REF. NO _PREF-EM-STA-CON-TRN-0007 bed TRANSMITTAL = ("2 PRefChem mace TRON HASUNA SALINDING ‘Mechanical Static 70 TINS INTEGRATED SERVICES SDN BHD saeer PROCEDURE Senin ‘Document Noy nev NO. DRAWING NO. No. seuseusrea! 7 [NA 5_| PRefChem 6F1 Procedure Jan 2000 2 [wa 1ISC Clean FoR = NO. OF COPIES] TYPE CD Approval/ Return As Per Your Request Print(s) Each Bi information only /File Ci issued For Construction ‘Sepia(s) Each Ci Review / Comments CAs Built Original{s) Each Ci further Action CDlothers: ‘Soft Copy(s) Each REMARKS Reproved come caiprbye (uranaan 2H 8 £90 RAG) ( arannon Hen) Penton’ Executive Planner, Mechs Position: Gtr (CoC Dept: Engineering & Maintenance Dept: G4/@ Date: 14" Oct 2020, date: (¢//o/2020 ‘The above documents was transmitted from the office of Mechanical Static contact Person dees: asia Salina PRetChem office ‘Adri, Mechanica Static Fst Floor, Engineering & Maintenance Guiding MWED2, e-malchasine slindiog@prefehemcom ___Pengeran. Please Acinowedge Receipt by Retuzn Of The Sncd Copy & email To The Sendereon (OEMs) i 06 Physical Asset Management Administrative Procedure [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure Procedure 03 Maintenance Management 01 PETRONAS Maintenance Management System Bolted Flange Joint Integrity (BFJI) Procedure Document Ref. No.: renceNoLabell Revision o Published: {LastReviewDateLabel] Next revision date: [NextReviewDateLabel This hard copy document is vail for 48 hours only unless clearly identified as controlled copy. Date & time printed 6 October 2020, 5:20 PM. Page 0 of 128PRPC OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM (OEMS) e: PRefChem PRefchem| Manufacturing & Engineering - Engineering & Maintenance Procedure 06 Physical Asset Management [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Administrative Procedure ‘This hard copy document is vali for 48 hours only unless clearly identified as controllee copy. ‘Date & time printed 6 October 2020, 5:20 PM Page 1 of 128‘OPERATIONAL EXCELLENCE 7 MANAGEMENT SYSTEM ear PRefChem (OEMS) i PRefchem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure [ReferenceCadeLabel] Bolted Flange Joint Integrity (BFII) Procedure BOLTED FLANGE JOINT INTEGRITY (BFJI) PROCEDURE Tis hard cony documents vai fr 48 how's only ues leary tented as controled copy Date & time printed 6 Gctober 2020, 5:2 Page 2 of 128‘OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM eee e PRefChern (oems) PRefChem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure Table of Contents ‘TABLE OF CONTENTS 1.0 INTRODUCTION 11 PURPOSE 1.2 score 1.3. GLOSARY OF TERMS. 13.1 Specific Definitions of Abbreviations. 1.3.2 Specific Definitions of Terms. 14 SAFETY 1.5. PRECAUTIONS 1.6 PERSONNEL 17 TOOLS & EQUIPMENT 2.0 MANAGEMENT OF BOLTED FLANGE JOINT INTEGRITY. 2.1 PLANNING AND PREPARATION OF BF! PROGRAM .. 2.1.1 Organization Chart. 2.1.2 BFII Execution Personnel Work Matin: 24.3 Roles & Respons 2.1.4 — Flange Master Register 241.5 — Resource Plannir 2.1.6 Joint Integrity Control Sheet (JICS) 2.1.7 Training and Assessment.. 2.1.8 Quality Assurance Planning ..... 2.2 PRE-EXECUTION.. 2.24 Resources Mobilization 2.2.2 — BEIIBriefing..... 2.2.3 Dry Run And Tagging.. “This hard copy document is vali for 48 hours only unless clearly identified as contrlles copy, Date & time printed 6 October 2020, 5:20 PM Page 3 of 128‘OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM ore e PRefChern (OEMS) PRefChem Manufacturing & Engineering - Engineering & HIE Maintenance 06 Physical Asset Management Administrative Procedure [Refere Procedure CodeLabel] Bolted Flange Joint Integrity (BFJI) 3.0 2.24 Site Preparation 2.25 Document Readiness. 23° EXECUTION. 2.3.1 Executing BFIA. 2.3.2 Joint Inspection Hold Points 233 BRIA Tagging os 23.4 BFIA Defects and Rectification.. 23.5 Leakage Control and Rectification 23.6 BFA Monitoring & Reporting . 23.7 Audit & Assurance... 2.4 POST EXECUTION 2.4.1 Monitoring During Start-Up. Petite 2.4.2 Start-Up Re-Torqueing, Leak Rectification & Monitoring 24.3 — Online Leak Sealing... 2.4.4 — Lesson Learnt, 2.45 — Root Cause Failure Analysis. eee 38 2.4.6 — BFII Results and Reports... ‘TECHNICAL REQUIREMENT OF BOLTED FLANGE JOINT INTEGRITY 3.1 FACTORS INFLUENCING BOLTED FLANGE JOINT INTEGRITY 40 3.2. DEFINITION OF CRITICAL JOINTS. eater a1 3.3. JOINT DISSASSEMBLY.. 3.3.1 Cleaning and Examination of Flange and Fastener Contact Surface: 3.3.2 Reuse or Replacement of Bolts, Nuts and Washers... 3.4 JOINT ASSEMBLY ees 45 3.4.1 Alignment of Flanges Joints 3.4.2 Installation of Gasket... This hard copy document is valid for 48 hours only unless clearly identified as controlled copy. Date & time printed 6 October 2020, 5:20 PM Page 4 of 128OPERATIONAL EXCELLENCE PRPC MANAGEMENT SYSTEM (OEMs) PRefChem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFIL) Procedure 3.4.3 Lubrication of Working Surfaces of Fastenei 3.4.4 _ Installation of Bolts.. 3.45 Numbering Of Bolts....... 3.46 Tightening Method / Load Control Technique 3.4.7 Tightening Sequence.... 3.4.8 Joint Tightness Acceptance Criteria. 35 TARGET TORQUE DETERMINATION 354 Standard Flange 3.52 Non Standard Flange... 3.6 LEAK RECTIFICATION 6 3.7 JOINTLEAK & TIGHTNESS TEST osonmnnnninnninnnnnnninnnnnninnnnnn62 3.7.1 Failure of Joint Leak & Tightness Test. 3.8 START-UP RE-TORQUING ANNEX A: PROCESS FLOW OF BFiI MANAGEMENT PRODECURE A. BFJA OVERALL PROCESS FLOW snnnnninnununsneninen '[A2__ PLANT TURN-AROUND CYCLE BFIA OVERALL PROCESS FLOW vse JIT ORGANIZATION CHART BFJI WORKFLOW. G4 PENNING spams cess 67 2 BRILACTIVITY.. ee ANNEX D: JOINT INTEGRITY CONTROL SHEET (JICS) 1. ANNEXE: — RACIMATRIX.. ANNEX ANNEX ANNEX F: RECOMMENDED TORQUE .. FA TABLE SUMMARY 80 TABLE F1 - RECOMMENDED TORQUE VALUES AT 60% BOLT YIELD 2 ‘This hard copy document is vali for 48 hours only unless clearly Identified as controlled copy Date & time printed 6 October 2020, 5:20 PM Page 5 of 128‘OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM er Se PRefChem (oEMs) PRefChem Menufecturing & Engineering -Enginesring & Maintenance 06 Physical Asset Management [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure Administrative Procedure TABLE F2 — RECOMMENDED TORQUE VALUES AT 40% BOLT YIELD... TABLE F3 ~ RECOMIMENDED TORQUE VALUES AT 60% BOLT YIELD TABLE Fa ~ RECOMMENDED TORQUE VALUES AT 40% BOLT VIELD ‘TABLE F5 — RECOMMENDED TORQUE VALUES AT 60% BOLT YIELD ‘TABLE F6 ~ LEAKAGE CONTROL TORQUE VALUE AT 60% AND MAXIMUM TORQUE VALUE ..87 83 84 35 86 ‘TABLE F7 ~ LEAKAGE CONTROL TORQUE VALUE AT 40% AND MAXIMUM TORQUE VALUE... 88 ‘TABLE FS — RECOMMENDED TORQUE VALUES AT 60% BOLT YIELD ‘TABLE F9 - RECOMMENDED TORQUE VALUES AT 40% BOLT YIELD TABLE F10 ~ RECOMMENDED TORQUE VALUES AT 60% BOLT VIELD ‘TABLE F11 ~ RECOMMENDED TORQUE VALUES AT 40% BOLT VIELD.. ‘TABLE F12 — LEAKAGE CONTROL TORQUE VALUE AT 60% AND MAXIMUM TORQUE VALUE 93 89 90 1 92 ‘TABLE F13 ~ LEAKAGE CONTROL TORQUE VALUE AT 40% AND MAXIMUM TORQUE VALUE 94 TABLE F14~ RECOMMENDED TORQUE VALUES FOR INSULATING FLANGE GASKET... 95 ‘TABLE F15 ~ RECOMMENDED TORQUE VALUES FOR INSULATING FLANGE GASKET.. ‘TABLE FL6 ~ RECOMMENDED TORQUE VALUES AT 40% BOLT YIELD 96 97 ‘TABLE F17 ~ LEAKAGE CONTROL TORQUE VALUE AT 40% AND MAXIMUM TORQUE VALUE 98 TABLE F18 ~ RECOMMENDED TORQUE VALUES AT 60% BOLT YIELD .. TABLE F19 ~ LEAKAGE CONTROL TORQUE VALUE AT 60% AND MAXIMUM TORQUE VALUE ‘TABLE F20— RUBBER GASKET & COMPRESSED NON-ASBESTOS FIBER (CNAF)... ANNEX G: RECOMMENDED GASKET CONTACT SURFACE FINISH .. ANNEX H: ALLOWABLE GASKET CONTACT SURFACE FLATNESS. ANNEX: FLANGE FACE INDICATIONS TOLERANCES. ANNEXJ: FLANGE JOINT ALIGNMENT GUIDELINES. J GENERAL so 1.2. GUIDELINES FOR ALIGNING FLANGES... 99 100 101 102 103 105 107 107 107 This hard copy document Is valid for 48 hours only unless clearly identified as controlled copy Date & time printed 6 Cetober 2020, 5:20 PM Page 6 of 128OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM ae ean Se: PRefChem PRefChem Manufacturing & Engineering - Engineering & Naintenance 06 Physical Asset Management Administrative : Procedure {feferenceCodeL abel] Bolted Flange Joint Integrity (BFII) Procedure 13. LARGE PIPING CONNECTED TO LOAD SENSITIVE EQUIPMENT. 107 JA CRITICALLY STIFF PIPING . 415 TERMS AND DEFINITIONS. ANNEX K: TJ GASKETS SURFACE FLATNESS ..snsnnn ANNEX L: LENS RING GASKET... ANNEX M: BOLT ROOT AND TENSILE STRESS AREA . ANNEX N: FLANGE BOLTING INFORMATION .. [ANNEX O: FLANGE JOINT LEAKAGE TROUBLESHOOTING AND CONTROL.. (0.1. TROUBLESHOOTING AND INVESTIGATING FLANGE LEAK. 115 0.2 _ JOINT INTEGRITY CONTRIBUTED BY DESIGN AND PRACTICE... : a7 0.3. LEAKAGE PROBLEMS, POSSIBLE CAUSE AND POTENTIAL SOLUTIONS, 120 (0.4 LEAKAGE CONTROL WORKS & RE-TORQUEING GENERAL PROCEDURE 123 0.5 LEAKAGE CONTROL ACCEPTANCE CRITERIA snes ANNEX P: TRAINING & QUALIFICATION OF BOLTED JOINT ASSEMBLY PERSONNEL... 125 PA TRAINING PROGRAM REQUIREMENT. : 125 2.2. MINIMUM QUALIFICATION. sss 25 °.3._BFUI CERTIFICATION ASSESSMENT ICA) REQUIREMENTS . sn 6 PBF CERTIFICATION VALIDITY 127 DOCUMENT HISTORY This hard copy document is valid for 48 hours only unless clearly identified as contrllee copy. ‘Date & time printed 6 October 2020, 5:20 PM Page 7 of 128vec Beco (OEMS) [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFJI) =e 1.0 INTRODUCTION This document is a major revision of previously issued OEMS Administrative Procedure PRPC- 06_03_02-13-0P-030999 Maintenance Management — Bolted Flange Assembly Joint Integrity (BFIA_JIT) Management. This document provides the minimum management and technical requirements that are applicable during handling of bolted flange joint assembly (BFA) and the recommended practice and guidance for managing BFIA activities in order to achieve zero leak of the bolted flange joints. ‘This procedure described in this document is applicable to PRefChem and ALL Contractors that involve in the BFIA activities. 1.1 PURPOSE ‘This procedure provides requirement in managing the integrity of a bolted joint assembly works, from initiation, planning & preparation, pre-execution, execution and post-execution 1.2 SCoPE This procedure shall apply to bolted flange joints activities for daily maintenance, shutdown, turnaround and projects. It is also applicable for battery limit blinding and process blinding activities. ‘This procedure shall cover both Critical Joints and Non Critical Joints ‘This procedure shall apply to Bolted Flanges Joint Assembly (BFIA) including piping flanges, process equipment flanges, and instrumentation flanges. This procedure covers circular geometry joint. For OEM circular geometry joint assembly, and other than circular geometry, such as those used in rotating casing, valve bonnet, and sight glasses, OEM BFIA manual/specification shell be referred. ‘This hard copy document Is valid for 48 hours only unless clearly identified as controled copy. Date & time printed 6 October 2020, 5:20 PM Page 6 of 128OPERATIONAL EXCELLENCE Maintenance 06 Physical Asset Management [ReferenceCadeLabel] Bolted Flange Joint Integrity (BFII) Procedure eee MANAGEMENT SYSTEM PRefChem (oems) J PRefchem Manufacturing & Engineering - Engineering & Administrative Procedure 1.3 GLOSARY OF TERMS 1.3.1 Specific Definitions of Abbreviations Bry Bolted Flange Joint BRIA Bolted Flange Joint Assembly Bra Bolted Flange Joint Integrity cB ‘Construction Industry Development Board cop Community of Practice EIS Equipment Isolation Sheet EWR Emergent Work Request Ts, PETRONAS Group Technical Solutions Her Hydraulic Bolt Tensioning, Tw Hydraulic Torque Wrench JHA Job Hazard Analysis ICA Joint Integrity Competency Assessment sis, Joint Integrity Control Sheet ar Joint integrity Team. JMS Job Method Sheet KPI Key Performance indicators es. Material Control Sheet MIw Manual Torque Wrench MTW-M Manual Torque Wrench with Multiplier oru Operating Unit ASR Pre-Activity Safety Review PTA Project Technical Authority Prw Permit To Work cA Quality Assurance ac Quality Control ‘This hard copy document Is valé for 48 hours only unless clearly identified as contrlied copy, Date & time printed 6 October 2020, 5:20 PM Page 9 of 128‘OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM PREC e PRefChem corms) i PRefChem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Procedure {ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure RCA, Root Cause Analysis RACI Responsible, Accountable, Consult, Informed SMe Subject Matter Expert A Turnaround . Technical Professional wes Work Control sheet 1.3.2 Specific Defi Bolted Flanged | Bolted flanged connection with gasket in circular joint geometry including piping Joint Assembly | flanges, process equipment flanges, and instrumentation flanges. (8FsA) Bolted Flanged The management process in ensuring leak free BFIA. It does not cover leaks from Joint integrity | other parts such as on piping due to weld defects or corrosion, and threaded (eri) joint. Dry Run Joint site visit with Operation ; “The sequential removal and replacement of bolts on flanged joints while the unit beceetine is under reduced operating pressure while the unit is online, or once the unit is depressurized to replace corroded or defective bolts or to proactively increase the gasket stress to prevent leakage (in high-temperature or cyclic services) or to reseal a small stable leak. The procedure generally consists of removing one bolt atatimeina flange, re-lubricatingt,reinstalingit (or anew bolt), and retightening itto aspecified torque. Hot bolting is potentially hazardous and the utmost caution need to be exe when planning and carrying out this operation. It is not recommended despite being practiced in industey. port ‘This hard copy dacument is valid for 48 hours only unless clearly identified as controlled copy. Date & time printed 6 October 2020, 5:20 PH Page 10 of 128 AdministrativeOPERATIONAL EXCELLENCE | MANAGEMENT SYSTEM PRPC e PRefChem (oems) PRefChem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management ‘Administrative Procedure Procedure {ReferenceCodel abel] Bolted Flange Joint Integrity (BFII) Hot-bolting is not to be confused with start-up re-torqueing. Refer to ASME PCC-1 / PCC-2 for further information on joint tightening activities once the unit is fully operational. Live Tightening, Tightening all bolts on a joint while the unit is operational or has been in operation for a period of time. The technique used for tightening may be manual torque, hydraulic torque, or hydraulic tension. However, torque can typically no longer be considered accurate after more than a few days of operation. Therefore, other techniques such as turn- of-nut or tensioning are preferred. Hot bolting is also an option, but there is a higher risk associated with that activity due to the associated reduction in gasket stress ifthe tightening is performed while the joint is pressurized. Live tightening should not be considered the same as start-up re-torque, which is performed as part of the assembly operation; live tightening is an operational activity that may be performed on a periodic basis to recover relaxation (typically on high- ‘temperature joints that have a history of leakage) or asa reaction to joint leakage. ‘An engineering and risk analysis ofthe live-tightening operation should be carried ut to establish that the operation can be performed safely. Refer to ASME PCC-1 / PCC-2 for further information on joint tightening activities, ‘once the unit is fully operational. Start-up Re- torqueing Tightening all bolts on a joint while the unit is ramping up to operating ‘temperature in a circular pass until the nuts no longer turn, Start-up re-torquing (also raferred to as hot torque) is performed to increase the residual operational stress on the gasket (to recover initial gasket relaxation), to minimize the likelihood of leakage. Itis typically performed while the unit is online but may also be performed prior to operation using heating pads to bring the flange up to temperature. Since this activity will only increase the load on the gasket, the risk of leakage is significantly lower than for other activities (such as hot bolting). ‘This hard copy document is valid for 48 hours only unless clearly identified as controlled copy. Date & time printed 6 October 2020, 5:20 PM Page 11 of 128OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM ae e PRefChem (oes) PRefChem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure (ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure Refer to ASME PCC-1 / PCC-2 for further information on joint tightening activities ‘once the unit is fully operational Owner Pengerang Refining Company Sdn Bhd & Pengerang Petrochemical Company Sdn Bhd (PRefCher} P-Bolt PETRONAS torque value calculation software Fur Flange Management Tool 14 SAFETY Prior to starting the BFIA work, the JIT Supervisor shall ensure all necessary safety precautions are in place, and the personnel and area are safe to execute the work, Observe and identify hazards involved with works, and perform Job Hazard Analysis (JHA). All hazards information shall be clearly communicated and understood by all parties involved prior to work execution, Work perform shall comply with all safety requirements specified in this procedure, Permit to Work (PTW) and all relevant HSE procedures. Mandatory PPE shall always be worn such as fire retardant coverall, safety helmet, safety goggle, safety shoe, and impact resistance glove. Consider the requirements for special Personal Protective Equipment (PPE) such as heat resistance suit and gloves, SCBA, chemical suit, splash goggle, or others for blinding / de-blinding work and Re-Torqueing or Leakage Control Works. BFIA work impose high risk on hand injury mainly due to impingement. Always observe the position of hand while working, and ensure clear and constant communication if tools are being handled by more than one person such as HTW and HBT machinery. ‘Ths hard copy document is valid for 48 hours only unless clearly identified as controlled copy. Date & time printed 6 October 2020, 5:20 PM Page 12 of 128irene (OEMS) i | 06 Physical Asset Management Administrative a [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure 1.5 PRECAUTIONS 15.1 Torqueing Work with Energized Piping or Equipment Leakage Control As these works are performed while piping or equipment isin operation; high pressure and/or high ‘temperature, hazards should always be observed and identified prior to work execution. Hot Bolting, Start-Up Re-torque and Live Tightening Hot-bolting, start-up re-torque, and live tightening are potentially hazardous and the utmost caution needs to be exercised when planning and carrying out these operation. Its not recommended despite being practiced in industry. Specific procedures shall be reviewed by Bolting Specialist and approved by TP Static/PTA/BTA prior to execution. For hot-bolting, refer to ASME PCC-1: Article 311 and ASME PCC-2 : Appendix B for further information ‘on joint tightening activities once the unit is fully operational 1.6 PERSONNEL Only trained and competent JIT Supervisor, Joint Maker, and Control Bolting Technician are allowed to perform the BFJA works as specified in this document. JIT Supervisor trained and passed the assessment under PRefChem training & assessment module are allowed to perform the BFJA works and to lead joint making and bolt tightening works Only Joint Maker and Control Bolting Technicians that are trained and passed assessment under PRefChem training & assessment module are allowed to perform the perform manual torqueing and HTW & HBT respectively. “This hard copy document is valid for 48 hours only unless clearly identified as controlled copy. Date & time printed 6 October 2020, 5:20 PM Page 13 of 128,OPERATIONAL EXCELLENCE PRPC MANAGEMENT SYSTEM (OEMS) PRefChem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management {ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure 17 TOOLS & EQUIPMENT All tools and equipment for BFIA activity shall in a good safe and condition. This is important to ensure that the work is carried out safely and to eliminate any potential injury due to defective tools. JIT Supervisor shall ensure the correct tools and their size to be used for the BFJA activity. ‘Tempered and/or unauthorized modified tools and equipment are prohibited to be used in any of the PRefChem facility. Should modified tools and/or equipment are to be used, prior approval shall be obtained from PRefChem’s Technical Authority. Non-inspected and defective tools and equipment shall be removed immediately from site, ‘Ts hard copy document Is vali for 48 hours only unless clearly Mentiied as controled copy, Date & time printed 6 Getober 2020, 5:20 PM. Page 14 of 128OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM ee e PRefChem (oEms) PRefChem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure 2.0 MANAGEMENT OF BOLTED FLANGE JOINT INTEGRITY The following are the general main activities for a successful BFII program categorized in stage of execution. BEI Overall Process Flow Peon 1 epee 1 petronwmertaetobe =a Shans Pettaoe |! etttieoate romance ‘regen | Netntteees tee Figure 1: BFII Overall Process Flow 2.1 PLANNING AND PREPARATION OF BFJI PROGRAM The BFII Management Key Deliverables in planning phase are as follows: iI Implementation Plan JMS and JHA BFIl Organization Chart © R&R and RACE © Flange Master Register “This hard copy document is valid for 48 hours only unless clearly identified as contrlled copy, ‘Date & tine printed 6 October 2020, 5:20 PM Page 15 of 128OPERATIONAL EXCELLENCE = Brecon (OEMS) PRefchem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure Administrative Procedure © Resources required (ie, tools, JIT Supervisor, JIT inspector, JIT Ve Joint Integrity Control Sheet (JICS) Flange damage and repair work procedure fil training and assessment plan 2.1.1 Organization Chart etc) Organization Chart for JIT shall be established for each works. The Organization Chart shall consist of Contractor and PRefChem personnel. Recommended Organization Chart is as shown in ANNEX B. ‘This hard copy document is vali for 48 hours only unless clearly identified as controlled copy. ‘Date & time printed 6 October 2020, 5:20 PM Page 16 of 128OPERATIONAL EXCELLENCE ee MANAGEMENT SYSTEM e: (OEMs) Petes PRetChem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management [ReferenceCodeLabel] Bolted Flange Joint Integrity (BF3I) Procedure Administrative Procedure 2.1.2 BFIl Execution Personnel Work Matrix Please refer Table 1 below for BFil Execution Personnel Work Matrix, Cart Note: "Y" means "attend the job" and/or “perform inspection” Table 1 Execution Personnel Work Matrix “This hard copy document is valid for 48 hours enly unless clearly identified as controlled copy, Date & time printed 6 October 2020, 5:20 PM Page 17 of 128,PRPC OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM PRefChem. (OEMS) PRefchem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Procedure Procedure [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) 2.1.3 Roles & Responsibilities ‘The typical key members and their roles and responsibilities in the JIT organization structure include, bbut not limited to, the following personnel: (QAQC Manager Identify JIT personnel, establish the strategy and set the KPI for BF! Program. Lead JIT in implementing effective planning and execution of BFJI Program in order to achieve Zero Leak Start-up. Accountable that all BFII procedures are correct and correctly Implemented in practice. Accountable for Lessons Learnt Review and keeping of records of BFII activities. ‘Accountable in any decisions for joint acceptance, joint rectification and process waivers. = Ensure compliance to BFil procedure - 100% (determined by carrying ‘out quality check on the information in JICS during execution through regular audits) JIT Lead Responsible in coordinating and performing BFlI activities from Planning until Post Execution, Work closely with planners, mechanical ‘engineers, QA/QC and Material Coordinator to gather the information and provide input related to BFA. Responsible for all required BF procedure are available and correct. Responsible for establishing, monitoring and daily update on Joint Master List. Ensure readiness of materials, equipment, manpower, tagging and. documents as plan, This includes verification of materials ‘specification, equipment calibration, manpower competency, correct tagging with JCS. Responsible in ensuring Contractar’s compliance with BFil Procedure uring Execution. Perform Dry Run Operation to identify the correct joint(s) to be blinded/de- blinded, assembled and tightened. ‘This hard copy document is vald for 48 hours only unless clearly identified as controlled copy. Date & time printed 6 Getober 2020, 5:20 PM Page 18 of 128,OPERATIONAL EXCELLENCE fae MANAGEMENT SYSTEM e: PRefChem corns) Phetchem Mavutciurrg & Exgreeina Erpnening & tamecence 06 Physical Asset Management Administrative Procedure {ReferenceCodelabel] Bolted Flange Joint Integrity (BFII) Procedure Ensure compliance with Owner procedures and in adherence to Permit To Work (PTW) throughout BFJI execution Ensure the correct materials and tools are available and used throughout the execution of BF works. JIT Verifier "© Supervise 8FJI execution works and ensure steps done by Joint Maker/ Controlled Bolting Technicians meets BFll procedure and PTS 12.00.06 requirement. Witness and sign off critical Hold Points listed in the wes. Notify any defect found on the flange surface, bolts and nuts to JIT Lead and obtain recommendation for rectification, Sign off BFJI Tag and JICS upon work completion and inspection result is satisfactory. Verify the completion of works after Start Up per given acceptance criteria and verify inspection record in JICS. Ensure all housekeeping work has been completed and tags are removed. ‘+ Witness execution of all joints at Hold Points, sign and keep record of the ICs. Bolting Specialist/ = Accountable that all BFA procedure are correct and that all TP/SME requirements are included, + Accountable to approve deviation fram the agreed procedures after consultation with SME + Accountable that all QA/QC procedures is correctly followed in managing BIA Act as Subject Matter Expert on technical and engineering matters. + Gather inputs ie. operating parameters of the equipment, joint specification from Engineering data and Operations to establish Joint Integrity Management Procedure, bot tightening method and torque value foreach type of joints. Conduct BFil trainings and assessment for qualified personnel ‘This hard copy document is valid for 48 hours only unless clearly identified as contelled copy Date & time printed 6 October 2020, 5:20 PM Page 19 of 128OPERATIONAL EXCELLENCE Maintenance PRPC MANAGEMENT SYSTEM PRefChern (OEMS) PRefChem Manufacturing & Engineering - Engineering & 06 Physical Asset Management Administrative of the JCS, Participate in QA/QC ausits. ‘= Ensure joint activities complies recommendation Procedure [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure JIT Inspector = Responsible that all BF! activities comply with the requirements. ‘Witness execution of critical joints at Hold Points, sign and keep record ith BFII Procedure through JICS. = Perform inspection of joints, record findings and propose = Sign off JICS once the joint has been properly assembled according to the procedure and meets all requirements, ‘Inform JIT Supervisor on any defect found. required Hold Points. Technician, card, etc. of the JICS, and raise EWRr tagging system. IIT Supervisor = Accountable that all BFIA executed meating all requirements unless obtain written approval from QAQC Manager for any deviations. "Accountable for all critical BFIA witnessed by the JIT Verifier at the Obtain correct materials and issue to Joint Maker / Controlled Bolting Ensure Joint Maker / Controlled Bolting Technician executes the activities according to BFl requirements Le. PPE, PTW, competency Witness execution of critical joints at Hold Points, sign and keep record "Ensure Joint Maker / Controlled Bolting Technician understands the importance of BF and the purpose of tagging system Le. via trainings. Verify and inform JIT Verifier for any defects found at the joints Ensure records and traceability of joints via JICS, repair report and ‘This hard copy document Is vala for 48 hours only unless clearly dentiied as controlled copy. Date & time printed 6 October 2020, 5:20 PM Page 20 of 128Procedure ‘OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM PRPC ee PRefChemn (oems) PRefchem Manufacturing & Engineering ~ Engineering & Maintenance (06 Physical Asset Management ‘Administrative [ReferenceCodeLabel) Bolted Flange Joint Integrity (BFII) Procedure Joint Maker/ ‘A qualified personnel by OPU given the responsibility to execute the joints breaking and joints reinstatement work using MTW. Responsible in executing BFIA by complying with BFJI Procedure and JICS for joints involving hydraulic torque and hydraulic tension. Inform any defects or anomalies to,IT Supervisor during joint breaking and joint making. = Perform rectification of joint as instructed by JIT Supervisor. Controlled Botting Technician + Aperson qualified by 8 Qualifying Organization given the responsibility to execute the joints breaking and joints reinstatement work using HIW and HBT, * Responsible in executing BFIA by complying with BFiI Procedure and AICS for joints involving manual torque Inform any defects or anomalies to JIT Supervisor during joint breaking and joint making. + Perform rectification of join as instructed by IT Supervisor. Bolting Engineer ‘Accountable in ensuring the torque value to be used for BFIA activities are properly calculated and reviewed. In case of unavailability of torque value, he / she shall produce the torque calculation; based on the agreed recognized codes / standards * The torque calculation shall be submitted to Bolting Specialist/TP/SME for review and approval = Responsible to review the Online-Leak Sealing clamp calcul provide recommendation to the Bolting Specialist/TP/SME. and 2.1.4 Flange Master Register Flange Master Register (FMR) shall be established for critical and non-critical joints prior to execution of the BFJA work and to be continuously updated until work completion. The FMR shall include ‘minimum the following: “This hard copy document is vali for 48 hours only unless cearly dentiied as controlled copy, Date & time printed 6 October 2020, 5:20 PM Page 21 of 128‘OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM oe e PRefChem (OEMS) PRefchem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure {ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure ‘© Flange Joint number ‘+ Equipment number ‘© Line number + Isometric number © P&ID number ‘+ Systern/Sub-system number ‘+ Flange Voint) size, Flange Rating, Bolt Diameter, Number of Bolts Flange Material (eg; CS,5/, HDPE, etc.) + Bolt specification ( eg 87, B8, B16, etc) © Bolt Coating (eg; Black, HDG, Fluorocarbon etc.) © Gasket specification © Approved lubricant © Torque value © Flange Criticaity ‘* Approved tightening method (eg MTW, HTW, HBT * Torque Too! information (serial number, drive siza) ‘© Tension Tool Information (serial numbers, pump gauge serial number) ‘© Name of Joint Maker and/or CBT who completed the BFIA ‘* Name of JIT Supervisor and/or JIT Verifier who verified the BFJA completion ‘The updated FIR shall be submitted to JIT Verifier for review prior to be uploaded into the Flange Management Tool (FMT). “This hard copy document is valid for 48 hours only unless clearly identified as controlled copy. Date & time printed 6 October 2020, 5:20 PM Page 22 of 128,OPERATIONAL EXCELLENCE ue MANAGEMENT SYSTEM eS PRefChem (ors) hem Taruteaaring & Enginearng-Enginening & renmenee (06 Physical Asset Management Administrative Procedure [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure 2.1.4.1 Flange Management Tool (FMT) Flange Management Tool (FMT) is a P-EDMS based application used to store Flange Master Register. The FMT should be utilized as a primary database to store and update the flange information and history. The data and information in the FMT shall always be kept updated, 2.1.5 Resource Planning 2.1.5.1 Manpower JIT Lead shall determine the number of manpower required to perform the BFJA works with the following basis: Number of flange joints Flange joint sizes Applicable norms i.e. TA, Maintenance , Construction, ete Period / windows available Number of flange joints to be attended per day 2.1.5.2 Tools & Equipment ‘The number of tool and equipment i.e. MTW, HTW, HBT required shall be determined with the following basis: 1. Number of joints to be attended with each tightening method 2. Applicable norms Le. TA, Maintenance , Construction, ete 3. Period / windows available “This hard copy dacument is valid for 48 hours only unless clearly identified as contrllee copy. Date & time printed 6 October 2020, 5:20 PM Page 23 of 128OPERATIONAL EXCELLENCE PRPC MANAGEMENT SYSTEM (OEMS) Prefchem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFJI) Procedure 4, Number of manpower / team required to attend each tightening method 5. Number of flange joints to be attended per day It is recommended for JIT Leader to ensure the availability of in-situ machining services in case repair of flange surface is required upon inspection. 2.1.6 Joint Integrity Control Sheet (JICS) JICS shall be prepared by JIT Lead for each joints as per approved Flange Master Register. It shall be the evidence of compliance to BFIl procedures and work completion during execution ‘Sample of JICS is as per Annex D 2.1.7 Training and Assessment BFAI Trainings shall be planned and organized by JIT Lead, ‘Trainings shall be organized by JIT Lead during the planning stage to ensure sufficient qualified personnel It is a mandatory requirement that Joint Makers and JIT Inspectors and Senior JIT Inspectors be ‘qualified by JIT Assessors in accordance with ANNEX P As part of qualification process, the JIT Trainer shall conduct training, demonstration and practical ‘according to approved JIT Training materials to equip the candidates with general knowledge of bolted joint assembly and related technical areas. Details of training and qualification requirements, certification validity end course outline can be referred to ANNEX P. This hard copy document is valid for 48 hours only unless clearly identifed as controlled copy. Date & time printed 6 October 2020, 5:20 PM. Page 24 of 128,OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM PRee &: PRefChem (OEMs) | pRetchem ‘Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure {ReferenceCodeLabel] Bolted Flange Joint Integrity (BFI1) Procedure | Only trained and qualified Joint Maker and CBT are allowed to perform j making and bolt tightening/tensioning works. Only trained and qualified JIT Inspector are allowed to perform flange inspection. 2.1.8 Quality Assurance Planning It is recommended for QAQC Manager to identify and independent audit to conduct system and site implementation audit on BF, which is specified in the Quality Plan. ‘Scope and Terms of Reference for the audit shall be determine by the JIT Lead and approved by QAQC Manager. 2.2 PRE~EXECUTION 22.1 Resources Mobilization Sufficient manpower, tools and equipment shall be mobilized to site prior to execution. JIT Supervisor shall ensure only trained and qualified manpower; and calibrated tolls with validity of one (1) year are ‘mobilized. Calibration certificate shall be submitted to JIT Lead for verification. Any non-calibrated tools shall be immediately removed from site 2.22 BFII Briefing JIT Lead shall carry out briefing to Joint Integrity Team. The briefing shall cover the work process and requirements for 8FJI execution, Special precaution and requirements for hazardous services such as ‘oxygen service, and critical work shall be emphasized during this briefing. ‘This hard copy document is valid for 8 hours only unless clearly identified as contralied copy, Date & time printed 6 October 2020, 5:20 PM Page 25 of 128,OPERATIONAL EXCELLENCE PRPC MANAGEMENT SYSTEM (OEMS) PRefchem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure 2.23 Dry Run And Tagging Dry Run and tagging activity shall be jointly carried out by relevant parties e.g, JIT, Operation Team, Contractors, etc. and lead by the Operations Supervisor. Approved Flange Master Register shall be referred to perform tagging activities. Tagging activity shall comply with the following: ‘Tags shall be visible and must be protected or kept in appropriate distance against high temperature (i.e. hanging downwards to avoid contact with hot surface), For any touched joints/Joint tempering after joint completion, new BFII Tag shall be attached and similar work flow shall follows. For leak test conducted, a record form shall be filled by Operation, 2.2.4 Site Preparation Evaluate site condition for height and space restrictions to ensure safe execution of work. Identify requirement for scaffolding for working at heights, and clear working area for any obstructions. For insulated flange joints, the insulation removal and reinstatement work shall be incorporated into the work plan, Identify area to temporarily store the insulation material and ensure the area is protected from weather to avoid insulation damage. 2.2.5 Document Readiness Al required documents shall be reviewed, approved and distributed to all Joint Integrity Team (JIT) members. Its also recommended Contractor to have a pocket-size printout of approved Bolt Torque and Tension values to all of his IT members for reference during Execution and Inspection. “This hard copy document Is valid for 48 hours only unless clearly identified as controled copy. Date & time printed 6 October 2020, 5:20 PM Page 26 of 128,[ ‘OPERATIONAL EXCELLENCE Tansee vere BA ecien (oEms) i 06 Physical Asset Management Administrative Procedure iar ‘This hard copy document is valid for 48 hours only unless clearly dentined a controlled copy. Date & time printed 6 October 2020, 5:20 PM Page 27 of 128OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM ee Se PRefChem (OEMs) PRefChem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure [ReferenceCodeLabel] Bolted Flange Joint Integrity (BF) Procedure 23° EXECUTION The BFiI Management deliverables for the execution phase are as follows: ‘© Daily BFL! Reports * Completed JICS and tagging records ‘© Inspection Findings & Rectification reports 2.3.4 Executing BFIA ‘The following system and procedure shall bein place and adhered to when executing BFIA + PTW + JHA.and Rsk Assessment (RA) + BFil procedure # Taggings ~Refer Section 2.33, + JIS with Hold Points requirement Pre cautions for special / extremely hazardous services such as Oxygen, H2S, Hydrogen, Butadiene, Benzene, etc. ‘© Torque Value tables © Hydraulic Pressure to Torque/Tension conversion chart Joint Maker, Control Bolting Technician shall ONLY proceed with BFJA if all the above are available. 23.2 _ Joint inspection Hold Points Hold Points for witness by JIT Inspector andor JIT Verifier shall be as follows: "tris hard copy dacument is valid for 48 hours only unless clearly identified as controlled copy. Date & time printed 6 October 2020, 5:20 PM Page 28 of 128eave Bo nccien (OEMs) J [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFJI) * After joint breaking for inspection of flange surface, bolts and nuts condition, * Before joint reinstatement for inspection of flange surface condition, bolts and nuts condition and specification and gasket specification, ‘During joint assembling for verification of gasket position, marking of bolts number, flange alignment and torque/tension values. Aiter joint reinstatement for verification of gap uniformity, alignment and bolt tightness Please refer toJICS in Annex D for Hold Points requirement. ‘© Aiter flange repair /re-machining prior to joint assembly for inspection of remaining raise face thickness, and flange face serration. ‘This hard copy document is valid for 48 hours only unless clearly identified as contrlleg copy. Date & time printed § October 2020, 5:20 PM Page 29 of 128OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM PREC e PRefChem (OEMS) PRetChem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure 23.3 BFA Tagging ‘This hard copy document Is vali for 48 hours only unless clearly Wentified as controled copy, Date & time printed 6 Cctober 2020, 5:20 PM Page 30 of 128,OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM PRP ete Breeton (OEMs) PRefChem Manufacturing & Engineering Engineering & Maintenance 06 Physical Asset Management Administrative Procedure [ReferenceCodel abel] Bolted Flange Joint Integrity (BFII) Procedure e ower manent or vERIRER JOINT IDENTIFICATION. ‘This hard copy document is valid for 48 hours only unless clearly identified as controlled copy. Date & time printed § October 2020, 5:20 PM Page 31 of 128OPERATIONAL EXCELLENCE PRPC MANAGEMENT SYSTEM PRefChem (OEMs) PRefchem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure L om maKen/cor aT veRE JOINT IDENTIFICATION ‘This hard copy document is vali for 48 hours only unless clearly identified as controlled copy, Date & time printed 6 October 2020, 5:20 PM Page 32 of 128PRPC OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM (OEMS) Se: PRefChem PRefchem ‘Manufacturing & Engineering - Engineering & Maintenance (06 Physical Asset Management Administrative Procedure [ReferenceCodeL abel] Bolted Flange Joint Integrity (BFII) Procedure Figure 2: BFIA Tagging ‘This hard copy document is valé for 48 hours only unless clearly identified as controlled copy. Date & time printed 6 October 2020, 5:20 PM Page 33 of 128,OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM tenet e PRefChem (oEms) PRefChem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure Tagging description and process shall be as follows: ‘JIT tag shall be attached on the joint after the joint has been identified and confirmed by Operation and JIT Verifier. ‘© WHITE Section (Joint identification) shall be signed by Operation and JIT Verifier during Dry Run activities. ‘+ RED Section shall be signed by JIT inspector and JIT Verifier once the joint is accepted for joint making. In the presence of defect, it shall be repaired and accepted by JIT Verifier and JIT Inspector. ‘YELLOW Section (Joint Set-up and Tightening) shall be signed by Joint maker / CBT and JIT Verifier for Critical Joint and Non Critical Joint. ‘+ ORANGE or GREEN Section shall be signed by JIT Verifier and JIT Inspector upon successful completion of the joint in accordance to acceptance criteria. Each section of the tags shall be recorded with Name/ID and date of inspection. 2.3.4 BRIA Defects and Rectification All indications shall be inspected and evaluated by the JIT Inspector according to ASME PCC-1 Appendix D. Any confirmed defect on the BFJA that do not passed the acceptance criteria shall be reported by JIT Inspector to JIT Verifier Repair method of defective flanges shall be agreed by Bolting Specialist/TP. Upon completion of the repairs, the joint shall be accepted and signed off by JIT Inspector and JIT Verifier before proceed with the next BFIA work. 23.5 Leakage Control and Rectification Leakage control and rectification workis a reactive flange joint tightening when leak(s) occur during operation due to either thermal expansion, inherent vibration, gasket relaxation, damaged sealing TH This hard copy document I valid for 48 hours only unless clearly kentifed as contrlled copy Date & time printed 6 Oetober 2020, 5:20 PM age 34 of 128(OEMS) Procedure surface or any other situations where unit shutdown may not be viable or the system can’tbe taken ‘out of service, Leakage control work shall be performed with full supervision of the bolting specialist, mechanical supervisor and operation personnel. Self Breathing Apparatus (SCBA) is recommended to be wore when attending leakage control & rectification for other than Category D service. ‘Annex F describe the limits of torque value and % bolt yield stress for leakage control work. Leakage control attempt with live tightening shall ONLY be performed with MTW or HTW method, Live tightening using HBT Is not allowed. 2.3.6 BFIA Monitoring & Reporting BFIA activities monitoring and reporting shall include blinding, joint breaking, joint reinstatement, de-blinding, defect rectification, and leak rectification. IT Supervisor and JIT Lead shall monitor and report daily minimum the following: ‘+ Total BFIA activities carried out against planned schedule Issues and rectification ‘© Manpower loading All findings and actions taken shall be documented and recorded in FMR. 2.3.7 Audit & Assurance ‘This hard copy document is valid for 48 hours only unless clearly identified as controlled copy. Date & time printed 6 October 2020, 5:20 PM Page 35 of 128,OPERATIONAL EXCELLENCE PRPC MANAGEMENT SYSTEM (OEMS) PRefChem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Procedure {[ReferenceCodeLabel) Bolted Flange Joint Integrity (BFII) Procedure BFJI Program compliance audit to be conducted as per Quality Plan on the BFII Program compliance, 2.4 POST EXECUTION 2.4.1 Monitoring During Start-Up JIT Supervisor shall ensure that all BFIA activities are complete, all JICS are approved by JIT Verifier, and satisfy PASR/PSSR requirement for Operations Team to proceed with leak test. Once the leak testis satisfied, it will be handed over to Operation Team for RFSU. Any leak during Start Up must be recorded, 2.4.2 Start-Up Re-Torqueing, Leak Rectification & Monitoring ‘An optimum number of Joint Maker and/or Control Bolting Technicians shall be maintained as standby during start-up after BFIA activities. They are to be assigned to attend and rectify any leaks ‘occurred during start-up up until plant stable operation. They also are to be assigned to attend to the identified flange joints that require start-up re-torqueing, Bolting Specialist is responsible In verifying, calculating and providing the torque and/or tension values to the Joint Maker and/or Control Bolting Technicians in any case the new torque and /or tension are of higher values. 2.43 Online Leak Sealing Flange leaks may unable to be arrested by re-tightening / re-torqueing, yet the system or unit ‘cannot be shutdown due to any reason. Hence, online leak sealing may be required to arrest the leak, ‘This hard copy document is valid for 48 hours only unless clearly identified as controlled copy. Date & time printed 6 Octoner 2020, 5:20 PM Page 36 of 128‘OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM Mises e PRefChem (oEMs) . PRefChem Manufacturing & Engineering - Engineering & Naintenance 06 Physical Asset Management Administrative Procedure {[ReferenceCodeLabel] Bolted Flange Joint Integrity (BFL) Procedure Online leak sealing design and calculation shall be reviewed and approved by Specialist and ‘Technical Authority respectively prior to installation. ‘This hard copy document is valid for 48 hours only unless clearly identified as controlled copy. Date & time printed 6 October 2020, 5:20 PM Page 37 of 128,OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM Pe Pe BP evecnen (oems) PRefchem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Procedure [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure 2.8.4 Lesson Learnt JIT Lead shall record any lessons learnt during BFIl activities. A list of Lessons Learnt, which has been recorded throughout BF! Program shall be referred for this exercise. Root Cause Failure Analysis If necessary, RCFA shall be conducted for the following: ‘© Leaked joints reported during start-up and unit stabilization ‘+ Flange, bolts or gasket defects found during joint inspection 2.4.6 BI Results and Reports JIT Lead shall ensure all results and reports are compiled and analyzed. Compilation and analysis of results may encompass, among others: BFUI KPIs or plan vs. actual ‘+ Problematic BFJA and rectification report ‘= Flange leak history + Reporting and documentations Lessons Learnt All records and documents shall be properly updated into the FMT for future references and ensure continuous improvement of BF Program This hard copy document is valid for 48 hours only unless clearly Kdenttied as controlled copy. Date & time printed 6 Getaber 2020, 5:20 PM. Page 38 of 128‘OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM PR re eS PRefChem (OEMs) PRefChem Menufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure [ReferenceCodeLabel) Bolted Flange Joint Integrity (BFIL) Procedure ‘his hard copy document is valid for 48 hours only unless clearly Identified as controlled copy. Date & time printed 6 October 2020, 5:20 PM Page 39 of 128,‘OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM PRP vedas e PRefChem (OEMs) PRefChem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Procedure [ReferenceCodeLabel) Bolted Flange Joint Integrity (BFII) Procedure 3.0 3 TECHNICAL REQUIREMENT OF BOLTED FLANGE JOINT INTEGRITY FACTORS INFLUENCING BOLTED FLANGE JOINT INTEGRITY The following factors have a direct bearing on the tightness and integrity of BFJA and thus must be taken into account when dealing with BFA’ Condition/Cleanliness of gasket face of flanges Serrations on flange gasket face to be verified using comparator (e.g. Spiral wound gasket requires flange surface finish of 3.2 -6.3 microns. For other type of gasket to refer ASME PCC1 Table C-1) Condition of the nut bearing face of flange (rear end where nut sits) Gasket condition (ie. Specifications, Dimension, Physical conditions, and etc.) Positioning of gaskets on flanges Bolt and nut conditions (ie, Specifications Dimension, Physical conditions, and ete.) Positioning of washers (if applicable) Alignment of flanges (le. Flange gap, parall 5m, Centerline High/Low, rotational) Calculated Torque values for MTW/HTW Correct HBT values (if applicable) MTW/HTW-Tightening sequence and number of passes HBT —number of tools, sequence of tensioning and number of passes Calibration of hydraulic torque wrench and HBT tool Correct capacity of hydraulic power pack used in HBT and HTW. Correct Hydraulic pressure to torque conversion tables (Hydraulic torque) Correct Hydraulic pressure base an used tools of the HET Establishing line of contact for RT gaskets (lapping testing with engineer's blue) “Measuring te pitch for the re-use of bolts This hard copy document is valid for 48 hours only unless clearly Identified as controlled cony. Date & time printed 6 October 2020, 5:20 PM Page 40 of 128OPERATIONAL EXCELLENCE PRPC MANAGEMENT SYSTEM (OEMs) PRefChem| Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure * Precautions for lethal and toxic services such as Oxygen, H2S, butadiene, or benzene services and etc. (special lubricant, uncontaminated tools and gloves, etc.) 3.2 DEFINITION OF CRITICAL JOINTS Critical Joints are defined by the following criteria; Joints in Category M FI Amine, H:S, etc.) Service as defined in ASME B31.3 Eg. Toxic, Lethal substances (ie Joint with hazardous High Purity medium (Ie Acid, Caustic, Oxygen) Joint used in Hydrogen services Joints operating at temperatures 350°C and above (due to thermal expansion) Joints operating under cyclic conditions Joints subject to High pressure (Rating Class >600#) 2 3 4 5. 6. Joints in Cryogenic services 7. 8. Joints within Reactor Circuits 8 Joints with history of frequent leaks either at start-up (heat up) or during shutting down phases. 10. All non-standard flanges inclusive of flanges with size of DN1SO0 and above 11. Joints with medium operated within auto-ignition temperature (AIT) 3.3 JOINT DISASSEMBLY Before any joint is disassembled, assurance shall be obtained from Operation Team and Mechanical Supervisor that all pressure, including that due to a liquid head, has been removed from the system and that proper procedures have been followed to ensure that joints can be safely opened. “This hard copy document is valid for 48 hours only unless clearly identified as contrllee copy. Date & time printed 6 October 2020, 5:20 Pit Page 41 of 128ae pave BP rrecien Procedure When significant numbers of bolts are loosened in rotational order, the elastic recovery of the clamped parts can result in excessive loads on the relatively few remaining bolts, making further disassembly difficult and sometimes causing galling between the nut and bolt sufficient to result in torsional failure of the bolt as further loosening is attempted. Disassembly should be done in a cross pattern, Crack open at 15-30 degree for all nut in cycle and repeat one more cycle for all nuts. This exercise will avoid the bolt and nut galling/jammed, The reported incidents of disassembly difficulties have typically involved: ‘a. flanges larger than DN 600 (NPS 24) b._ flange thicknesses greater than 125 mrn (5 in.) bolt diameters Mas (1.3/4 in.) and larger For Joints with history of leaks, measure and record the flange gap around the circumference before disassembling the joint. A sufficient number of loosened nuts shall be left in place until all tension has been relieved, to guard ‘against falling components, or pipe spring or other unanticipated movement. Due to the possibility of residual liquid in the pipe along with any unrelieved pressure, the first bolts loosened should be in a location that will direct any pressure release opposite of the line of fire from the Joint Maker. Generally, for joints in the vertical plane, this will be at the top of the joint and then at the bottom to drain the liquid. 3.3.1 Cleaning and Examination of Flange and Fastener Contact Surfaces Alter joint has been disassembled, clean and examine flange and fastener contact surfaces as described below, Remove all indications of the previous gasket installation from the gasket contact surfaces; use approved solvents and/or soft-wire brushes if required, for cleaning to prevent surface contamination and damage to existing surface finish, Carbon steel wire brushes shall not be used on stainless steel flanges and fasteners. Examine the gasket contact surfaces of both mating joint flanges for compliance with required surface finish and for damage to surface finish such as scratches, nicks, gouges, and burrs ‘This hard copy document is valid for 48 hours only unless clearly entiied as controlled copy. Date & time printed 6 October 2020, 5:20 PM Page 42 of 128OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM PRPC e PRefChem | (OEMS) PRefChem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure [ReferenceCadel abel) Bolted Flange Joint Integrity (BFII) Procedure Indications running radially across the facing are of particular concern, Refer to ANNEX! for acceptable limits of gasket contact surface imperfections and their locations. Dedicated tools, solvent and gloves shall be used for any BFIA cleaning and examination activities involving oxygen service to prevent contamination with oll and grease. Notes: "= Flange gasket face surface profile on Critical Joint shall be examined using surface-finish ‘comparator gages by JIT Inspector during intial inspection. = In the event that weld build-up of the flange gasket face or Heat Exchanger tube sheet is necessary, a repair procedure shall be prepared based on latest edition of ASME PCC-2 and approved by TP/SME. Weld build up and subsequent machining of the flange gasket face or Heat Exchanger tube sheet shall be carried out to restore the flange gasket face to acceptable condition. Flatness check shall be carried out after machining. For Critical Joint with history of leaks, and which has access for mounting a dial gage (e.g. Heat Exchanger flanges, Manhole flanges, reactor cover flanges), the flatness shall be checked using the dial gage and maintained within the limit specified in ANNEX H. 3.3.2 Reuse or Replacement of Bolts, Nuts and Washers 2) Examine bolt and nut threads and washer faces of nuts. Bolts and nuts shall be replaced for the following conditions: a. Damaged bolts/threads (1. rust, corrosion and burrs) bb. Bolting in service that has undergone Online Leak Sealing. & Bolting that have leaked boiler feed water, steam, condensate or caustic due to risk of caustic embrittlement. 4d, Bolts that has subjected to Residual Bolt Stress of more than 75% Bolt Vield Stress ‘This hard copy document is valid for 48 hours only unless clearly identified as controlled copy. ‘Date & time printed 6 October 2020, 5:20 PM Page 43 of 128OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM fer e PRefChem (OEMS) PRefChem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure [ReferenceCodeLabel) Bolted Flange Joint Integrity (BFII) Procedure 2), Before lubricant is applied, perform free-running check or measure the dimension and elongation Of the stud length. Any reduction of the stud dimension or elongation of the stud length shall be replaced 3) Bolt/Nut combinations for which the nuts will nat turn freely by hand past where they will come to rest ater tightening shall be replaced/corrected; this includes tapped hole threads. (See ASME PCC.2, Article 3.3, which covers repair of damaged tapped hole threads). 4) Visual inspection nut bearing or washer-bearing surfaces of flanges for coating, scores, burrs, visual evidence of out-of-square ness shall be replaced, '5) Remove all debris/coating on washer for critical joints. Roughness, gouges, and protrusions shall bbe removed from these surfaces. See ASME PCC-1 Appendix M for a suitable through-hardened washer purchase specification guideline. 6) If separate washers are scored or cupped from previous use, replace with new through-hardened washers (surface-hardened washers are not suitable}, 7) Pre loaded washers shall not be reused but shall be replaced whenever the joint is dismantled. Care shall be taken to ensure that the washers are positioned according to the model number. 8) Thread dies generally do not result in a smooth, reconditioned surface; therefore, turning bolt threads in a lathe is the preferred method to recondition costly fasteners. The process will remove thread material; therefore, the user is cautioned to ensure the tolerance limits are as per ASME 21.1 requirement. Any fastener with thread dimensions is more or less than the minimum major diameter or the minimum pitch diameter shall be replaced. 9) Nuts are generally replaced rather than reconditioned, ASME PCC-1 Appendix N provides ‘supplementary information on the bolt reuse topic. Notes: + Use of washers is optional. However, itis generally recognized that the use of through-hardened steel washers will improve the translation of torque input into consistent bolt stretch. See ASME PCC-1 Appendix M for a suitable through-hardened washer specification guideline. ‘This hard copy document is valid for 48 hours only unless clearly dentiied as controlled copy. Date & time printed 6 October 2020, 5:20 PM Page 44 of 128OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM Mice e PRefChem (OEMs) PRefChem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure [ReferenceCodeLabel) Bolted Flange Joint Integrity (BFL) Procedure "= Flat washers protect the nut-contact surface of the flange from damage and provide a smooth and low-rietion turning surface for the nuts. These are important considerations when torqueing methods (either manual or hydraulic) are used for bolt tightening. Flat washers also promote improved load distribution 3.4 JOINT ASSEMBLY Pre assembly work including flange and gasket surface inspection shall fallow as per 3.3.1 3.4.1 Alignment of Flanges Joints Procedures for aligning flanged joints are provided in ANNEX J. 3.4.2 _ Installation of Gasket Place a new gasket in position after determining the defect free sealing surface. Refer ANNEX H and | for defect assessment and acceptance criteria, BFIA step as below: 1. Verify that the gasket complies with the dimensional (0.D., I.D., thickness) and material specifications. Position the gasket to be concentric with the flange I.D., taking suitable measures to ensure that itis adequately supported during the positioning process. No portion of the gasket should project into the flow path, 3. Ensure that the gasket will remain in place during the joint assembly process; a very light dusting of spray adhesive on the gasket (not the flange) may be used if required. Particular care should be taken to avoid adhesive chemistry that is incompatible with the process fluid (oF could result in stress corrosion cracking or pitting of the flange surfaces. Do not use tape strips radially across the gasket to hold it in position. Do not use grease. mest" This hard copy document is valid for 48 hours only unless clearly identified as controled copy Date & time printed 6 October 2020, 5:20 PM Page 45 of 128‘OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM ene © PRefChem (OEMS) PRefChem Manufacturing & Engineering - Engineering & Maintenance (06 Physical Asset Management Administrative Procedure {ReferenceCodeLabel] Bolted Flange Joint Integrity (BF3I) Procedure 4. For RT) joints that are critical, lapping of the flange groove using lapping tool with lapping, ‘compound shall be carried out in order to ensure sealing contact. This shall be verified using. “Engineers Blue/ Prussian Blue” prior ta joint making. Reuse of Gasket is Strictly Prohibited! However, corrugated metal gasket with facing layers (e.g Kammprofile}, lip seal/memibrane gasket, RT! rings and lens ring has the possibility of being refurbished and reused provided they have been inspected and found acceptable as per original specification. 3.4.3 Lubrication of Working Surfaces of Fasteners Lubrication reduces the coefficient of friction and results in less required torque to achieve a given tension, improves the consistency of achieved load from bolt to bolt within the joint, and aids in the subsequent disassembly of the fasteners. 1. Ensure that the lubricant is chemically compatible with the process fluid and bolt/nut/washer ‘materials. Particular care should be taken to avoid lubricant chemistry that could contribute to stress corrosion cracking, galvanic corrosion, oxygen auto ignition, etc. 2. In the event that lubricant cannot be used either due to incompatibility with the fluids or HSE reasons, the torque values have to be adjusted to cater to Nut Factor of 0.2 3. In case a lubricant other than that specified in Annex F is used, it shall be noted that the ‘torque values in this Annex cannot be used. New torque table shall be developed for the selected lubricant. 4, Ensure that the lubricant has proven to be suitable for the expected range of service temperature(s) and anti seize requirements. 5. Before lubricant is applied to the bolt and nut threads, nuts must run freely by hand past where they will come to rest after tightening. If nuts will not turn freely by hand, check for cause and make necessary corrections/replacements, This hard copy document is valid for 48 hours only unless clearly identified as contrelled copy. Date & time printed 6 October 2020, 5:20 PM. Page 46 of 128OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM PRPC e PRefChem (OEMS) PRefChem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFL) Procedure 6. The lubricant shall be applied after the bolts are inserted thraugh the flange bolt holes to avoid possible contamination with solid particles that could create unwanted reaction torque. Lubrication must be applied irrespective of the tightening method used. 7. Do not apply either approved lubricant or unapproved compounds to the gasket or gasket- contact surfaces; protect against inadvertent application to these surfaces. 8. Fornon coated bolts, apply lubricant liberally and completely to the nut contact faces and to the threads on both ends of the bolts past where the nuts will come to rest after tightening 9. For new coated bolts and nuts, free running nut checks as described in (5) are required. 11. Install bolts and nuts so that they are hand-tight. The marked ends of the bolts and nuts must be located on the same side of the joint and facing outward to facilitate inspection, 2. Snug up to between 15 Nm (10 ft-b) and 30 Nm (20 ft-lb), but not to exceed 20% of the Target Torque (see Section 3.5). If nuts do not hand tighten, check for cause and make necessary corrections. 3. Accessibility of workspace not allowing full HBT to be used, hence requires combination of HBT + HTW. In this case, procedure shall be submitted by controlled bolting vendor, and approved by TP/Bolting Specialist. 3.4.4.1 Bolt/Nut Specifications Verify compliance of bolts and nuts specification 1. materials, length of bolts, thread pitch, coating, and nut thickness equal to nominal bolt diameter (heavy HEX series nuts) ‘This hard copy document is valid for 48 hours only unless clearly identified as controlled copy, Date & time printed 6 October 2020, 5:20 PM Page 47 of 128OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM a e PRefChem (OEMS) PRefChem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure 3.4.4.2 Bolt Lengths Check bolts for adequate length. This length should consider the presence of washers and nut. height. As minimum, the thread shall be flushed with the nut face, Excessive thread protrusion can hinder joint disassembly due to corrosion, paint, or damage. Hence, excess thread protrusion beyond the nut should be mini ized. ‘The use of bolt tensioners requires that the threaded portion of the bolt extend at least ane bolt diameter beyond the outside nut face on the tensioner side of the joint. Galvanized or coated bolts may require special tensioner puller sleeves. 3.5 Numbering OF Bolts 3.45.1 Numbering Of Bolts When A Single Tool Is Used Alternative to Legacy Numbering Sequence {An alternative numbering system for the Legacy method is designed so that the number assigned at each bolt location represents the sequential order for tightening that bolt; in other words, the cross pattern tightening sequence is identified by the assigned bolt number and, therefore, a separate reference table is not required during the tightening process. An example of bolts numbering using Alternative to Legacy Numbering Sequence are shown in Figure 3 and Table 2. ‘This hard copy document is vali for 48 hours only unless clearly identified as controlled copy. ‘Date & time printed 6 Cetober 2020, 5:20 PM Page 48 of 128,OPERATIONAL EXCELLENCE PRPC MANAGEMENT SYSTEM PRefChem. (OEMS) PRefChem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure [ReferenceCodeLabal] Bolted Flange Joint Integrity (BFII) Procedure j ele BelcKumberng oquence te Be Marked Clskvise on Flange [ete (4) oe |ess7a6ee s.s21.7.2 10 eeine 17,9, 18,24, 8.19, 94, 7,95 22,2, 16,10, 6 16622 4.26 12 8 164 25 17,95, 4,9, 27,19, 44,7, 45,28, 226 16 10,6 16.32, 6.28.20 10 10 2617.96 14, 24.29, 8.27.19, 14,7. 15. 22,512.26 18, 10.6 16 2224.28.20. 39 81620 518,20 29,8.65.27.19, 47,36 74 512.96 26 16 10 6 16 23,30, 696,26 20,10 8 TE 38. 25.17-9.5:15.21 29,97.8.85 27.19 17.1525, 91 9,2 34,76 1810 616.22. 50 38, 496.26.20.126 16245240 sh 3,26.17.9,51% 21,2997 3. 45,35,27,1911,7,1,28,34, 28-2 63,0,26 18 10,61422,0,56404. 2628.20.12 816, pri res 0,20.25 17.5, 540,01 9507 453 SLARAE AT IDALTABERLIDAT ARO ARNE TRIO CTU SEIOTOAGUEE 149 41,59.25, 17.95 15,2128 5745.50 9548 982719 11,7528 BLIRAT.SE NOME IG 3618 OG TATE OTD, wale 798 aL aT Sa 7 453A AT IN TAT BSE DL BOATS BURGE ID ELUTE DO TOMER LORETO, 38 TES ECREY ETETETECE CATT ICROETECETECESTS 2 $4 96,26, 20,12, 16,24, 3240, 48 6 a a 65,5749 3,26.17,9.5.18.21 29,5748 58,6. 567,9,5143 95.27.18,1,7,15.28 91,99, BOR OOO. 42,94, 26, 18 10,6 14,22, $0, 36,46 64 62,76 4 68,60, 53, H, 36,26 20 32,616 24,32 40198, 56. 64,72 1: 75.65.57.48,61.38.26.17,9.518.2,29,57 45 66, 69,8, 7867 9951.40.95 271914 TABIRALARATSERTIATO 65.56. 50.42.58, 26 16, 10,6 16,22 0 $646.56 62 70.476, 6860.52 64 36.26.20 128, 16,2632, 60 6,56.64 72 1. 7465.57-48,41.58.2617,9,51,21.28,97 4555 6169.73, 7567,695148 95,7 18147 182851, 98.07 5568.71.79, 27a ca 50,02.86, 26:38 10,61420.90 38.46 9462707847668 6082.44 9608201281624 9240AR EERIE. n6L.7.6557.0841332517 96 187A ELTA TATRA TET ITE, 7565.57.68. 93 2517.95 14212997 A565 616077065 03 7ECT SRST AASERT IO LT IB DESLOOAT ER Table 2; Alternative to Legacy Cross-Pattern Tightening Sequence and Bolt Numbering System Note: The number assigned at each bolt loc: the bolt ms ‘When using Single Tool represents the sequential order for tightening hard copy document is valid for 48 hours only unless clearly identified as contrlled copy. ‘Date & time printed § October 2020, 5:20 PM Page 49 of 128‘OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM PRPC e PRefChem (oes) PRefChem Manufacturing & Engineering ~ Engineering & 7 Maintenance 06 Physical Asset Management Procedure [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure Figure 3: Alternative to Legacy Numbering Sequence for 12-Bolt Joint 3,24 Bolt Numbering Sequence Method Similar to the alternative legacy numbering method, the number assigned at each bolt location represents the sequential order for tightening that bolt. Using the 3,2,4 numbering method 2 reference table is not required for both bolt numbering and tightening activities. 1. Start by numbering the frst bot 2, Moving clockwise, keep adding 4 until the bolt number will exceed the total number of bolts for the flange. 3. Then, following the 3,2,4 sequence, replace that number with number 3,2, or 4 and keep ‘adding 4 again to the next bolts until the bolt number is equal to the total number of bolts. ‘row This hard copy document is valid for 48 hours only unless clearly identified as controlled cory. Date & time printed 6 October 2020, 5:20 PH Page 50 of 128OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM PRPC e PRefChem (OEMs) PRefChem ‘Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure [ReferenceCodeLabal] Bolted Flange Joint Integrity (BFII) Procedure Refer to the numbering sequence in Figure 4 below. ‘This hard copy document is valid for 48 hours only unless clearly identified as controlled copy. Date & time printed 6 October 2020, 5:20 PM Page St of 128OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM Hee! . PRefChem (OEMS) PRefchem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure Teaeu ate aas4e1s, Figure 4: 3,2,4 Bolt Numbering Sequence Method 3.0.5.2 Numbering Of Bolts When Multiple Tools Are Used Legacy methods shall be used. Example for bolt numbering systems for 16 bolt-joint with 4 tools shall be as follow: ‘Ths hard copy document is valid for 48 hours only unless clearly identified as contrlled copy. Date & time printed 6 October 2020, 5:20 PM Page 52 of 128MANAGEMENT SYSTEM noc e: (OEMS) i 06 Physical Asset Management Administrative Procedure {ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure 1. Mark the bolts adjacent clockwise to 12, 3, 6, and 9 o'clock positions with the number 1 Moving clockwise, split the angles between the above marked bolts and number the next 4 bolts as number 2. }. Moving clockwise, split the angles between the above marked bolts (number 1 and number 2) as evenly as it can and number the next 4 bolts as number 3. Repeat the above step until all bolts are numbered. Bolts will be at 90 or 180 degrees from an identically numbered bolt only in case 4 tools are used and that too only for a 16 bolt flange. ‘An example of bolts numbering for multiple tool usage are shown in Figure 5 and 6. For other than 4- tool case, mark the bolts evenly at the angles of : “360/Number of Tools” degree, starting with the adjacent clockwise from 12 o‘clock position with the number 1. Then, repeat step 2 to 4 above, 3.4.6 Tightening Method / Load Control Technique “The following Table 3 shows the tightening method selection criteria ‘1% inch and above all 315008 Linch and above Het all all inch and above HET Others All 1 i/B inch and aw Sh Others Al Tinch and below Tw Table 3: Required tightening method based on service application, ASME rating classes and bolt diameter ‘This hard copy document is valid for 48 hours only unless clearly identified as controlled copy. ‘Date & time printed § October 2020, 5:20 PM Page 53 of 128OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM PRPC e PRefChem (OEMS) PRefchem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative 5 Procedure [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure l Hydraulic Bolt Te ioning shall be used as per PTS 12.30.02 and PTS 12.00.03. ‘More stringent criteria than the Table 3 above may be employed, should the line or service has history of leaks or subject to higher risks if leak. Non-Control Tightening Method Such as Using Slogging and Impact Wrench is PROHIBITED For All Type of Joints! Regarding direct measurement of residual bolt elongation, it should be recognized that, if ultrasonic or ‘micrometer elongation control is used, initial bolt length readings must be obtained and documented for each bolt for which bolt elongation is to be determined; additionally, compensation must be made for temperature changes in the bolt after the intial length measurement. For accuracy, the instrument shall be calibrated to property read the bolts being tightened. Information stored in the instrument or tabled values may be too generic to produce the desired level of accuracy. For bolts constructed with a centerline indicator (gage) rod as shown in Figs. 1 and 2 of ASME-PCC-1 2019, neither initial length ‘measurements nor temperature compensation is required, thereby allowing direct determination of the true bolt elongation (and hence bolt stress) for both initial assembly and for troubleshooting purposes during operation. Proprietary force-sensing devices that can provide accurate and reliable real-time (increasing and decreasing) bolt tension readings/printouts are available from several manufacturers. 3.4.7 Tightening Sequence is recommended to apply pulling tool / tensioner up to 50% - 100% the total number of bolts. The number of pulling tool / tensioner shall be no lesser than 25% of the total number of bolts. HBT procedure shall be submitted to TP/Bolting Specialist for review. For MTW and HTW, single tool and multiple tool usage are permitted. For Critical Joints it is recommended to use multiple tool with minimum of 2 tools at simultaneous tightening, The numb of bolts and the tightening sequence shall be as per Figure 3, 4 and Table 2 ‘This hard copy document is valid for 48 hours only unless clearly identified as controlled copy. Date & time printed 6 October 2020, 5:20 PM Page 54 of 128‘OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM ia Se PRefChem (OEMS) PReichem Manufacturing & Engineering - Engineering & Mointenance (06 Physical Asset Management Administrative Procedure [ReferencecodeLabel] Bolted Flange Joint integrity (BFI1) Procedure 3.4.7.1 Single-Tool Usage Select ONLY Alternative To Legacy Numbering Sequence or 3,2,4 Numbering Sequence as per Section 3.4.4.1 The torque increment round-tightening information for the Alternative to Legacy pattern is detailed in Table 4 NOTE: ‘The cross-pattern bolt-tightening sequence and multi-round tightening are necessary to counter the elastic interaction that occurs when tightening bolts. See ASME PCC-1 Appendix for additional information regarding elastic interaction (or bolt cross-talk). ‘This hard copy dacument is valid for 48 hours only unless clearly identified as controlled copy. ‘Date & time printed 6 October 2020, 5:20 PM. Page S5 of 128OPERATIONAL EXCELLENCE PRPC MANAGEMENT SYSTEM (OEMS) PRefchem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Procedure [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFJI) Procedure sep Teading install | Hand tighten, then “snug up" to 25Nm (10 Fb) to 30 Nm (20 IB), not to exceed | | 20% of target Torque. Check flange gap around circumference for uniformity. if the gap around the circumference is not reasonably uniform, make the appropriate adjustments by selective tightening before proceeding. a Round 1 Tighten to 30% of target Torque (see Section 3.5). Check flange gap circumference for uniformity. Ifthe gap around the circumference is not reasonably uniform, make the appropriate adjustments by selective tightening/loosening before proceedinj Tighten to 60% of target Torque (see Section 3.5 J. Check flange gap around circumference for uniformity. fthe gap around the circumference is not reasonably uniform, make the appropriate adjustments by selective tightening/loosening | before proceeding. Round 3 Tighten to 100% of target Torque (see Section 3.5 ). Check flange gap around | circumference for uniformity. ifthe gap around the circumference is not reasonably uniform, make the appropriate adjustments by selective tightening/loosening before proceeding, Round 4 Continue tightening the bolts, but on a circular clockwise pattern until no further | nut rotation occursat the Round 3 target Torque value. For indicator bolting, tighten | bolts until the indicator rod retraction readings for all bolts are within the specified Round 5 In case hydros hydrotest. a) For Critical joint, repeat Round 4 after 4 hours. This will restore the short-term, creep relaxation/erbedment losses. b)_For Non Critical joint, repeat Round 4 immediately Round 2 Table 4: Torque increments for Alternative to Legacy-Cross Pattern Tightening Using Single Tool 3.4.7.2 Multiple-Tool Usage Bolt-grouping tightening shall not be applied on critical joint. Cross-pattern tightening sequence shall be used when tightening using multiple tools. This hard copy document is valid for 48 hours only unless clearly Identified as controlled copy. DDate & time printed 6 October 2020, 5:20 PM Page 56 of 128,OPERATIONAL EXCELLENCE Bacon (OEMS) Procedure See Figure 5 for an illustration of the tightening sequence for a 16-bolt flange using 4 tools. Figure 5: Bolts Numbering & Tighening Sequence for 4 Tools. See Figure 6 for an illustration of the Legacy cross-pattern tightening sequence for a 12-bolt flange using 2 tools. ‘This hard copy document is vali for 48 hours only unless clearly identified as contrlleé copy. Date & time printed 6 October 2020, 5:20 PM Page 57 of 128,OPERATIONAL EXCELLENCE Maintenance (OEMS) 06 Physical Asset Management Administrative Procedure [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure [O Wise JO Ran 0 eae Figure 6: Bolts Numbering & Tightening Sequence for 2 Tools, For HTW, the number of passes for tightening shall be as follows: a) Astround at 30% of target load value in cross pattern. bb) 2nd round at 60% of target load value in cross pattern, ©) 3rd round at target load value in cross pattern. 4d) 4th round at target load value in circular pattern until no further nut movement. ‘This hard copy document is valid for 48 hours only unless clearly identified as controlled copy. Date & time printed 6 October 2020, 5:20 PM Page 58 of 128OPERATIONAL EXCELLENCE PRPC MANAGEMENT SYSTEM PRefChern (OEMS) PRefchem Manufacturing & Engineering - Engineering & Maintenance (06 Physical Asset Management Administrative Procedure [ReferenceCodeLabel} Bolted Flange Joint Integrity (BFII) Procedure €) For critical joints, repeat 4th round after at least 4 hours if hydrostatic test fs not done. In case hydrostatic testis done, this pass shall be carried out after the tes. 3.4.7.3 Measurement of Gaps For the purpose of maintaining parallelism during the tightening passes of assembly, take measurements of the gap between flanges around the circumference. Measurements and adjustments are not needed past this point if the flanges remain parallel. Gap measurement between flanges shall be recorded in JICS for initial hand tightening and final round of bolt tightening For ical Joints which have leak histories, gap measurement shall be recorded at each tightening pass. 1) Measure the gap between flanges at eight or more equally spaced locations of good-quality flange surface around the circumference. Use a measuring device that allows for good comparison between points. Gap measurements are not intended as indicators of gasket stress. 2) if necessary, bolts at the location of the highest readings (largest gap between flanges) can be tightened, 3) If the difference in torque required to keep the gap uniform is greater than 50%, disassemble the Joint and locate the source of the problem, 3.48 Joint Tightness Acceptance Criteria 1. No movement of nut at target torque value or 100% tensioning, 2. Flange gap shall be uniformed and any difference in gap shall be within 0.8 mm measured across any diameter. 3, Flange misalignment shall not exceed 1.5 mm at any point. 4. No leaks at flange joint during energization ie. leak test, commissioning, start-up, etc. ‘This hard copy document is valid for 48 hours only unless clearly identified as controlled copy. Date & tima printed 6 October 2020, 5:20 PM Page 59 oF 128,OPERATIONAL EXCELLENCE c MANAGEMENT SYSTEM pee e PRefChem (OEMs) PRefChem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure 3.5 TARGET TORQUE DETERMINATION Torque value tabulated according to bolt size can be referred from ANNEX F. However, the factors such as ternperatures, pressure and bolt materials that are not specified in this ANNEX, the required torque values shall be calculated with considerations given to the Operating Temperature and Vield Strength of the bot. For high temperature services, care shall be taken to ensure that the torque value used at ambient temperature will not cause the bolt to yield or flange to deform at Operating Temperature. Low Yield Strength of some bolt materials may necessitate the use of more than 50% of Yield Strength in the calculation of the Torque Values (e.g. Incoloy, B8 Class 1 etc.) 3.5.1. Standard Flange ‘Standard flange is flanges covered under codes and standards listed below: a) ASME BI6.5 b) ASME 816.47 Series Aand B c)APIGOS d)_Mss-sP 44 ‘The recommended torque value determination is referring to ASME PCC-1 Appendix J and/or K. However, targeted torque value also may be calculated with any other the applicable codes & standards such as BS 3580, Pressure Vessel Guide by Dennis R. Moss ,tc., subjected to Specialist and PTA approval. ‘This hard copy decument is vali for 48 hours only unless clearly identifad as controled copy, ‘Date & time printed 6 October 2020, 5:20 PM. Page 60 of 128,OPERATIONAL EXCELLENCE cae BB cn Maintenance 06 Physical Asset Management [ReferenceCodeLabel] Bolted Flange Joint Integrity (BFII) Procedure Administrative Procedure 3.5.2 Non Standard Flange "Non-standard flange is flange which not covered under section 3.5.1 such as customized flanges made by the OEM/vendor, rectangular shape flange, diamond shape, oval shape, etc. ‘The recommended torque value determination is using P-Bolt or any equivalent torque value calculation software, subjected to Specialist or/and PTA approval ‘This hard copy document Is valid for 48 hours only unless clearly identified as controlled copy. ‘Date & time printed 6 Octobar 2020, 5:20 PM. Page 61 of 128OPERATIONAL EXCELLENCE MANAGEMENT SYSTEM fee . PRefChem (oEMs) PRefchem Manufacturing & Engineering - Engineering & Maintenance 06 Physical Asset Management Administrative Procedure [ReferenceCodeLabel) Bolted Flange Joint Integrity (BFII) Procedure 3.6 LEAK RECTIFICATION For equipment flanges, the targeted torque values for retightening or leakage control work purposes is recommended to be calculated using the codes and/or standards applied by the OEM/vendor. 3.7 JOINT LEAK & TIGHTNESS TEST BFIA shall be checked to ensure leak free joint prior to start up. The Operations Coordinator should determine the following for joint tightness test: ‘+ Method of leak detection (e.g, visual, bubble-forming solution, sniffer, leak sound) Trest fluid (e.g, air, inert gas, water, service fluid) + Test pressure (e.g., low pressure or up to a code mandated visual inspection pressure) ‘© Acceptance criteria (often simply “no detectable leaks”) Usage of Temporary and/or Reused Gasket During Leak & Tightness Testis Strictly Prohibited! Refer to ASME PCC-2, Article 5.1 for general good practices for pressure and tightness testing of pressure equipment. 3.7.1 Failure of Joint Leak & Tightness Test ‘Any joints that failed the leak & tightness test shall be braken and a complete thorough inspection on. the BFIA shall be performed. The joint then may be reassembled upon completion of inspection and repair (if necessary) with new gasket and retighten to the targeted torque value. This hard copy document is valid for 48 hours only unless clearly identified as controlled copy. Date & time printed 6 October 2020, 5:20 PM Page 62 of 128OPERATIONAL EXCELLENCE Maintenance MANAGEMENT SYSTEM oe e PRefChem (OEMs) PReIChem Manufacturing & Engineering - Engineering & 06 Physical Asset Management Procedure [ReferenceCodeLabel) Bolted Flange Joint Integrity (BFII) Administrative Procedure 3.8 START-UP RE-TORQUING Start-up re-torque may be performed for the following joints: '* Joints with history of leaks during process unit start-up / ramp up © Joints that are to be retorqued during process unit start-up as per Licensors' recommendations * Identified Joints that are subjected to gasket relaxation and bolt load loss “This hard copy document is valid for 48 hours only unless clearly identified ae controlled copy, Date fi time printed 6 October 2020, 5:20 PM Page 63 of 128azt 40 99 a6eg ie “Ada paynuco se paytsp! 320 9 paduid 2U SSajun uo sun bp 305 Pea st uewND0p AAD ‘sig onnwea oa ona ‘vonmexa->1d ‘ujuueld paRHeT “aupweaa neue ry ‘mots $$390ud TIVUANO Waa auN2IGOwd LNAWOVNVW 148 40 MOTH SSIIO¥d = “WXGNNV59 2603 aa 02: ‘02 -Adeo payonuad se paunUapt AMBP 5: Swousnsop Ae: Saeigonasiaieod ‘uopn2ex3, uopnoara-o14 Syjuuela pusEsy Weer} MOS SS30OUd TIVUINO Vid8 TIDAD GNNOWW-NUNLINVId TVANNEXB: —_JITORGANIZATION CHART nical rviso Joint Maker JITVeritier “This hard copy document is valid for 48 hours only unless clearly identified as controlled copy. ‘Date & time printed 6 October 2020, 5:20 PM Page 66 of 128ANNEX C: —BFII WORKFLOW C1 PLANNING 1 5 : : ' ' ' t ! ' ' ' ! ' ! 1 i ' : ! ' ' ' ! ' ' ' 1 ' ' i ' 1 Work-st Over! ! ' Joint Maker | urrsuperisor | Planner! i Boting | oe upervisor | Mechanical | © Cperation Speciet Supervisor | cashier i | Ce i fi eo ( 1 ! Work ' ' H ' ' ' i ‘ ' ! ' ! ' ' d i ' t ' : ' ' H ' 1 t ' ! ' 1 ; ' ' ‘ : ' ' ' ie ' i i ' 1 i ' ‘ ' ' ‘ ' t ' t i ' ' ' ; ' t ' ' ' 1 ' ' ' Provide Hl 1 ' ' 1 ' ' 1 ! ' 1 '€ ' ' | ' t t ' ' 1 = : i ! ea ' ' 1 ' 1 ' ' t ' 1 ' 1 i ; L ! 1 1 i ' i : ' ‘This hard copy document js valid for 48 hours only unless clearly identified as controled copy, ‘Date & time printed 6 October 2020, 5:20 PM. Page 67 of 1282 BEMACTIVITY ' | Work-tst Onner? te Jot Makar | asuperieor rvaiter | (Rat, 1 cyeratun | spout } | Slower : “This hard copy document is valid for 48 hours only unless clearly identified as controled copy. 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