BO-0475 - Const - Work - Pro - For Gasket Install (Rev 0) - 20150605

BOLTED FLANGE JOINTS AND GASKET
ASSEMBLY PROCEDURE
Project Title:
UPGRADE FIRE WATER SYSTEM AT
JUAYMAH NGL AND FRACTIONATION
(JNGLF)
Location: Document Number: Revision
JUAYMAH -SAUDI ARABIA 10-00475-SEG-QCP-018 00
UPGRADE FIRE WATER SYSTEM AT JUAYMAH NGL

AND FRACTIONATION (JNGLF)-RTR
BI 10-00475
CONTRACT No. 6600042445
ASSEMBLY PROCEDURE
ISSUED BY: SINOPEC ENGINEERING GROUP SAUDI CO.LTD.

Approvals:
Tong Guo Wang

Approved by :
Project Manager
Reviewed by : Wang jin Xin

QA/QC Manager
Prepared by : Davud shabir

Piping QC Inspector
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TABLE OF CONTENTS
1.0 PURPOSE ------------------------------------------------------------------------------ 3
2.0 SCOPE ---------------------------------------------------------------------------------- 3
3.0 REFERENCES ------------------------------------------------------------------------ 3
4.0 RESPONSIBILITIES ----------------------------------------------------------------- 4
5.0 PRE-ASSEMBLY INSPECTION -------------------------------------------------- 4
6.0 TORQUING------------------------------------------------------------------------------ 5
7.0 TORQUING TOOLS ------------------------------------------------------------------ 5
8.0 GASKETS ------------------------------------------------------------------------------- 5
9.0 RECEIVING AREA & GASKET LOCATION ---------------------------------- 9
10.0 GASKET INSTALLATION --------------------------------------------------------- 10
11.0 STUD BOLT TIGHTENING PROCEDURE ------------------------------------ 11
12.0 STUD BOLT ADDITIONAL TIGHTENING PROCEDURE WHERE LEAKS

OCCUR DURING PRESSURE TESTING --------------------------------------12
13.0 ADDITIONAL REQUIREMENTS FOR PIKOTEK GASKETS------------- 13
14.0 INSPECTION OF BOLTED FLANGE JOINT ASSEMBLY-----------------------14

15.0 ATTACHMENTS ---------------------------------------------------------------------- 17
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1. PURPOSE
This procedure covers Gasket Installation and Flanged joints assembly in piping work to
determine and ensure that the correct gasket is installed in Project UPGRADE FIRE WATER
SYSTEM AT JUAYMAH NGL AND FRACTION (JNGLF)
2. SCOPE
This procedure covers the minimum requirements to assemble bolted flanged joints and
gasket installation.
3. REFERENCES
SAES-A-205 Positive material identification
SAES-L-100 Applicable Codes and Standards for Pressure Piping Systems
SAES-L-101 Regulated vendors list for pipe fitting and Gaskets
SAES-L-109 Selection of Pipe Flanges, Stud Bolts and Gaskets
SAES-L-105 Piping Material Specification
SAES-L-350 Construction of Plant Piping
SAES-S-070 Installation of utility piping system
SAEP – 351 Bolted Flange Joints Assembly
ASME B16.1 Cast iron pipe flanges, fittings
ASME B16.5 Pipe Flanges and Flanged Fittings NPS 1/2 through NPS 24
ASME B16.20 Ring Join Gaskets and Grooves for Steel Pipe Flanges
ASME B16.21 Nonmetallic Flat Gaskets for Pipe Flanges
ASME B16.47 Large Diameter Steel Flanges NPS 26 through NPS 60
ASME B31.3 Process Piping
ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other
Liquids
ASME PCC-1 Guidelines for Pressure Boundary Bolted Flange Joint Assembly
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4. RESPONSIBILITIES
4.1 Piping Construction supervisor
 Piping Construction Supervisor shall arrange correct material as per IFC
drawings and provide IFC drawings to fitters’ team.
 Construction supervisor shall notify to QC inspector prior to start of activity at
site through internal RFIs.
 Arrange all resources as required by this procedure or applicable company
requirements including certified / trained manpower, calibrated tools and work
permits
4.2 Quality Control Inspector
 Monitor daily bolts torqueing / tightening and Gasket installation activities, and
verify compliance with procedure and Company Specifications. Prepare daily
QC inspection records and final acceptance documentation.
 Initiate RFIs for Company inspector and coordinate with Company inspector.
 Report and record any violation as per applicable requirement as NCR.
5. PRE-ASSEMBLY INSPECTION
5.1 The gasket shall be verified for correct type, rating, dimension and compatibility
with the flange face. Also, it shall be free from any damage particularly in the
seating element. Ensure that spiral wound gaskets are stored flat especially for
large sizes, 24 inches and larger.
5.2 All gaskets shall be color coded by verified after installation gasket rating such as
CL-150, CL-300, CL600 and all that. (Refer to Attachment “J Tag for Gasket
Rating Verification After Installation & Gasket Color Coding for Stripes)
5.3 Bolts, nuts and washers shall be visually checked for proper size, grade, and
dimension and for any physical damage to shanks or threads which would affect
the bolt assembly or performance. Also, check the suitability of the stud bolts and
nuts material for the service temperature and the compatibility with the flange
material.
5.4 The flange facing, particularly the seating area, shall be visually examined for
cleanliness and ensure that no damage, such as scratches exist. For ring joint
type flanges, the ring and the ring groove shall be tree of damage and dirt.
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5.5 Proper lubricant for bolts and nuts shall be used. Lubricant for bolts and nuts shall
be Jet-Lube SS-30 or other acceptable lubricants listed in attachment “A”, Friction
Factors for Different Lubricants listed in Table-SAEP-351-01.
5.6 Tightening tools shall be checked for adequacy, performance and calibration, if
required.
5.7 Lubricant shall not be used in the gasket and the gasket seating area.
5.8 Flange shielding shall be installed / reinstalled when required.
6. TORQUING
6.1 Torque values vary according to flange rating, bolt size, type of gasket, and
friction factor of the thread lubricant. Torque values for raised face flanges (ASME
B16.5) & gasket type are specified in attachment "G", Torque Values for ASME
B16.5 RF Flanges & Gasket. While piping works, ANSI B16.5 class 150 RF &
ANSI B16.5 class 300 RF flanges are most frequently used.
6.2 The torque values are specified in attachment “B”, Torque Values for Low-Alloy
Steel Bolting and attachment "C”, Torque Values for Isolating Gaskets (PIKOTEK)
on ASMEB16.5 and ASME B16.47 Series A & B, Class 150 through Class 2500
Flanges.
6.3 Attachment “B”, Torque Values for Low-Alloy Steel Bolting applies to all gaskets
listed in Section8, except for insulating gaskets.
6.4 Attachment "C”, Torque Values for isolating Gaskets (PIKOTEK) on ASME B16.5
and ASME B16.47 Series A &B, Class 150 through Class 2500 Flanges applies to
isolating gaskets (e.g., PIKOTEK), based on a friction factor of0.16.
7. TORQUING TOOLS
7.1 Selection of the proper tool depends on the stud bolt size, physical location of the
flanged joint, and criticality of the flange. Identifying the proper tools shall be
reviewed by COMPANY Representative and agreed on. There +are various types
of tools available to achieve the proper torque value.
7.2 The manufacturer’s instructions shall be followed for the operation, limitation and
maintenance of all torque wrenches used to perform flange bolts tightening.
7.3 Torque wrench calibration shall be performed in accordance with manufacturer’s
recommendations.
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8. GASKETS
8.1 Gaskets shall be suitable for the intended service and compatible with the flange
type in terms of facing, rating and bolting. The following types of gaskets are
prohibited
8.1.1 Gasket with Asbestos as filler or base material.
8.1.2 Flat smooth metallic ring (other than metal grooved type).
8.1.3 Flat sheets RTJ flanges for all classes.
8.1.4 Flat sheets on raised when the pressure is higher than 200 psig.
8.1.5 Non-metallic gasket at temperatures higher than the acceptable limits of the
gasket material.
8.2 Gasket selection shall be in accordance with ASME B31. 3 and the following:
8.2.1 Spiral wound type 316 stainless steel winding, flexible graphite filled, with
carbon steel guide ring, per ASME B16.20, for raised face flanges in most
services, including steam and process hydrocarbons.
In oxidizing environments, the maximum temperature is limited to
454°C.Gasketsoperating in temperatures below minus 45°C, the guide ring
shall betype 304 stainless steel material. Filler materials that deteriorate at
elevated temperatures, e.g. Teflon, shall not be used.
8.2.2 Full face synthetic rubber gasket, ASTM D1418 Class CSM on flat face
flanges, may be used for most acid services up to 70% concentration and to
65°C. For sulfuric acid above 70 percent concentration (including oleum),
and nitric acid (all concentrations), use full face ASTM D1418 class FKM
elastomer on flat face flanges. When raised face flanges are to be used, the
flange finish shall be 3.2 to6.4 micrometers Ra, and the gaskets shall be
PTFE-filled spiral wound Alloy 20stainless steel with stainless steel inner
ring. Applications involving other acids must be approved by the Company
Representative.
8.3 Gasket Color Coding
Gasket color coding is shown in attachment “H", Modified Color code for Material
Identification of ASME B16.20.
8.4 Spiral Wound Gaskets

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8.4.1 Filler material for spiral wound gaskets shall be suitable for the intended
design conditions.
8.4.2 For general hydrocarbons and process hydrocarbon services including
steam. ASME B16.20 spiral wound gaskets with 316 stainless steel winding
and high purity flexible graphite filler shall be used for raised face flanges.
8.4.3 The inner and the outer rings material shall be carbon steel. The inner and
outer rings material for gaskets operating in temperatures below minus 45°C
shall be type 316 stainless steel material.
8.4.4 Outer rings are required for all sizes; Inner rings are required for the
following flanges;
1) Flanges size 24“and larger.
2) Flanges class 900#and above.
3) Spiral wound gasket with graphs or PTFE filler materials.
8.5 Octagonal low carbon steel ring joint gaskets and pressure energized Type R, per
APISPEC 6A shall be used with API SPEC 6A Type 6B flanges and ASME RTJ
flange type. Type BX gaskets per API SPEC 6A shall be used with Type 6BX
flanges.
8.6 Metal Grooved Gaskets
8.6.1 Generally, metal grooved gaskets are considered as a preferred alternative
to spiral wound gaskets in piping system and process equipment for raised
face flanges.
8.6.2 Metal Grooved gaskets are recommended for the following services:
1) Piping system subject to daily temperature cycling of than 200°C.
2) Flanges of 36" inch nominal diameter and larger.
3) High temperature service Piping system of 350°C and higher.
4) Flanges that are subject to high bending moment due to piping
configuration.
8.7 Process Equipment Gaskets
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8.7.1 Selection of the gaskets within the process equipment (such as pressure
vessels, heat exchanger, filters, etc.) shall be per the applicable standard or
specification.
8.7.2 Gaskets at the interface of the piping system with the process equipment
(such as pressure vessels, heat exchanger, filters, etc.) shall be governed by
this standard.
8.8 Insulating Gaskets
8.8.1 An insulating gasket kit such as PIKOTEK gaskets, with isolating bolt sleeve
sand washers shall be used for isolating dissimilar metal flanged joints (i.e.
Electrical isolation), and insulating joints for cathodic protection.
8.8.2 Insulating gaskets are not required for the following services:
1) Hydrocarbon gas service.
2) Dry gas service other than hydrocarbon.
3) When the service temperature is above the limitation of non-metallic
gasket application.
4) If field experience has proved that galvanic corrosion did not occur in
similar conditions.
5) When mass ration of SS compared to the CS is very low where galvanic
corrosion in the CS will be in significant.
6) When the internal liquid media is not electrolyte (will not be ions
conductor).
8.8.3 When the designer can demonstrate that galvanic corrosion will not occur
between the dissimilar metals.
8.8.4 In flammable services and when the insulating gasket kit is ineffective due to
electrical external bonding between the dissimilar metals caused through
contacts with pipe supports, structure, etc.
8.8.5 The PIKOTEK
1) PIKOTEK gasket is proprietary gasket. It is categorized as non-metallic
type of gasket with self-energized Teflon seal supported by glass
reinforced epoxy laminated to 316 stainless steel core. For low pressure
services, the stainless steel laminate may not be required.
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2) When PIKOTEK gasket is specified adequate gap between flange faces
shall be provided and considered during design and fabrication. The
minimum required gap shall be 3.2 mm.
3) PIKOTEK gaskets shall not be used in the following services: Services
operating at 154°C and higher;
a) Hydrocarbon gas service in 300 ASME class flanges and higher.
b) Chemical incompatibility of the non-metallic components of the
gasket with service media.
4) The usage of PIKOTEK gaskets in refineries shall be reviewed by the

Company and shall be compatible to the chemical limitations. Latest
manufacturer information shall be consulted for verification.
8.8.6 Gasket limitation and octagonal ring to be use as per ASME B16.20
1) Flanges in class 900 and higher ratings
2) Underwater pipelines in Class 300 and higher ratings
3) Design temperatures in excess of 480°C
4) API SPEC 6A Type 6B flanges
5) Hydrogen service in Class 300 and higher ratings
9. RECEIVING AREA & GASKET LOCATION
9.1 Gaskets are visually checked during receiving in a clean area or warehouse
appropriate to ensure gaskets, especially fillers and lubricated items are not
fouled by sand and dust. Packaging is only opened as needed (due to oxidation
and rusting concerns) to allow basic checks to assure gasket quality.
9.2 For all gaskets to be used on the project and the gaskets received are checked
against the color code chart. Color code chart (gaskets) is clearly posted in
storage area.
9.3 Incoming gasket segregation in a warehouse or other approved facility that
prevents mixing of incoming gaskets with those already received and accepted.
Gaskets received, inspected and accepted are identifiable, yet any marking or
color coding system for this inspection acceptance does not affect gasket sealing
or serviceability.
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9.4 Segregation is achieved by clear separation, color coding and the marking of bins
or areas where gaskets are located / stored.
9.5 Damaged or non-conforming gaskets are identified, rejected, segregated or
controlled and tracked per Quality system procedures to prevent use. (Quarantine
System established) Gaskets with minor damages to windings can be used as
"test" or temporary" gaskets, but they are identified / marked as such in the
special process control procedure approved by Company.
10. GASKET INSTALLATION
10.1 Tools
At first make sure that the following tools are available and in good condition:
1) The correct gasket chosen for the specific application.
2) A calibrated torque wrench.
3) A wire brush.
4) Lubricants for the bolts.
10.2 Cleaning of All Flange Surfaces

1) Make sure that the flange surfaces are clean.
2) Check the bolts and the flange surface if they are technically ok and free from
any serious defects.
3) Always blush in the direction of the grooves.
4) To avoid damage on the flange surface please use a brass drift.
10.3 Flange Conditions

1) Make sure that the flanges are parallel and report at irregularities.
2) The flange joints shall be assembled and bolts tightened in accordance with
SAEP-351(ref. SAES-L-350 para. 12.3)
3) Pipe fit up and tolerances shall be in accordance with the requirements of
SAES-L-350 para. 9.4 & 9.5
4)
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10.4 Important for the Gasket

1) Insert the gasket carefully between the flanges.
2) The gasket has to be centralized in the flange.
3) Ensure that the gasket is installed in a dry state.
4) It is important that the gasket is not pinched or otherwise damaged when
bringing the flanges together.
5) Gasket shall be handled in accordance with manufacture’s instruction. Gasket
shall be replaced whenever opening of flange assembly (ref. SAES-L-350 para.
12.7)
10.5 Lubrication of Bolts

1) Apply lubricant to the bolt and the nut threads as well as to the face of the nut
to reduce friction when tightening.
2) Pay attention that the lubricant does not contaminate the gasket or the flange
surfaces.
3) The recommended service temperature of the lubricant has to be within the
process service temperature limits.
10.6 Bolt Tightening
Make at least 4 stages to the required torque as follows:
1) Finger tighten bolts.
2) Use 30% of the required torque.
3) Use 60% of the required torque.
4) Use the full torque.
10.7 Re-use of Gaskets
For safety reasons never reuse a gasket.
11. STUD BOLT TIGHTENING PROCEDURE
Step 1: Align flanges and gasket. Forced tightening is not allowed to overcome non
acceptable alignment tolerances. Clamp securely in place.
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Step 2: Apply lubricants to stud threads over length and nut engagement and to face
of nut which contacts flange. Ensure that the nuts run freely down the thread
of the studs.
Step 3: Install all studs and nuts hand tight, ensure that studs pass freely through the
flange holes. Position the nut on one end of the stud such that only the
crown of the stud projects beyond the face of the nut. The excess stud
length should project beyond the nut on the other side.
Step 4: Number each stud according to its position in the flange as shown on
attachment “D”, Stud Bolt Tightening Sequence.
Step 5: For insulting gaskets like PIKOTEK, enough gap (1/2” of gap is recommended)
should be available between flange faces to avoid any damage to seals
during inserting the gaskets, if due to any reasons, seals are damaged,
change the seal before installing PIKOTEK.
Step 6: Matting flange faces and the gaskets should be dry and tree from grease, oil or
water.
Step 7: Tighten studs per the Stud Bolt Tightening Sequence, for 4 to 32 bolts see the
attachment “D” and for 36 to 68bolts see the attachment “E” for bolts
numbering and then follow the tightening sequence of attachment “F”,
Cross-Pattern Tightening Sequence. An appropriate tool should be used
such as an air impact wrench or equivalent.
Step 8: For joints containing RTJ or Spiral Wound Gaskets, repeat step 7.
Step 9: Tighten the stud bolts in stages to obtain the final required torque from the
appropriate torque, in attachment “B”, Torque Values for Low-Alloy Steel
Bolting. The first stage should not be more than 30% of the final torque. The
final torque shall be within ±5% of the required torque value.
Apply the torque evenly to each stud following the stud bolt tightening
sequence. The final torque must be within ±5% of the required values per Section 6
above.
12. STUD BOLT ADDITIONAL TIGHTENING PROCEDURE WHERE LEAKSOCCUR

DURING PRESSURE TESTING
Step 1: Depressurize the piping system and re-torque stud bolts to maximum torque
value shown on attachment “B”& attachment “C”.
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Step 2: If leak does not stop after re-torqueing has been performed, disassemble the
flange joint and inspect as follows:
1) Inspect stud bolts and nuts for defects or damage to threads or improper
cleaning of threads.
2) Inspect flange faces for damage, misalignment
3) Inspect gasket for damage or defects.
Step 3: After all defective and damaged items have been repaired or replaced,
reassemble the flange joint using a new gasket and tighten the bolts using
the maximum torque values.
13. ADDITIONAL REQUIREMENTS FOR PIKOTEK GASKETS
Step1: The insulation kit found in this package should check out to the specifications as
listed on the package label.
Step 2: Inspect all flange surfaces and ensure that large pits or detects will not cause
leakage when the system is pressurized. Wipe sealing surfaces clean prior
to installing the gasket.
Step3: Align the flanges so that the bolt holes line up. Improper alignment could cause
damage to the sleeve during installation by pinching the thread form through
the plastic sleeve. When proper alignment has been achieved install all of the
sleeves onto all of the bolt holes. All sleeves should slide easily into both
mating flanges.
Step 4: Install one nut onto one end of each stud. Be sure to lubricate the threads and
nut surfaces with a suitable compound. From the opposite end of the stud nut
assembly, install one steel washer and one plastic washer (in that order).
Make sure all steel washers are butted against the nuts. Do not butt plastic
washer against nuts. Remove the sleeves from the flange and slide them over
the stud.
Step 5: Insert the stud, nut, steel washer and plastic washer assembly into the bolt
holes around the lower half of the bolt pattern and install a plastic washer,
steel washer and nut on the exposed end of the stud. Do not thread up studs
to the point where the gasket cannot be installed. Be sure to leave enough
space between the flanges to install the gasket Lubricate the appropriate
surfaces before final make-up.
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Step 6: Insert the gasket between the flanges and allow the gasket to rest on the sleeve
and stud assemblies. Check the condition of the O-ring/Teflon seals making
sure they are secure in each one's respective groove. Install the remaining
stud nut, plastic washer and steel washer assemblies into the upper half of
the bolt circle pattern.
Step 7: If a device was used to spread the flanges then remove it at this time. Thread all
nuts onto all the remaining studs and in doing so bring the flanges into
contact with the gasket. If misalignment exists between the flanges and
gasket, tighten the nuts in such a way as to minimize pinching or point loading
of the flange against the gasket.
Step 8: Make sure that a sufficient number of threads are within the nut of each stud
prior to torque-up. Torque the assembly to one-half of the torque limit
specified on the torque chart. Do this using an approved flange bolt tightening
sequence pattern. Repeat the sequence this time torqueing to the maximum
torque limit as specified.
Step 9: Test for shorts across the flange and then pressure test assembly. For safety
reasons it is best to initiate your test pressures much lower than those
normally encountered by your system. Work your pressure up to acceptable
limits by stepping pressure 10% per pressure increments.
14. INSPECTION OF BOLTED FLANGE JOINT ASSEMBLY
Stage 1: Flange Face Inspection- “Yellow Tag” (Use SAIC-L-2014, Section A)

A. Construction shall initiate the RFI to inspect flange for alignment and
gasket seat area prior to final installation on the pipe spool.
B. Damaged flanges shall be reported for disposition; replace or re-face.
C. Check internal cleanliness of piping and document if acceptable.
D. Record results in form SATR-A-2001, and install “Yellow Tag” for

acceptable flanges.
E. Provide a photocopy of the report in the Hydro Test Package where the
piping system belongs to for future reference during Pre- Test Punch listing
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Stage 2: Temporary Flange Alignment - “Green Tag”
A. Temporary flange alignment shall be provided by attaching and signed
“Green Tag” to identify temporary flange connection.
Stage 3: Gasket, Bolt/Nut& Alignment Verification- “White Tag” (Use SAIC-L-2014,
Section B, C, D, E)
A. Construction shall issue RFI prior to installation of permanent gaskets in
flanges with “Yellow Tags”. Construction shall prepare bolts, nuts and
gasket materials and ensure that flanges are aligned within the allowable
tolerances prior to issuance of RFI for Gasket Verification.
B. Inspect pipe internals for cleanliness.
C. Gasket type shall be suitable for the intended service and piping
classification (Rating, flange facing, material class and bolting). Gaskets
shall be in accordance to ASME B16.20.
a. Spiral Wound Gasket - Refer to SAES-L-109, Para. 12.3
b. Ring Joint Gasket: Size, Rating, Material type, serial number and
physical condition, 100% PMI for Alloy material - Refer to SAES-L-109,
Para. 12.2. A copy of the PMI Report for alloy gasket materials shall be
attached to the Hydro Test Package.
c. Sheet Gasket /Rubber Gasket - Refer to SAES-L-109, Para. 12.8
d. Pikotek Gasket shall not be used in refineries, gas plants and at

operating temperatures of 280°F and higher.
D. Verify bolts and nuts: (Use SAIC-L-2014, Section F)
a. Verify bolts and nuts to conform to ASME B16.5 or ASME B16.47: size
(diameter and length)
b. The material specification for stud bolts and nuts shall be in accordance
with Table 4 of SAES-L-109 for the applicable design temperature range
and service.
c. For alloy materials, 5% PMI may be conducted on random selection per
SAES-A-206, Para. 7.2.3.
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E. Verify flange alignment. Refer to SAIC-L-2014, Sections A, B, C & D,

whichever is applicable for acceptance criteria and tolerances.
Notes: 1. Final alignment is usually achieved when piping is provided

with permanent support. Alignment may be put on “HOLD”
until permanent supports are installed.
2. Spiral wound gasket should not be installed not until the
flange is ready to be tightened. Partially tightened
permanent gaskets may incur damage and will cause
rejection, subject to replacement.
F. Record inspection findings in form SATR-L-2001 and a copy of the
completed checklist shall be attached to the corresponding hydrostatic test
package.
G. Attach the “White Tag” to the flange joint signifying that the gasket was
verified. This is applicable if tightening will be performed in other time.
Note: All flanges previously tagged with “Green Tags” will be re-inspected
and re- tagged with “White Tags”.
H. To ensure that the permanent gasket rating is identified after installation,

color coded tag will be sign and attach to the flange as per the color coding
scheme shown in Attachment “J”.
Stage 4: Bolt Tightening - “Pink Tag” (Use SATR-L-2001)
A. Method and Procedure for bolt tightening shall be pre- approved prior to
tightening. i.e. Calibrated Torque Wrench Method, Bolt Tensioning Method,
etc.
B. Construction shall issue RFI prior to bolt tightening.
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C. Verify conformance of tightening activities to the approved Bolt Tightening

Method.
D. Document all inspections done and findings in SATR-L-2001 and attach a

copy to the corresponding Test Package where the piping system belongs
to for future reference during Pre- Test Punch listing.
E. Attach “Pink Tag” to identify completely tightened flange joints. Any

unauthorized removal of bolts or tags shall cause the joint to be rejected
and void.
Notes:
1. All tightened flanged joints shall not be disturbed or loosened without

the approval and witnessing of SECL QA/QC and or PID Inspector.
Construction Group shall notify QA/QC prior to modification of tightened
flange joints.
2. In the event that the tightened flange joint requires opening or loosening,
all associated inspection reports shall be marked null & void and the
tagging removed or cancelled.
3. Disciplinary action shall be given to personnel who perform
unauthorized alteration to completed flange joint connections.
15. ATTACHMENTS
ATTACHMENT - A Table - SAEP-351-01- Friction Factors for Different Lubricants
ATTACHMENT - B Table –SAEP-351-02- Torque Values for Low-Alloy Steel Bolting
ATTACHMENT - C Table-SAEP-351-03- Torque Values for Isolating Gasket

ATTACHMENT - D Figure SAEP-351-01-Stud Bolt Tightening Sequence
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Attachment “A”
Table - SAEP-351-01- Friction Factors for Different Lubricants
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Attachment “B”
Table –SAEP- 351-02- Torque Values for Low-Alloy Steel Bolting
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Attachment “C”
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Table-SAEP-351-03- Torque Values for Isolating Gasket(PIKOTEK)
on ASME B16.5 and ASME B16.47 series A & B, Class 150 through
Class 2500 Flanges
Attachment “D”
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Figure SAEP-351-01-Stud Bolt Tightening Sequence(4 to32 Bolts)
Attachment “E”
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Figure SAEP-351-02-Stud Bolt Numbering (36 to 68 Bolts)
Attachment “F”
Table-SAEP-351-04-Cross-Pattern Tightening Sequence (36 to 68 Bolts) per (ASME PCC-1)
Attachment “G”
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Torque Values for ASME B16.5 RF Flanges & Gasket
ANSI B16.5 Class 150RF ANSI B16.5 Class 300RF
Flange Size Torque /Round(ft-lb) Bolt Tighten Seq' Torque /Round(ft-lb) Bolt Tighten Seq'
1st 2nd Final No. Size 1st 2nd Final No. Size
1/2" 4 8 16 4-bolt 1/2" 4 8 16 4-bolt 1/2"
3/4" 6 12 23 4-bolt 1/2" 10 20 40 4-bolt 5/8"
1" 8 15 30 4-bolt 1/2" 10 20 40 4-bolt 5/8"
1-1/4" 12 24 45 4-bolt 1/2" 14 28 55 4-bolt 5/8"
1-1/2" 14 28 56 4-bolt 1/2" 23 46 90 4-bolt 3/4"
2" 25 50 113 4-bolt 5/8" 15 30 60 8-bolt 5/8"
2-1/2" 25 50 113 4-bolt 5/8" 23 46 90 8-bolt 3/4"
3" 33 66 130 4-bolt 5/8" 31 62 125 8-bolt 3/4"
3-1/2" 36 92 113 8-bolt 5/8" 35 70 140 8-bolt 3/4"
4" 25 50 113 8-bolt 5/8" 45 90 180 8-bolt 3/4"
6" 25 50 202 8-bolt 3/4" 45 90 190 12-bolt 3/4"
8" 50 100 236 8-bolt 3/4" 75 150 297 12-bolt 7/8"
10" 80 160 327 12-bolt 7/8" 78 156 310 16-bolt 1"
12" 80 160 327 12-bolt 7/8" 115 230 460 16-bolt 1-1/8"
14" 120 240 492 12-bolt 1" 100 200 400 20-bolt 1-1/8"
16" 120 240 492 16-bolt 1" 143 286 570 20-bolt 1-1/4"
18" 180 365 731 16-bolt 1-1/8" 161 322 645 24-bolt 1-1/4"
20" 180 365 731 20-bolt 1-1/8" 178 356 710 24-bolt 1-1/4"
24" 260 520 1036 20-bolt 1-1/8" 275 550 1100 24-bolt 1-1/2"
Attachment “H”: Color Code for Gasket
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(Modified Color code for Material Identification of ASME B16.20 as per Doc. VE-762885)
Classification Basic Material O.D Ring Color Color

Full Face
Non-Metallic None
(Sheet Gasket)
316SS-IR / CS-CR Green
321SS-IR / CS-CR Turquoise
322SS-IR / 316SS-CR Pink
347SS-IR / 316SS-CR Blue

Spiral Wound
6Moly (S31254)-IR / CS-CR Purple
Inconel 625-IR / CS-CR Gold
Inconel 825-IR / CS-CR White
Monel-IR /Monel-CR Orange
Soft Iron None
Ring Joint 5CR-1/2Mo Bule+Yellow
347 SS Blue
Attachment “I”: Tags for Flange, Gasket and Bolting Inspection Stage
Sn Stage Color Code
1 Flange Face Inspection Yellow
2 Temporary Alignment Green
3 Gasket Verification White
4 Final Bolt Torquing Pink
1. Flange Face Inspection 2. Temporary Alignment
Hold Tag
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SEG QC Inspector
SEG QC Inspector
ASSEMBLY PROCEDURE
Project Title:
(JNGLF)
Yellow Color Tag Green Color Tag
3. Gasket Verification 4. Final Bolt Torquing
SEG QC Inspector SEG QC Inspector
Aramco PID Inspector Aramco PID Inspector
White Color Tag Pink Color Tag
Remark: Tags are made by Laminated Plastic Sheet with Nylon Cable Tie
Attachment “J” : Tag for Gasket Rating Verification After Installation & Gasket Color Coding
for Stripes
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ASSEMBLY PROCEDURE
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(JNGLF)
Figure 1. Application of Color of Stripes
Attachment “K” : STAR-2001 Flange Joint Tightening Inspection Report
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ASSEMBLY PROCEDURE
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(JNGLF)
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ASSEMBLY PROCEDURE
Project Title:
(JNGLF)
29 of 35
ASSEMBLY PROCEDURE
Project Title:
(JNGLF)
30 of 35
ASSEMBLY PROCEDURE
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(JNGLF)
31 of 35
ASSEMBLY PROCEDURE
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(JNGLF)
Attachment “L” : SAIC-L-2014

SAUDI ARAMCO ID/PIEU - 30-Apr-2017 - REV. 2015.03.00 (Standards Cutoff - March 2015) Rev. 2015.03.00 31-Mar-15
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
INSPECTION OF BOLTED FLANGE JOINT ASSEMBLY SAIC-L-2014 30-Apr-17 PIPING-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
EQUIPMENT ID NUMBER(S) / LINE NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID. PLANT NO.
Flange Jts. #:
LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.
SCHEDULED INSPECTION DATE & TIME ACTUAL INSPECTION DATE & TIME QUANTITY INSP. MH's SPENT TRAVEL TIME
SAUDI ARAMCO USE ONLY
SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?
SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
General Inform ation:

Line Class: ________________Schedule___________________
A
Flanges Type__________________Rating(s)________________
Inspected Flange No. ___________________________________
Type & Pressure rating of the mating flanges conforms w ith the IFC
SAES-L-350,
A1 draw ings & line class for piping. (Refer to Attachment 1 for flange
Para. 12.2
rating and piping classification. )
SAES-L-109,
Flange dimensional requirement, flange facing and bore of w elding
A2 sections 7, 8 &
neck flanges shall comply w ith Attachment-2
9
The gasket contact areas of the flanges are not coated. (to ensure SAES-L-109,
A3
proper contact surface for sealing purpose .) Para.12.10
SAES-L-350
A4 The flange joints shall not be used to support the piping system.
section 12.5
Blind flanges and blanks that meet the ANSI/ASME code shall be SAES-L-350
A5
used for hydrotest. section 12.6
Gaskets shall be handled in accordance w ith manufacture's

SAES-L-350
A6 instruction. Gasket shall be replaced w henever opening of
section 12.7
flange assem bly.
The seal rings for the clamp connectors shall be provided from SAEP-351
A7
the clam p connector m anufacturer . section 6.1.6
Mechanical joints criticality assessment for the facility shall be SAEP-351,

A8
conducted to identify critical flanges. section. 4.1
Lubricant shall be applied to both the nut bearing surface and the SAEP-351,
A9
male threads. section. 6.4.1
Lubricants of proven coefficient of friction shall be chemically SAEP-351,

A10
compatible w ith the bolt/nuts/w asher materials. section. 6.4.2
Friction factors for some common lubricant are addressed in SAEP-351,

A11
Attachment-3 section. 6.4.2
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ASSEMBLY PROCEDURE
Project Title:
(JNGLF)
SAUDI ARAMCO ID/PIEU - 30-Apr-2017 - REV. 2015.03.00 (Standards Cutoff - March 2015) Rev. 2015.03.00 31-Mar-15
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
INSPECTION OF BOLTED FLANGE JOINT ASSEMBLY SAIC-L-2014 30-Apr-17 PIPING-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
The nuts shall be turned freely by hand before applying the SAEP-351,
A12
lubricant. section. 6.4.3
Tightening tools shall be checked for adequacy, performance and SAEP-351,

A13
calibration. The tools accuracy should not exceed ±5%. section. 8.2
B Flange alignm ent (pipe to pipe) tolerances

Rotation of flanges, measured as the offset betw een elevations of
SAES-L-350,
B1 bolt holes on opposite sides of a flange centerline, shall not exceed
Para. 9.4 c
± 2.4 mm
The tilt of a flange measured at the periphery across any diameter SAES-L-350,
B2
shall not exceed 1.6 mm from the square position. Para. 9.4 d
The joint should be aligned w ithout any external forces. SAEP-351

B3
Attachment-4 shall be follow ed. section 7.1
For clamp connector, the hubs shall be aligned to allow engagement

SAEP-351
B4 of the seal ring lips to hub sealing surfaces. Clamp connector
section 7.2
installation guideline line is addressed in Attachment-5 .
Alignm ent for flanges over 3-inch NPS connected to

C
m achinery/equipm ent is w ithin the follow ing tolerances:
SAES-L-350,
C1 Vertical bolt hole offset: ± 2.4 mm
Para. 9.5 a
SAES-L-350,
C2 Horizontal bolt hole offset: ± 2.4 mm
Para. 9.5 b
SAES-L-350,
C3 Rotational offset: ± 2.4 mm
Para. 9.5 c
Flange face tilt across diameter: 0.025mm per 25 mm (0.001 inch
per inch) of flange outside diameter up to a maximum of 0.672 mm SAES-L-350,
C4
(0.030 inch), and 0.254mm (0.010 inch) for all flanges w ith an Para. 9.5 d
outside diameter less than 10 inches.
SAES-L-350,
C5 Flange face separation: gasket thickness ± 1.6 mm
Para. 9.5 e
SAES-L-350,
C6 Combination of vertical, horizontal and rotational offset: ± 3.2 mm
Para. 9.5 f
Alignm ent of Flange Joints w ith spectacle plate is w ithin
D
the follow ing tolerances:
SAES-L-350,
D1 Vertical bolt hole offset: ± (2.4 mm + 30%) = ± 3.12mm
Para. 9.5 a
SAES-L-350,
D2 Horizontal bolt hole offset: ± (2.4 mm + 30%)= ± 3.12mm
Para. 9.5 b
SAES-L-350,
D3 Rotational offset: ± (2.4 mm + 30%)= ± 3.12mm
Para. 9.5 c
SAES-L-350,
D4 Combination of vertical, horizontal and rotational offset: ± 3.2 mm
Para. 9.5 f
E Gasket Verification
The gasket rating and dimension for piping system shall be verified
as required by ASME B16.20 and ASME B16.21. For other gaskets SAEP-351,
E1
that are not w ithin the scope of ASME, the rating and the section. 6.1.1
dimensions shall be according to the manufacturer’s specification.
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ASSEMBLY PROCEDURE
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Spiral w ound gasket:

ASME B16.20,
E12 The filler is flush w ith the metal w indings, not below the metal
Para. 3.2.2
w indings.
The ring gaskets have the follow ing identification:
a. manufacturer's name or identification trademark
b. gasket number prefixed by the letters R,RX,or BX
follow ed by the gasket material identification. ASME B16.20,
E13
c. The gasket is marked w ith an ASME B 16.20 designation. Para. 2.4
(NOTE: Refer to Attachment-6 (Table 2) for Identification
Markings )
(ASME B16.20, Para. 2.4)
The dimension of the ring-joint gasket indicated by letter designation
(R, RX, or BX) stamped on the ring gasket w as verified to conform
ASME B16.20,
E14 w ith the flange size and flange standard w here it w ill be used.
Para. 2.5
(NOTE: Verification is made w ith the details on IFC draw ing and
Tables 3 to 8 of ASME B16.20). { ASME B16.20, Para. 2.5}
F Bolting
Bolts, nuts and w ashers shall be visually checked for proper size,
SAEP-351,
F1 grade, dimension and for any physical damage to shanks or threads
section. 6.2.1
w hich w ould affect the bolt assembly or performance.
The bolts/nuts combinations for w hich the nuts w ill not turn freely SAEP-351,
F2
by hand shall be verified. section. 6.2.2
Bolts and nuts shall be replaced w hen reassembling existing SAEP-351,

F3
flanges. section. 6.2.3
Any abuse bolts and nuts shall be replaced even after the flange SAEP-351,
F4
assembly. section. 6.2.4
SAEP-351,
F5 Reconditioned nuts are not acceptable.
section. 6.2.5
SAES-L-109,
F6 The bolting material shall be in accordance to Attachment-7.
Para 13.2
Bolting material installed in aggressive external environment such as
offshore and underground piping are protected using one of the
follow ings:
a) Ceramic-fluoropolymer coating per 09-SAMSS-107,
SAES-L-109,
F7 b) Using Corrosion-resistant alloys
Para 13.3
c) Painting the exposed portions of the bolts and sealing the gap
betw een flange faces,
d) Encapsulating the bolted flange connection w ith heat shrinkable
tubing.
The nuts shall have full thread engagement after the flange SAEP-351,
F8
assembly. section. 6.2.5
G Bolt Tightening & Gasket Control Procedure
SAEP-351
G1 Hammering/flogging is not permitted during bolts losing or tightening.
section 8.1
SAEP-351
G2 Impact w rench shall not be used.
section 8.2
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ASSEMBLY PROCEDURE
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(JNGLF)
Manual torque w renches shall not be used for 1” bolts size and
SAEP-351
G3 larger. All manual torque w renches shall have calibrated torque
section 8.3
measurement.
Tightening sequence shall be according to ASME PCC-1, paragraph
SAEP-351
G4 11 w here applicable. Attachment-8 of the procedure includes
section 9.1
copy of ASME PCC-1, Table 4.
Tightening shall have a minimum of four passes (33%-66%-100%- SAEP-351

G5
100%) to achieve the required torque load. section 9.2
Flange load factor shall be considered w hen using blot tensioner SAEP-351
G6
less than 100%. section 9.3
Flange shielding shall be installed/reinstalled w hen required.
SAEP-351,
G7 NOTE: Flange shielding is normally used for personnel protection
section. 4.4
against possible liquid splash or high temperature during
NOTE: a) Satisfactory completion and approval of this Checklist allows the performance of Bolt
Tightening for the listed flange joints to proceed.
b) SATR-L-2001 shall be used to document bolt tightening.
REMARKS:
ATTACHMENTS:
Attachment 1 - SAES-L-105 Section 8 Line Class Designator System
Attachment 2 - SAES-L-109 Sections 7, 8 & 9 (Flange dimensional requirement, flange facing and bore of w elding neck flanges)
Attachment 3 - SAEP-351 Appendix B – Lubricant’s Coefficient of Friction
Attachment 4 - SAEP-351 Appendix C – Mechanical Joint Alignment Requirements
Attachment 5 - SAEP-351 Appendix D – Clamp Connector Installation Guideline
Attachment 6 - ASME B16.10 Table 2 (Ring Gasket Markings) & Table 19 (Color Coding and Abbreviations for Spiral-Wound Gasket
Materials)
Attachment 7 - SAES-L-109 Section 13.2 Bolting Materials
Attachment 8 - SAEP-351 Appendix E - Tightening Sequence
REFERENCES:
1. SAES-L-105, Piping Material Specifications, 07 July 2013
2. SAES-L-109, Selection of Flanges, Stud Bolts and Gaskets, 12 Jan. 2015
3. SAES-L-350, Construction of Plant Piping, (11 March 2014)
4. SAEP-351, Bolted Flange Joints Assembly, 01 December 2013
5. ASME B31.3, ASME Code for Pressure Piping_Process Piping, 2010 Edition
6. ASME B16.20, Metallic Gaskets for Pipe Flanges- Ring-Joint, Spiral-Wound, and Jacketed, ( 2012)
7. ASME B16.21, Nonmetallic Flat Gaskets for Pipe Flanges,(2011)
8. ASME B16.5, Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24, ( 2013)
9. ASME B16.47, Large Diameter Steel Flanges NPS 26 through NPS 60, ( 2011)
10. SAES-L-450, Construction of On Construction of On -Land and Near and Near -Shore Pipelines Shore Pipelines, 10 November 2012
Contractor / Third-Party Saudi Aramco

Construction Representative* PMT Representative
Work is Complete and Ready for Inspection: T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:
QC Inspector PID Representative

Performed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:
QC Supervisor Proponent and Others

Quality Record Approved: T&I Witnessed QC Record Reviewed Work Verified
Name, Organization,
Name, Sign and Date:
Initials and Date:
*Person Responsible for Completion of Quality Work / Test Y = YES N = NO F = FAILED
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BOLTED FLANGE JOINTS AND GASKET

UPGRADE FIRE WATER SYSTEM AT JUAYMAH NGL

ISSUED BY: SINOPEC ENGINEERING GROUP SAUDI CO.LTD.

Tong Guo Wang

Reviewed by : Wang jin Xin

Prepared by : Davud shabir

1.0 PURPOSE ------------------------------------------------------------------------------ 3

2.0 SCOPE ---------------------------------------------------------------------------------- 3

3.0 REFERENCES ------------------------------------------------------------------------ 3

4.0 RESPONSIBILITIES ----------------------------------------------------------------- 4

5.0 PRE-ASSEMBLY INSPECTION -------------------------------------------------- 4

7.0 TORQUING TOOLS ------------------------------------------------------------------ 5

8.0 GASKETS ------------------------------------------------------------------------------- 5

9.0 RECEIVING AREA & GASKET LOCATION ---------------------------------- 9

10.0 GASKET INSTALLATION --------------------------------------------------------- 10

11.0 STUD BOLT TIGHTENING PROCEDURE ------------------------------------ 11

12.0 STUD BOLT ADDITIONAL TIGHTENING PROCEDURE WHERE LEAKS

13.0 ADDITIONAL REQUIREMENTS FOR PIKOTEK GASKETS------------- 13

14.0 INSPECTION OF BOLTED FLANGE JOINT ASSEMBLY-----------------------14

5.8 Flange shielding shall be installed / reinstalled when required.

8.4 Spiral Wound Gaskets

8.8 Insulating Gaskets

4) The usage of PIKOTEK gaskets in reﬁneries shall be reviewed by the

9. RECEIVING AREA & GASKET LOCATION

10. GASKET INSTALLATION

10.2 Cleaning of All Flange Surfaces

10.3 Flange Conditions

10.4 Important for the Gasket

10.5 Lubrication of Bolts

11. STUD BOLT TIGHTENING PROCEDURE

12. STUD BOLT ADDITIONAL TIGHTENING PROCEDURE WHERE LEAKSOCCUR

13. ADDITIONAL REQUIREMENTS FOR PIKOTEK GASKETS

14. INSPECTION OF BOLTED FLANGE JOINT ASSEMBLY

Stage 1: Flange Face Inspection- “Yellow Tag” (Use SAIC-L-2014, Section A)

B. Damaged flanges shall be reported for disposition; replace or re-face.

C. Check internal cleanliness of piping and document if acceptable.

D. Record results in form SATR-A-2001, and install “Yellow Tag” for

a. Spiral Wound Gasket - Refer to SAES-L-109, Para. 12.3

c. Sheet Gasket /Rubber Gasket - Refer to SAES-L-109, Para. 12.8

d. Pikotek Gasket shall not be used in refineries, gas plants and at

D. Verify bolts and nuts: (Use SAIC-L-2014, Section F)

E. Verify flange alignment. Refer to SAIC-L-2014, Sections A, B, C & D,

Notes: 1. Final alignment is usually achieved when piping is provided

H. To ensure that the permanent gasket rating is identified after installation,

Stage 4: Bolt Tightening - “Pink Tag” (Use SATR-L-2001)

B. Construction shall issue RFI prior to bolt tightening.

C. Verify conformance of tightening activities to the approved Bolt Tightening

D. Document all inspections done and findings in SATR-L-2001 and attach a

E. Attach “Pink Tag” to identify completely tightened flange joints. Any

1. All tightened flanged joints shall not be disturbed or loosened without

ATTACHMENT - B Table –SAEP-351-02- Torque Values for Low-Alloy Steel Bolting

ATTACHMENT - C Table-SAEP-351-03- Torque Values for Isolating Gasket

Table - SAEP-351-01- Friction Factors for Different Lubricants

Table-SAEP-351-04-Cross-Pattern Tightening Sequence (36 to 68 Bolts) per (ASME PCC-1)

1/2" 4 8 16 4-bolt 1/2" 4 8 16 4-bolt 1/2"

3/4" 6 12 23 4-bolt 1/2" 10 20 40 4-bolt 5/8"

1" 8 15 30 4-bolt 1/2" 10 20 40 4-bolt 5/8"

1-1/4" 12 24 45 4-bolt 1/2" 14 28 55 4-bolt 5/8"

1-1/2" 14 28 56 4-bolt 1/2" 23 46 90 4-bolt 3/4"

2" 25 50 113 4-bolt 5/8" 15 30 60 8-bolt 5/8"

2-1/2" 25 50 113 4-bolt 5/8" 23 46 90 8-bolt 3/4"

3" 33 66 130 4-bolt 5/8" 31 62 125 8-bolt 3/4"