JOINT INTEGRITY CONTROL SHEET (JICS)

SECTION I – JOINT IDENTIFICATION & PART DETAILS DATA (JIT INSPECTOR) SECTION IV – CONTROLLED BOLTING, JOINT INSPECTION AND COMPLETION (CONTROLLED BOLTING TECHNICIAN)

MO No: Area/ Equipment No: Joint No: Joint Description: Operating Joint  Critical  MANUAL (MTW)  BOLT TENSIONING (HBT)
Unit : Line No: Temp.: Type:  Non-Critical  HYDRAULIC (HTW) TORQUING *HTW and HBT report must be attached
Friction Coefficient Approved Lubricant
Joint Size: Joint Rating:  150  600  1500 Flange Type:  RF  FF Tension Value (lbs.) Pump Pressure (Bar/PSI)
MOLYKOTE 1000™ (µ= 0.13) / P37
 300  900  2500  RTJ  Other,
Bolt Size: (µ= 0.14) (Ta) (Pa)
 Other, _______ _____
Bolt Length: Bolt Material:  B7  B16 Gasket Type:  SPW  MG Passes @ Target Torque Pump (Psi/bar)
(Tb) (Pb)
 B8  A660  RTJ  Other, Torque
(Nm/ft.lb)
No of Bolts:  Other, ______ _____ Percentage
(Tc) (Pc)
Tightening Method:  MT  HT  HBT* *Bolt & Nut Replacement Required:  YES  NO  N/A Pass 1 @ 30%
W W (torque sequence) (Td) (Pd)
Flatness Check Machine:  YES  NO  N/A
Pass 2 @ 60% % of bolt tensioning shall not exceed the bolt yield
strength
SECTION II – JOINT DISASSEMBLY AND INSPECTION (JIT INSPECTOR) Pass 3 @100%
Tool Model:
Flange Surface Condition: Any  YES Remarks: EWR Report Ref No: EWR Closure Status (Assigned Pass 4 @100%
marks or indentations?  NO Person Name, Sign & Date): (clockwise) Serial No.:
Flange Require Remachining/  YES Remarks: Pressure Gauge Serial No.:
Pass 5 @100%
Replacement?  NO Controlled Bolting’s Technician
(clockwise, after
Bolts and Nuts Require  YES Remarks: 4hrs or after HT) (CBT). Name, Sign & Date
Replacement?  NO
JIT Inspector Name: Date: Signature: Remark: 1) Controlled bolting report shall be attached after JIT Verifier Name, Sign & Date
completion

Remark: 1) JIT Inspector to inform JIT Supervisor and trigger EWR if any deviation / additional rectification required
2) JIT Inspector to ensure Section II completion prior proceeding to Section III
3) Flatness check report shall be attached after completion
4) Gasket seating surface shall be clean immediately after break joint to ensure timely defect detection and repair Flange Gap (Parallelism) & Alignment (Hi-Lo) After Tightening:
5) JIT Inspector to attach “White” section of JIT tag after completion of Section II
6) JIT Inspector to attach “Red “ section of JIT tag after completion of Section II POINT Parallelism (mm) Hi-Lo (mm)
A
A

SECTION III – JOINT ASSEMBLY (JIT INSPECTOR) B

B
D
No. Item Comply? No. Item Comply? EWR Report Ref No: EWR Closure C
1 Flange Alignment 3 Flange Marking Status (Assigned C

1.1 Parallelism – Prior to tightening,  YES 3.1 Bolt sequence marking has  YES Person Name, Sign
D
maximum misalignment around the  NO been done  NO & Date):
circumference <0.8 mm
1.2 Lateral Alignment  YES 4 Gasket *Ensure flange gap is uniform. If not, make appropriate adjustments by selective tightening.
Prior to tightening, maximum lateral  NO *Ensure flange is properly aligned.
misalignment between flanges i.e. Hi-Lo 4.1 Check correct specification  YES 1. Compliance to parallelism (Max  YES  NO Note:
of gasket is used  NO misalignment around the circumference <
NPS ≤ 4” = 2mm and NPS > 4” = 3mm
2 Fasteners Check & Flange Surface 5 Graphite Tape 0.8 mm)
Prep. 2. Compliance to lateral alignment (Hi-Lo)  YES  NO  NPS ≤ 4”, 2mm
2.1 Bolt and nuts have been serviced and  YES 5.1 If graphite tape is used, the  YES  NPS > 4”, 3mm
brushed with soft wire brush  NO tape should be applied in a  NO 3. No looseness of nuts  YES  NO Note:
2.2 Lubrication of working surfaces e.g.  YES single layer (flat)
threads and nut faces have been circumferentially on the face 4. Min thread flush with the nut face  YES  NO Note:
 NO
lubricated with approved lubricant of the gasket. Ensure the Remarks:
2.3 Full length free run nut check has been  YES tape is not spirallly wrapped
performed without any issue  NO around the gasket. JIT Inspector Name: Date: Signature:
2.4 If required to hold gasket in place, light  YES
dusting of Super 77 3M has been applied  NO Remarks: 1) Attach “Yellow” section of JIT tag after completion of Section IV
to Flange Face
SECTION V – JOINT ACCEPTANCE
Remarks: 1) Check “YES” if all condition satisfied
2) JIT Supervisor to trigger EWR JIT Supervisor Name: JIT Verifier Name:
3) For Critical Joint with leak history, it’s recommended to conduct pre-gap check prior to disassembly.
Signature: Signature:
JIT Inspector Name Date: Signature:
Date: Date:
JIT Verifier Name Date: Signature:

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 SECTION VI – RE-TORQUING AND LEAKAGE CONTROL DETAILS ( JOINT MAKER/CONTROLLED BOLTING TECHNICIAN) NOTES:
Activity :  RE-TORQUING  LEAKAGE CONTROL WORKS

Tools:  MTW  HTW

* HTW report must be attached
Operating Conditions: 1. Pressure Parameters during 1. Pressure ___________________________
Works:
________________________________ 2. Temperature ___________________________

2. Temperature

_______________________________

 RE-TORQUING RECORDS  LEAKAGE CONTROL RECORDS

Re-Torquing Stages Y/N Torque Applied(Nm/ft.lb) Leak Control Trials Torque Applied(Nm/ft.lb)
(If applicable) (if applicable)

S At 50% Op Temp, @ S1 Starts at leak location

1 T=_____°C
S2 First Trial
S At 75% Op Temp, @
2 T=_____°C S3 Second Trial

S4 Third Trial

SECTION VII – JOINT COMPLETION RE-TORQUING AND LEAKAGE CONTROL WORKS ( JOINT MAKER/ CONTROLLED BOLTING TECHNICIAN)

Flange Gap & Alignment After Tightening: A

Location A B C D

Parallelism
(mm) D B

Hi-Lo

*Ensure flange gap is uniform. If not, make appropriate adjustments by selective tightening.
*Ensure flange is properly aligned. C
1. Uniform gap between flanges (Max 0.8 mm across any  YES  NO Note:
diameter)
2. Mating Flange is Aligned  YES,  NO, MAX  NPS ≤ 4”, 2mm
UNIFORM MISALIGNMENT  NPS > 4”, 3mm
GAP
3. No looseness of nuts  YES  NO Note:

4. Min thread flush with the nut face  YES  NO Note:

5. Leak Arrested?  YES  NO Note:

SECTION VIII – JOINT ACCEPTANCE RE-TORQUING AND LEAKAGE CONTROL WORKS

JIT Verifier Remarks by JIT Verifier

Name:
Signature:
Date:
JIT Cert. No:

JIT Lead Operation Supervisor

Name: Name:
Signature: Signature:

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