also, criticality identification determines
non-standard or specially designed connections that require additional attention.
Besides the detailed method listed below any rationale method is permitted. All or part of the information given can be used
to establish a criticality rating method. Table 03-1 shows an example of a criticality rating method based on ASME piping
information and PCC-1.
Table 03-1
The following detailed method for establishing a criticality method is based on discussions with Fluor HSE (Health, Safety,
and Environment).
· A flange with a criticality of 1 shall be the highest flange criticality, decreasing to 2 then 3. Referencing Table 03-2, the
Flange Criticality shall be determined by the combination of factors “Flammability / Combustibility”, “Personal Injury”,
“Environmental Damage” and “Mechanical Complexity of Joint”.
· A joint shall have a Flange Criticality of 1 if any of the factors are “High”, a joint shall have a Flange Criticality of 2 if any
of the factors are “Medium” but none are “High” and a joint shall have a Flange Criticality of 3 if none of the factors are
“Medium” or “High”.
Practice 000.200.0780
Date 14Jan2019
Attachment 03
Table 03-2
FLAMMABILITY / COMBUSTIBILITY
The possibility of commodity leakage, burning, or exploding (considering the consequence of injury or death to personnel).
High
Combustible liquids (see 29 CFR 1910.106), two different commodities in adjacent lines when mixed after leaking from their
respective flange mix creating an explosion, fire or explosive environment.
Gas which when leaked can form an explosive environment.
Commodities that will auto-ignite.
Medium
Flammable liquids (see 29 CFR 1910.106). Those not considered high.
Low
Non-combustible and non-flammable commodities.
PERSONAL INJURY
Practice 000.200.0780
Date 14Jan2019
Attachment 03

Physical harm or death caused by leakage of the commodity through the force of the commodity exiting through a flange
leak, creating a dangerous atmosphere for inhalation or through contact.
High
Commodities which can cause major injury requiring hospitalization or result in death. Two different commodities in adjacent
lines when mixed after leaking from their respective flange mix creating a dangerous environment. (Examples such as
radioactive material, hydrofluoric acid, H2S, super heated steam)
Medium
Commodities which can cause only minor injury. These not considered “high”
Low
Commodities which cause no bodily injury.
ENVIRONMENTAL DAMAGE
Damage to the environment from a leakage of the commodity.
High
Uncontainable environmental damage, short term irreversible effects.
Medium
Containable environmental exposure. Those not considered “high.”
Low
No environmental risk.
MECHANICAL COMPLEXITY OF JOINT

A measure of complexity of a joint is as compared to a standard ASME flange.
High
Custom designed flanges, vendor proprietary flanges, flanges on critical machines, body flanges on vessels over 6 ft in
diameter.
Medium
RTJ flanges, flanges with special gasketing, body flanges on vessels under 6 ft in diameter.
Low
Standard ASME flanges with standard gasketing
Practice 000.200.0780
Date 14Jan2019
DEFINITIONS
The following terms and acronyms apply to this practice.
Title Description
3rd Party Bolting Contractor Contractor specializing in flange assembly and flange management.
American Petroleum Institute American Petroleum Institute

(API)
Approved Suppliers List (ASL) Approved Suppliers List
Authority Having Jurisdiction An official organization or person who has the delegated authority to
(AHJ) determine, mandate and enforce code requirements established by
jurisdictional governing bodies regulations.
CA Contract Administrator
Certificate of Conformity Document prepared by the Notified Body which declares compliance to the
(COC) PED of the equipment or piping considered, based on examinations
performed according the applicable Conformity Assessment Procedure.
CII Construction Industry Institute
Civil Structural Architectural Civil Structural Architectural

(CSA)
Client Owner or their authorized representative.
Criticality Rating (CR) A method of assessing the importance of an item with respect to various
categories such as its design, manufacturing routines, and the consequences
of failure. The criticality for equipment and materials is established on a scale
of 1 to 4 with 1 being the most critical, 4 being the least critical. Form
000.200.F0077, Criticality Rating Form, has the standard categories and
definitions for criticality used on Fluor projects.
CWP Construction Work Package
DAS Discipline Application Specialist
Practice 000.200.0780
Date 14Jan2019
Declaration of Conformity Document prepared by the Manufacturer which declares compliance to the
(DOC) PED of the pressure equipment considered based on examinations
performed by the Manufacturer’s Inspection/QA department and/or assigned
NoBo according to the applicable Conformity Assessment Procedure.
Dust Hazard Analysis (DHA) Dust Hazard Analysis
EI Energy Institute
Engineering Procurement Engineering Procurement Fabrication Construction

Fabrication Construction
(EPFC)
EOR Engineer of Record
Essential Safety Requirement The Essential Safety Requirements are included in Annex I of the PED. The
(ESR) Manufacturer must address all design / operating and reasonably foreseeable
process conditions of the pressurized equipment and demonstrate
compliance to the Essential Safety requirements defined in the PED. These
include requirements on Design, Materials, Manufacturing, Inspection and
Testing, Operation Instructions, and Marking.
FAT Factory Acceptance Test
Field Construction site or fabrication yard.
Flange Assembly Includes alignment, bolt tightening and inspection of the surface finish and
flange components (flanges, bolting, washers, gasket, bolt tightening,
lubrication, and materials).
Flange Management Tracking document used to indicate variables used in bolted joint systems as
agreed to by the Client and 3rd Party Bolting Contractor.
Fluor Construction Fluor entity performing construction / construction management and/or

fabrication.
Global Supplier Manager Global Supplier Manager

(GSM)
Practice 000.200.0780
Date 14Jan2019
GRW Global Reference Warehouse
HSE (HSE) Health, Safety and Environmental
ICP (ICP) Individual Contract Plan
IEC International Electrotechnical Commission
Installation Work Package An Installation Work Package (IWP) is a portion of scope derived from a
(IWP) CWP. It is comprised of an Installation Code and a Sequence number, which
contains all necessary elements for a single construction crew to complete
that portion of the scope of work. It includes critical documents along with a
detailed execution plan. The WFP team will confirm that a released IWP will
contain constraint free work that can be executed by a single foreman and
crew within a practical construction timeframe (typically a 1-2 week shift).
Isometric Control Utility (ICU) Isometric Control Utility – A database application used to track, status, and
report the progress of piping isometric spool drawing production.
Issued For Construction (IFC) Issued For Construction
LE Lead Engineer
MES Miscellaneous Electrical Supports
Model Review (MR) A plant design review with the Client and/or Licensor that uses an electronic
3D model.
MPS Miscellaneous Pipe Supports
MTO Material Take Off
NTE Not-to-Exceed
OBS (OBS) Organizational Breakdown Structure
PAM Project Activity Model
Practice 000.200.0780
Date 14Jan2019
Particular Material Appraisal A document that - for materials which are not listed in a harmonized standard
(PMA) nor have European approval - provides a statement that a material fulfills the
requirements of the ESR and are suitable for the proposed use and
conditions. It prescribes the physical and chemical properties of a material.
PMA’s shall be submitted by the Manufacturer to the Notified Body for
approval.
PCM Project Contracts Manager
PDN Potential Deviation Notice
PEP Project Execution Plan
PFD Process Flow Diagram
PIM Project Information Manager
PM Project Manager
Process Industry Practices Process Industry Practices is a process industries standards organization that
(PIP) issues practices suitable for purchase orders or contracts. The practices are
harmonized from non-proprietary best practices from member companies.
Process Safety Start-up Safety review conducted prior to startup (commissioning) of a new or
Review (PSSR) modified processing / manufacturing plant or facility to verify that installations
meet the original design or operating intent, to catch and re-assess any
potential hazard due to changes during the detailed engineering and
construction phase of a project
PSM (PSM) Project Surveillance Manager
PU Package Unit
Purchase Order (PO) Purchase Order - A PO is the Buyer's official notification to the seller of
authority to manufacture, supply, ship, and invoice for the goods specified in
the order and Fluor’s commitment to pay for the value of the goods ordered. It
is a legal document and should clearly and precisely cover the essential
elements of the order in a manner that will render misunderstandings
improbable.
Practice 000.200.0780
Date 14Jan2019
RAS Required at Site
Reference Plant Type (RTP) A standard identifying attribute of a (part of) Scope of Facilities used to
classify the components of a project in such a way that data can be collected
and analyzed for historical data collection and for benchmarking execution
and financial data. A listing of Reference Plant types to be used on Projects
can be found in Practice 000.000.0500, Unison Data Standards.
Request for Quotation (RFQ) Taken to be synonymous with inquiry, it is the document used to obtain price
and delivery on a competitive basis for the goods required for projects.
Rough Order of Magnitude Rough Order of Magnitude

(ROM)
RPC Revamp Planning Coordinator
SAT Site Acceptance Test
Scope of Facilities (SOF) The Scope of Facilities is part of the Project Baseline Scope of work. It
describes the facilities that will be provided as part of the project.
Scope of Work (SOW) The Scope of Work is the Baseline Document for the project that includes the
Scope of Services (SOS) and Scope of Facilities (SOF) for the project.
SPI SmartPlant Instrumentation
Statement of Compliance Document prepared by the manufacturer of a product (not being the “overall”
(SOC) manufacturer) or their authorized representative which states compliance to
the PED of the pressure equipment considered based on examinations
performed by the Manufacturer’s Inspection/QA department and/or assigned
Notified Body according to the applicable Conformity Assessment Procedure.
Supplier Quality Surveillance Fluor’s Supplier Quality Surveillance group provides inspection services, and
(SQS) reduces potential quality variances in delivered materials and services by
offering cost-effective solutions for monitoring Supplier quality system
performance prior to shipment. The SQS Representative oversees the
inspection of equipment and materials that are produced at Suppliers’
facilities, resolves Supplier-related quality problems, and contributes to a
quality ratings database for future procurement needs.
Practice 000.200.0780
Date 14Jan2019
UG Underground
VBA Visual Basic for Applications
Very Large Module (VLM) A VLM is a module weighing more than 600 tons. Generally, above 600 tons
requires nonconventional lifting / jacking and transporting methods.
Transportation is often by barge or heavy transport vessel (HTV). VLMs
provide an opportunity to maximize modular content. Construction of a VLM is
often segregated into stages in the module yard and the WBS level – Stage –
is used to define these boundaries.
Work Breakdown Structure Represents the way the project work will be defined, planned, managed, and
(WBS) controlled by subdividing the project scope of work into manageable
segments (elements). A WBS is a hierarchical framework (family tree),
composed of products and services that progressively and logically
subdivides the entire work content. It serves the control needs of a project by
providing a structure for performing work and defining how cost and schedule
data are summarized and reported. The WBS is developed from the project
scope to a level of detail that defines the framework for the organization and
reporting of project information, allowing for effective project control of costs
and schedule. Elements of the WBS serve as the foundation for the Project
Execution Plan as well as project control functions.

000.200.0780 Establishing Flange Assembly Requirements

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

000.200.0780 Establishing Flange Assembly Requirements

Uploaded by

Copyright:

Available Formats

1/14/2019 000.200.0780 Establishing Flange Assembly Requirements.

ESTABLISHING FLANGE ASSEMBLY REQUIREMENTS

3.0 INTERFACING DISCIPLINES

5.0 This section has been left intentionally blank

ESTABLISHING FLANGE ASSEMBLY REQUIREMENTS

See Attachment 02 for more information on considerations when reviewing

ESTABLISHING FLANGE ASSEMBLY REQUIREMENTS

7.0 SUPPORTING RESOURCES

8.0 SUPPORTING KNOWLEDGE

9.0 ATTACHMENTS, ADDENDA, WORK INSTRUCTIONS

ESTABLISHING FLANGE ASSEMBLY REQUIREMENTS

01 ROLES AND RESPONSIBILITIES CHART AND WORKFLOW

Note: reference to “Fluor Construction” also includes Fluor Fabrication

ESTABLISHING FLANGE ASSEMBLY REQUIREMENTS

01 ROLES AND RESPONSIBILITIES CHART AND WORKFLOW

ESTABLISHING FLANGE ASSEMBLY REQUIREMENTS

02 CONSIDERATIONS WHEN REVIEWING A FLANGE ASSEMBLY PROCEDURE

PRE BOLTING INSPECTION

FLANGE AND GASKET ASSEMBLY

FLANGE MANAGEMENT DOCUMENTATION

INSTALLATION BOLT LOAD

BOLT TIGHTENING METHODS

ESTABLISHING FLANGE ASSEMBLY REQUIREMENTS

03 IDENTIFICATION OF CRITICAL FLANGES FOR SPECIAL CONSIDERATION

ESTABLISHING FLANGE ASSEMBLY REQUIREMENTS

03 IDENTIFICATION OF CRITICAL FLANGES FOR SPECIAL CONSIDERATION

ESTABLISHING FLANGE ASSEMBLY REQUIREMENTS

03 IDENTIFICATION OF CRITICAL FLANGES FOR SPECIAL CONSIDERATION

MECHANICAL COMPLEXITY OF JOINT

ESTABLISHING FLANGE ASSEMBLY REQUIREMENTS

American Petroleum Institute American Petroleum Institute

Approved Suppliers List (ASL) Approved Suppliers List

CII Construction Industry Institute

Civil Structural Architectural Civil Structural Architectural

Client Owner or their authorized representative.

CWP Construction Work Package

DAS Discipline Application Specialist

ESTABLISHING FLANGE ASSEMBLY REQUIREMENTS

Dust Hazard Analysis (DHA) Dust Hazard Analysis

Engineering Procurement Engineering Procurement Fabrication Construction

EOR Engineer of Record

FAT Factory Acceptance Test

Field Construction site or fabrication yard.

Fluor Construction Fluor entity performing construction / construction management and/or

Global Supplier Manager Global Supplier Manager

ESTABLISHING FLANGE ASSEMBLY REQUIREMENTS

GRW Global Reference Warehouse

HSE (HSE) Health, Safety and Environmental

ICP (ICP) Individual Contract Plan

IEC International Electrotechnical Commission

Issued For Construction (IFC) Issued For Construction

MES Miscellaneous Electrical Supports

MPS Miscellaneous Pipe Supports

MTO Material Take Off

OBS (OBS) Organizational Breakdown Structure

PAM Project Activity Model

ESTABLISHING FLANGE ASSEMBLY REQUIREMENTS

PCM Project Contracts Manager

PDN Potential Deviation Notice

PEP Project Execution Plan

PFD Process Flow Diagram

PIM Project Information Manager

PSM (PSM) Project Surveillance Manager

ESTABLISHING FLANGE ASSEMBLY REQUIREMENTS