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REVISION DESCRIPTION
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INDEX
INDEX 3
4. RESPONSIBILITY 5
6. MATERIAL 6
APPENDIX D: SECURITY INSTRUCTION C.91 A & APPENDIX E: SECURITY INSTRUCTION C.91 B 21
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1.1. General
OML58 Block, operated by TOTAL E&P Nigeria Ltd, is located in Nigeria, at some 75km North-West from
Port Harcourt, close to the villages of OBITE and OGBOGU.
The project is composed of five main parts:
TOTAL E&P Nigeria Ltd, intend to upgrade the OML 58 facilities and mainly increase the gas export capacity
from 9.5 to 15.65 MMSCMD (Million Metric Standard Cubic Meter per Day) of marketable gas.
2. REFERENCE DOCUMENTATION
• TOTAL General specification GS PVV 171
• Contract UPG-D100 Exhibit A Appendix 10 Specific pre-commissioning / commissioning requirements
and explain the chapter on this document.
• GS EP COR 350 & 354 painting requirements.
• ANSI B31
2.1. Definitions
The following terms are used in this Procedure:
CONTRACTOR The Consortium made of SAIPON SNC, SCNL, PNL & DESICON
Engineering
3. SCOPE
This procedure is applicable for all lines on the OML58 Upgrade Phase1 Project.
4. RESPONSIBILITY
.
This procedure is managed by the CONTRACTOR QUALITY MANAGER and he is responsible for the
approval and issue of all revisions to this document.
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In accordance with project Codes and Standards, CONTRACTOR is responsible on applying correct bolt up
procedure on all piping and equipment assembly.
Vendor is responsible for correct bolt up procedure of “Package Equipment” critical flanges.
Flange assembling is carried out under responsibility of the Pipe Fitter Foreman. He is responsible to monitor
staff competence in term of Quality and Safety for the assembling work achievement.
The Pipe Fitter FOREMAN is, consequently, responsible for applying this procedure.
5. PERSONNEL QUALIFICATION
The personnel carrying out assembling operations shall be qualified. This qualification is obtained through
internal CONTRACTOR training or from a training given by an external company.
6. MATERIAL
The Pipe Fitter FOREMAN must check that the material is adapted for the work:
- Individual and collective adapted tools (bronze tools on high explosive risks zone, anti-deflagrant
material…),
- Adapted individual protections (gloves, screen, glasses, evacuation mask …),
- Adapted security, insulation or test spades,
- Insulation gasket in conformity with the specifications,
- Adapted tightening tools.
7. ASSEMBLING EXECUTION
7.1. General
The major factors for successfully sealing a bolted assembly and eliminating leakage are:
- proper selection and design of the components, i.e. flanges, gaskets and bolts;
- proper preparation, inspection and installation;
- correct bolt-up procedure
All gasket sealing surfaces shall be protected from damage (shock, stripe, corrosion, sanding…) by
installation of hardwood blanks and shall be inspected after prefabrication, lifting, offshore transfer and final
installation.
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5. Check that flange facing, dimensions and type of bolting are in accordance with the general
specifications.
6. Use straight steel rule edge to check facing flatness. Flange shall have bearing surfaces for bolting that
are parallel to the flange face within 1 degree. Damaged or badly corroded flanges should be repaired or
replaced.
7. Flanges at rest should be parallel, in case of misalignment; corrective measure will defined will be
defined with COMPANY and witnessed by COMPANY. Completed flanged connections shall be free of
residual stresses during assembly, particularly in machinery piping and shall not be “force fit” to achieve
fit-up. Guidelines of alignment allowance are given in figure n° 1 for pipe flanges. Any anomaly shall be
filed and reported using the “Assembly anomaly report card” given in Appendix B which is then
transmitted to COMPANY for decision.
8. All gaskets shall be new and unused whenever an opened assembly is to be closed again. Check
conformity of the gasket (material, dimensions, series, thickness, type) to ensure that it is in
compliance with the piping specification, class, pressure rating or the dismantled gasket.
9. Check the general aspect of the gasket:
• coating,
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• geometry,
• crushing,
• spiral windings,
• traces of corrosion or erosion.
All damaged gasket (including loose spiral winding) shall be rejected.
7.3. Assembly
1. The gasket is now under responsibility of pipe fitter foreman (final or temporary)
2. If required, grease RTJ seating face and if necessary seal the gasket.
CAUTION: Some services such as Oxygen or Hydrogen are not compatible with the use of grease.
3. Center the flange faces using appropriate tool (pin, centering device,). Align flange faces exactly, leaving
just enough space to insert a gasket. Once flanges have been aligned up, visually examine them to
assure that an acceptable fit has been obtained.
4. Install the first stud bolts.
Note: For a gasket in vertical plane, it is necessary to start the assembly by placing the lower stud
bolts which will be used as support for the gasket before tightening,
5. Install the gasket.
6. Center the gasket.
7. Insert all remaining studs and nuts on hand-tight. Do not pull up studs in a manner that reaches uneven
compression of the gasket.
8. Ensure all bolts are tensioned evenly and in sequence with at least two threads protrusion through the
nuts at both sides. Otherwise, distribute protrusion equally from the sealing facing
Note: If bolt tensioner is to be used, over length bolt are required (protrusion shall be at least one bolt diameter
on one of the two sides). Attention is to be paid for allowance for tensioning equipment access.
9. Tighten the stud bolts with manual wrench to obtain the parallelism of the flange faces.
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8. TIGHTENING
Bolts shall be of sufficient length to leave minimum of three threads at the end of tightening activity.
9. BOLT TORQUING
9.1. General
Hydraulic, pneumatic or beam type torque wrenches are commonly used in bolt torquing. The hydraulic
wrenches are normally preferred.
Reference to the tensioning equipment manufactures hydraulic pressure/tensioning values shall be used
for guidance.
The pressure to be applied is indicated in the equipment pressure / torque conversion specific chart.
9.2. Preparation
1. Using Appendix G table, determine the torque values necessary to achieve the desired bolt stress.
2. Bring all nuts up snug-tight with a short wrench using the "CRISS-CROSS" pattern shown in Appendix
A. Do not tighten the bolts using impact force.
3. All torque wrenches shall be of adequate capacity and recently calibrated. Certificates of torque
wrenches calibration shall be available.
4. In the event that seizure of the nut being torqued is encountered, back the nut off until seizure is
eliminated and torque again. Apply lubricant if necessary and replace the nut and/or bolt if seizure re-
occurs.
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10.1. General
The advantage of this method lies mainly in the homogeneity of tightening. It requires stud bolts over lengths
are equals to one bolt diameter. However, its implementation shall be carried out strictly in accordance with
the equipment manufacturer’s recommendations.
The hydraulic pressure to be applied is function of the bolt diameter and the type of tool; it is indicated in the
equipment specific tables as shown in table 5 in paragraph 13.3.
The tensioning of bolts shall be performed by trained personnel with appropriate equipment (bridges, pullers,
hydraulic pumps, connection pipes, manometers, etc.). Tools are shown in Appendix L.
Ideally all bolts should be tensioned in one operation to ensure even loading on the bolts and gaskets. It may
not be practical to tension all bolts in one operation, but at least 2 bolts diametrically opposed should be
tightened in one operation to ensure an acceptable degree of uniformity in loading.
CAUTION: Bolt tensioning should not be carried out on equipment or systems which are in service.
The trained personnel selected to perform the controlled bolt tensioning shall develop in the preliminary
operation a diagram correlating the required pressure to be reached in the hydraulic circuit connected to the
tensioners and the required load in each bolt.
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The following procedure provides an example of 20" - 900# flange and 4 bolts tightened at the same time. In
case the quantity of tensioner is different, each group below will have the same quantity as quantity of
tensioner.
1. Group the 20 bolts into five groups (quantity of tensionners is the quantity of each group, 4 A's, 4 B's, 4
C's, 4 D's and 4 E's) as shown in Appendix I and then mark them accordingly on the flange.
2. Mount the 4 hydraulic tensionners on the first 4 bolts A's group of bolts.
3. Check the hydraulic system if there is any pressure problem.
4. Check that the specified hydraulic pressure is applied to the tensioner before running the nut down on
each stud.
5. Apply equivalent hydraulic pressure by operating the hydraulic pump to give a bolt load equal to 40% of
the maximum bolt stress (see paragraph 11).
Note: It is often advisable to continuously re-apply the bolt stress, especially with Ring Type Joints, until no
further movement of the flange nuts can be obtained. Also, it may be beneficial to allow a few minutes
between each pressurization to allow the gasket to bed in.
6. Shift the tensionners to the next group and repeat the steps 3 to 5 until all group are 40% tightened.
7. Repeat the steps 2 to 5 with 70% of the maximum bolt stress
8. Shift the tensionners to the next group and repeat the steps 3 to 5, but applying a bolt load equal to 70%
of the maximum bolt stress.
9. Repeat the steps 2 to 5 with 100% of the maximum bolt stress
10. Shift the tensionners to the next group and repeat the steps 3 to 5, but applying a bolt load equal to
100% of the maximum bolt stress.
11. Repeat steps 3 to 5 on all group of bolts to check if the hydraulic pressure required is enough to obtain
the required bolt stress.
Note: As a check to see if an excessive load has been lost in the initial groups, assemble two tensioning
tools to randomly select but diametrically opposite group bolts. Apply 100% final hydraulic pressure and
attempt to further tighten the flange nuts. If the nuts cannot be further tightened, then tensioning is complete
and the tensioners may be removed. If the flange nuts can be further tightened, then repeat steps 2 to 5 by
increasing the hydraulic pressure to 100% of final hydraulic pressure, on the bolts of each group.
11.1. Correspondences
The bolt-up procedure with torque wrench method is based, as an example, on the bolt stress of A-193
Grade B7 or A-320 Grade L7 in making up the flange, while the bolt tensioning method is referred to a
generic maximum bolt stress.
Table n° 3 indicates the maximum bolt stress values recommended, it is important to notice that there are
some flanges where lower bolt stress values are appropriate depending on the flange rating, and/or type
bolting. In case of the Ring Joint Flanges, lower maximum bolt stress values are recommended for the
higher flange ratings to avoid excessive bolt loads which can lead to undesiderable deformations to ring
gasket and flange groove seating surfaces. Unlike raised face flanges, there is a little difference in gasket
seating area with ring joint flanges as flange ratings increase so bolting loads are more concentrated in
narrow zones of the ring groove. The remaining situations are all governed by the material strength of the
specific bolt indicated. See Appendix G for correspondence between bolt load and bolt diameter depending
on flange class and face type.
1. measure with caliper the bolt elongation of the four bolts diametrically opposite;
2. check the correspondence of the specified bolt stress in the range of ± 10% of the bolt elongation
measured;
3. if the above tolerance is not achieved in one bolt, then all the bolting of the joint will be checked and, in
case of no compliance, retensioned; in case of no compliance of all 4 bolts for more than two joints in
the same sampling, all the flanged joint tensioned by the crew who performed the bolt-up during that
working day, will be completely checked.
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Table n° 3
Each size of bolts for flange shall be submitted to a qualification procedure. The qualification shall be
carried out on mock-up flange and elongation of each bolt shall be measured to ensure uniform bolt
tension. For the finished joint, bolt elongation should correspond to maximum bolt stress value determined
as per Appendix G ± 10%.
Where L is the effective bolt length measured from center of nuts (as shown in Appendix J).
And A is the elongation coefficient.
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Any stretch Bolt Tensioner regardless of make, exhibits a Load Transfer Loss as the bolt load is transferred
from the Tensioner to the joints hexagon or round nuts. The Bolt load loss is a direct loss of stud elongation,
this is due to many different factors, such as thread deflections, radial expansion of the nut and ‘bedding in’
of the nut into the joint reaction surface. Because of this phenomenon it is essential that a load allowance is
made when calculating the required operating pressure of a Tensioner, to achieve a known residual bolt load,
extra load must be applied so the bolt will relax down to the required load on transfer. The load transfer factor
can be accurately calculated and is a direct function of joint clamp length and the nominal diameter of the
stud :
CAUTION: Applying the Load Transfer Factor to the required bolt Stress will Increase the % of yield being
generated on the bolt this value must be checked again
Tool Pressure = (Required Bolt Load x Load Transfer Factor) / Tool Hydraulic Pressure
Area
Units:
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Tool reference Tool T22 Tool T23 Tool T24 Tool T25
Pressure Area (mm²) 2,884 5,271 8,445 12,197
Max Pressure (bar) 1500 1500 1500 1500
Max Load (kN) 433 791 1267 1830
Max Piston Stroke (mm) 15 15 15 12
Dia Dia L L Tension Pressure (bar) Pressure (bar) Pressure (bar) Pressure (bar)
LTF
(in) (mm) (in) (mm) (kN) 40% 70% 100% 40% 70% 100% 40% 70% 100% 40% 70% 100%
1 1/2 M39 10 1/2 219 1,15 346 553 968 1383 303 530 757 189 331 472 131 229 327
1 1/2 M39 12 3/4 276 1,13 346 541 947 1353 296 518 740 185 323 462 128 224 320
2 M52 14 1/4 298 1,15 644 562 984 1405 351 614 877 243 425 607
2 M52 15 3/4 337 1,14 644 556 972 1389 347 607 867 240 420 600
2 M52 20 3/4 464 1,11 644 541 946 1352 337 591 844 234 409 584
2 1/2 M64 20 1/4 435 1,13 1032 554 970 1385 384 671 959
2 1/2 M64 20 1/4 435 1,13 1032 554 970 1385 384 671 959
2 1/2 M64 30 1/2 695 1,09 1032 534 934 1334 370 647 924
2 3/4 M70 22 1/4 478 1,13 1146 615 1077 1538 426 746 1065
Table n° 5
14. DISASSEMBLING
1. Respect security instructions C.39 in Appendix F, and C90-C91A-C91B in Appendix C,D if asbestos or
ceramic fibers are sealing the flanged assembly.
2. Chock the flanged assembly to be dismantled with wood chocks and/or hoist and sling.
3. Loosen the bolts without removing them,
4. Use flange spreader instead of wedges. Space the flanges, facing the flanged assembly which will be in
the direction of the wind (wind in the back),
5. Clean the gasket seating facings (calamine, grease, products, varnish…),
6. Inspect the supports, gaskets, stud bolts and line. In the event of an anomaly the PIPE FITTER FOREMAN fills
the anomaly report card (Appendix B) which is then transmitted to COMPANY for decision,
7. If necessary, grease the nuts, bolts, stud bolts.
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The colors being specific to each production site, PIPE FITTER FOREMAN will take care of giving information to
the assembling affected personnel on each working site.
15.2. Label
The label ensures the traceability of the executants for each assembly. Labels shall include specific valve /
equipment tag numbers, where necessary.
It is fixed by a wire to one of the stud bolts and at least includes the following indications:
• PONTICELLI NIGERIA LTD
• Executant’s name
• Execution date
PNL
Name : ………..
Dat
Fig.2
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C.90 03/02/98
The refractory ceramic fibers (RCF), just as the glass, rock fibers, etc… belong to the group of
vitreous artificial mineral fibers. They are used for the insulation at high temperature in the
following fields:
The exposure to ceramic fibers can cause momentary irritations of the eyes, skin and
respiratory tracts. To date, no other significant effect was observed.
Nevertheless, the International Research Cancer Center has classified ceramic fibers as being
possible carcinogens on the man after studies undertaken on the animal.
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C.91 A
REV.1
APRIL 17, 1997
The inhalation of asbestos dust can cause affections of the respiratory tracts of which most
serious are:
3°) PROCESS :
FOOT-NOTE: Gaskets, cords or braids not identified are to be treated as containing asbestos.
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C.91 B
REV.1
APRIL 17, 1997
The inhalation of asbestos dust can cause affections of the respiratory tracts of which most
serious are:
• During every exit from the capacity, removal of the combination in the protected zone by polyane
film and put in a plastic bag,
Plastic deposit of the bags in an identified dustbin (in charge of the client).
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C.39
JANUARY 92
DISASSEMBLING OF THE VALVE BONNETS
DISASSEMBLING FLANGED VALVES, FLANGES, OR BLIND SPADES
ON FLANGES
1) Ask the authorization to your FOREMAN in order to disassemble or receive the order.
2) Before any work begin, a task pack corresponding to the work is required. Start only when
this you are authorized to work.
3) Wear the necessary safety material planned for the work, as detailed hereafter:
Masks with cartridge, breathing insulating apparatuses, protect faces, glasses, gloves,
boots, special clothing, etc.
4) Check that the working station ensures your safety: ground continuity and handrail. If the
working environment do not have this continuity, systematically use your tether and your
harness of which you must attach your tether.
5) Open the cover of the valve completely so that it is free of air.
THEN CARRY OUT DISASSEMBLING
6) Think of what will arrive when the bonnet will be unbolted and fix it to the environment or
use lifting equipment if necessary.
7) Choose 2 bolts diametrically opposite fixing the bonnet to the body of valve and unbolt
them only partially.
8) Unbolt the other bolts completely.
9) Make oscillate the valve from the body of valve to break the gasket.
10) The gasket being broken and the bonnet dismantled from the body of the valve, you will be
able to unbolt the last 2 bolts completely and lift the bonnet with precautions due to its weight.
For valve disassembling, apply all the rules above to remove the valve of its FLANGE instead
of removing the bonnet from the body of the valve.
11) Place yourself on the wind each time it is possible so that possible emanations move away
from you, carried by the wind.
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Piping Area : Project : OML58 Upg Ph 1 ‐ OBAGI Site
Test Pack Number : Piping Class :
Torquing Device ref. : Report Number :
Reference Acceptable Table
DIA BOLT DIA BOLT NUT SIZE Torque value Torque value
Tension F kN
(inches) ISO (mm) f = 0.07 N.m f = 0.13 N.m
0,5 M14 21 33 48 80
0,625 M16 24 52 92 155
0,75 M20 30 78 160 270
0,875 M24 36 107 253 429
1 M27 41 141 376 639
1,125 M30 46 184 540 925
1,25 M33 50 232 745 1 285
1,375 M36 55 288 996 1 727
1,5 M39 60 346 1 297 2 261
1,625 M42 65 412 1 653 2 894
1,875 M48 75 561 2 549 4 493
2 M52 80 644 3 097 5 476
2,5 M64 95 1 032 6 068 10 828
SPD CST SPD QAQC CLIENT
Name :
Date :
Signature :
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The 5 groups are marked respecting criss cross method from Appendix A: for 4 tensionners,
group A is number 1 to 4, B is 5 to 8, …
12 BOLTS FLANGE
2 TENSIONNERS
The 6 groups are marked respecting criss cross method from Appendix A: for 2 tensionners,
group A is number 1 and 2, B is 3 and 4, ...
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