Welding Control Procedure For PipingRevision History Revision Revision date Page Scope of Revision 00 07-MAY-2012 ISSUED FOR REVIEW Doc No: SA-JER-TFAAA-PSCL-506504_rev.00 Title: GASKET INSTALLATION AND BOLT TORQUING PROCEDURE FOR RTR UNDERGROUND PIPING Page 2 of 6 TABLE OF CONTENTS 1. Purpose 4 2. References 4 Responsibility Gasket Storage Requirements 4 Gasket and Bolt Identification 5 Gasket and Bolt installation 5 Bolt Tightening 5 Additional Bolt Tightening Procedure(Possible Leakage occurred during pressure test) 6 Torquing 6 Torquing Tools 6 Attachment 6 4 Doc No: SA-JER-TFAAA-PSCL-506504_rev.00 Title: GASKET INSTALLATION AND BOLT TORQUING PROCEDURE FOR RTR UNDERGROUND PIPING Page 3 of 6 1. Purpose The purpose of this method statement is to control the correct installation and verification of permanent gasket and bolts for RTR piping. 2. References 2.1. Company References JERES L 351 Bolted Flange Joints Assembly JERES L 610 Non Metallic Piping JERES S 020 Industrial Drainage and Sewers JERES S 060 Water Systems JERES S 070 Installation Of Utility Piping Systems JERES L 105 Piping Material Specifications JERES L 1029 RTR (Fiberglass) Sewer Pipe and Fittings JERES L 1034 RTR (Fiberglass) Pressure Pipe and Fittings JERITP L 01200 Pipe and Fittings Fiberglass 2.2. Industry Codes and Standards ASME B31.3 Process Piping ASTM D4024 Standard Specification for Machine made Fiber Glass Flange 3. Responsibility 3.1 The warehousemen / Storekeeper, together with PSCL Piping QC inspector shall check all gaskets and bolts arriving at PSCL store for damage and for quantities against delivered documents. 3.2 The piping supervisor / Foreman shall check all gaskets and bolts for correct code, type, size and rating. 3.3 PSCL QC inspector shall ensure that item 3.2 above is carried out and shall signify his acceptance with appropriate marking on the flange, 3.4 It is the responsibility of PSCL piping QC inspector to verify all gasket and bolts installation on daily basis to ensure all relevant requirements are followed. 4. Gasket Storage Requirements 4.1 All gaskets shall be stored on racks indoor according to their type, size, rating and color code. Gasket should be placed on wooden sleepers or suitable supports at Flat Position and shall be protected from dust, rain, direct sunlight and heat. 4.2 Permanent gasket and temporary gasket shall be stored separately. Material personnel shall provide quarantine area for all damage gaskets. 5. Gasket and Bolt Identification 5.1 Verify correct marking on gasket and bolts (if applicable manufacture name, Type, size, rating). 5.2 RTR flanges when used shall be of flat face. All the Gasket shall be as per the Manufacturer recommendation (refer ATTACHMENT_1). 5.3 Bolts and nuts as per company procedure & approved IFC drawing. All the bolts used for underground Piping shall be Ceramic Coated. 6. Gasket and Bolt installation Doc No: SA-JER-TFAAA-PSCL-506504_rev.00 Title: GASKET INSTALLATION AND BOLT TORQUING PROCEDURE FOR RTR UNDERGROUND PIPING Page 4 of 6 6.1 All the flange assembly and gasket / bolt installation shall be as per the Manufacture recommendation (refer ATTACHMENT_1). 6.2 Permanent gasket shall be installed at line flanges, only authorized personnel shall be allowed to install gasket and bolts. 6.3 Damaged, broken or cut in to half and used gasket shall be removed from site to ensure that nobody will use them. 6.4 If any coated bolts shall be verify by PSCL piping inspector prior to use. 6.5 Flange pressure rating requirements and maximum torque requirements shall be in accordance with JERES-L-610 and Manufacturer recommendation (refer ATTACHMENT_1). Bolt Tightening 7.1 All the Bolts, nuts and washers shall be visually checked for proper size, grade and dimension conformance as per the IFC Drawing. 7.2 Install all studs, nuts & washers hand tighten, 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. 7.3 Numbering of each stud according to its position in the flange as per the Manufacture recommendation (refer ATTACHMENT_1). 7.4 Care should be taken to ensure that identification numbers are readily visible at all time. 7.5 Torque wrench shall be used to obtain the final torque value. Hammering shall not be allowed during Bolt Tightening. 7.6 After the Hand tighten, Stud bolts shall be tightened in stages, to obtain final torque values as per the Manufacturer recommendation (refer ATTACHMENT_1). The first stage shall be not exceeding 30% of the final torque value. The final torque values shall be within +/-5% of required torque as per the Manufacture recommendation (refer ATTACHMENT_1). Doc No: SA-JER-TFAAA-PSCL-506504_rev.00 Title: GASKET INSTALLATION AND BOLT TORQUING PROCEDURE FOR RTR UNDERGROUND PIPING Page 5 of 6 7.7 Bolt tightening shall be inspected by PSCL QC Inspector and the same shall be witnessed by Company Inspector and reports shall be signed off. 8. Additional Bolt Tightening Procedure (Possible Leakage occurred during pressure test) 8.1 Depressurize the piping system and re-torque stud bolts to maximum torque value as per the Manufacture recommendation (refer ATTACHEMTN_1) 8.2 If leak does not stop after re-torquing has been performed, disassemble the flange joint and inspect as follows: a) Inspect stud bolts and nuts for defects or damage to threads or improper cleaning of threads. b) Inspect flange faces for damage, misalignment. c) Inspect gasket for damage or defects. 8.3 After all defective and damaged items have been repaired or replaced, re-assemble the flange joint using a new gasket and tighten the bolts using the maximum torque values. 8.4 If after tightening a bolt or nut is slackened off for any reason, the bolt, nut and washer shall be discarded and not to be used again. 9. Torquing 9.1 Torque values vary according to flange rating, bolt size and type of gasket, as per manufacturers recommendation (refer ATTACHMENT_1). 9.2 The torque values are attached. 10. Torquing Tools 10.1 Selection of the proper tool depends on the stud bolt size, physical location of the flange joint, and criticality of flange. 10.2 Tools instruction shall be followed for the operation, limitation and maintenance of all torque wrenches used to perform flange bolt tightening. 11. Attachment ATTACHMENT_1-Assembly Inspections for Bondstrand fiberglass flanges. Doc No: SA-JER-TFAAA-PSCL-506504_rev.00 Title: GASKET INSTALLATION AND BOLT TORQUING PROCEDURE FOR RTR UNDERGROUND PIPING Page 6 of 6 Assembly Instructions for Bondstrand berglass anges Scope These instructions present Amerons recommendations for the proper use of Bondstrand berglass anges. The mounting of anges on the pipe is addressed by the assembly instructions for the particular joint type and adhesive used. Bondstrand FiberglassBondstrand anges are Glassber Reinforced Epoxy (GRE) lament-wound epoxy Flanges pipe anges in diameters 25 through 1000 mm (1-40 inch) designed to be used in combination with Bondstrand pipes. Flanges are used in Bondstrand pipe systems to connect appendages and equipment, or to make connection with other lines of similar or other material. It also gives the ability to divide a pipeline into several (prefabricated) sections making it easier to install. Three type of anges are available. Depending on the application and pressure one of the below described anges can be used. Bondstrand Flange Hubbed type ange Types Applicable for low pressure up to a maximum of 12 bar, and only in combination with at face counter anges. Never use this type of ange against raised face anges or in combination with wafer type valves. Hubbed type anges are available in sizes 2-16 with Quick-Lock adhesive bonded joints. Photo 1 - Hubbed ange Bondstrand Flange Heavy Duty (HD) type ange Types Ctnd The Heavy Duty type anges are used for pressures up to 50 bar. HD type anges are available with a Quick-Lock (sizes 1 - 16 inch) or Taper/Taper (sizes 2 - 40 inch) adhesive bonded joint. Heavy duty tupe anges can be used when connecting to raised faced metal anges and wafer type valves. Stub-end (lap joint) type ange Stub-end type anges are suitable for high pressures upto 100 bar. Stub end anges can be supplied with an o-ring groove or a at face in combination with suitable gasket. Stub-end type anges are available with a Quick-Lock (sizes 1 - 16 inch) or Taper/Taper (sizes 2 - 40 inch) adhesive bonded joint. Stub-end type anges can be used when connecting to raised faced metal ange and wafer type valves. Stub-end (lap joint) type anges consist of 2 parts; A Bondstrand GRE stub with a steel backing ring ange. Photo 2 - HD ange Photo 3 - Stub-end ange Always use a at faced (stub end) ange against an o-ring sealed stub end ange, when using stub-ends as ange pairs. Tooling Check the presence and quality of joint material (bolt, nut, washer, gasket) and tooling (Photo 1). The tooling and joint material listed below are, as a minimum, required to make a anged joint. A torque wrench and a ring spanner are required for proper assembly of Bondstrand berglass anges. Level Torque wrench Ring spanner Flange square Winches Band clamp Steel cross Photo 4 - Required tooling Ameron 2006. FP 196 B 10/06 supersedes FP 196 A 01/93. Page 2 of 8. Printed in The Netherlands. Gaskets For hubbed anges use a full-face gasket of a reinforced elastomer; For heavy duty anges use a full-face or raised face gasket of a reinforced elastomer or compressed ber; For o-ring sealed stub end anges use an o-ring. For at faced stub end anges use a raised face gasket of a reinforced elastomer or compressed ber; Gasket material must be suitable for the service pressure, temperature and uids in the system. Gaskets should be 3 mm thick. The hardness should be 60-75 Shore A; When connecting to rubber lined valves, use either at faced stub end anges or insert a spacer ring between valve and ange. See table 1 for pressure rating of the different gasket types. Table 1: Pressure rating of gaskets Size Reinforced Compressed Steel Rein-O-Ring Range Elastomer Fiber forced (stub end) Rubber 1 - 12 Inch 16 bar 20 bar 50 bar 100 bar 14 - 24 Inch 16 bar 16 bar 40 bar 75 bar 26 - 40 Inch 16 bar 16 bar 25 bar 50 bar Alignment Flange joints shall be installed aligned and stress free. Never pull anges together by tightening the bolts. See table below for maximum misalignment allowance. Table 2: Maximum misalignment allowance Flange A B Size Range mm mm 1 - 16 Inch 1 2 18 - 40 Inch 2 4 Leakage problems due to misalignment could be solved by using o-ring type gaskets e.g. Kroll & Ziller. Bolt Length Note that Bondstrand anges are thicker than metal anges and require washers. This should be taken into account when calculating the bolt length. For ange thickness see the appropriate product datasheet, dimension data. Connecting to otherWhen Bondstrand pipe is connected to metal pipe systems, the interface should be Pipe Systems anchored to prevent movement or loads being transmitted to the Bondstrand pipe system. Prepare the cut pipe end by shaving theAssembly of appropriate spigot. Apply adhesive to the pipe spigot and ange socket. Refer to the Bondstrand Quick-Lock assembly instructions for detailed instruction on joint preparation and assembly. Quick-Lock Flanges Without delay, slowly push the Quick-Assembly of Lock ange onto the Quick-Lock spigotQuick-Lock Flangesin a straight forward motion. Do not rotate or jiggle the ange. Ctnd Photo 6 - Push ange onto spigot Photo 7 - Check bolt holes alignment Photo 8 - Final seating Photo 9 - Check alignment of ange face Photo 10 - Remove excessive adhesive After joint assembly, check the alignment of the bolt holes. Carefully turn the ange to position the bolt holes. Final seating of the spigot can be accomplished by carefully tapping on a wooden block placed on the ange face. The spigot end should be seated against the bell stop of the socket. For sizes 6 inch a steel cross (see photo 15) can be used to get nal seating. Check the alignment of the ange face using a ange square. Once again check the alignment of the bolt holes. Remove excessive adhesive. Ameron 2006. FP 196 B 10/06 supersedes FP 196 A 01/93. Page 4 of 8. Printed in The Netherlands. Photo 11 - Cure adhesive joint Support the ange from underneath while curing to maintain proper alignment. Cure the adhesive joint using an Ameron approved heating blanket. Check the position of the thermostat. It should be facing inwards (6 oclock position) and must be covered by the blanket. For the smaller sizes (1-3) special inner blankets are available. Assembly ofTaper/Taper Flanges Photo 12 - Apply adhesive Photo 13 - Push ange onto spigot Photo 14 - Check boltholes alignment Prepare the cut pipe end by shaving the appropriate spigot. Apply adhesive to the pipe spigot and ange socket. Refer to the Bondstrand Taper/Taper assembly instructions for detailed instruction on joint preparation and assembly. Without delay, slowly push the Taper/Taper ange onto the Taper/ Taper spigot in a straight forward motion. Do not rotate or jiggle the ange. After joint assembly, check the alignment of the bolt holes. Carefully turn the ange to position the bolt holes. Pull the joint together using the winches. Check the insertion depth. Photo 15 - Check insertion depth Check the alignment of the ange face Assembly of using a ange square, or by using aTaper/Taper Flangeslevel and a measuring tape.Ctnd Photo 16 - Check alignment of ange face Photo 17 - Check alignment of bolt holes Photo 18 - Cure the adhesive joint Once again check the alignment of the bolt holes. Remove excessive adhesive. Cure the adhesive joint using an Ameron approved heating blanket. Check the position of the thermostat. It should be facing inwards (6 oclock position) and must be covered by the blanket. For the smaller sizes (2-3) special inner blankets are available. Do not remove the winches while curing the joint. Place the gasket between the two ange faces.Flange Jointing Photo 19 - Place gasket Insert the bolts and nger-tighten all nuts. Bolt threads must be clean and lubricated to attain proper torque. Use lubricated washers under both nuts and bolt heads to protect ange back face. Photo 20 - Insert bolts Ameron 2006. FP 196 B 10/06 supersedes FP 196 A 01/93. Page 6 of 8. Printed in The Netherlands. Tighten all nuts following the sequences shown under tightening sequence. Do not exceed the torque increments given in Recommended Bolt Torques. After all bolts have been tightened to the recommended torque, re-check the torque on each bolt in the same sequence, since previously tightened bolts may have relaxed. Caution: Excess torque can damage the ange and prevent sealing. Note! Always use washers on the back-facing of glassber hubbed and heavy duty anges. For stub end ange assembly with metal ange rings washers are optional. Photo 21 - Tighten bolts Tightening Sequence Recommended Bolt Torques Table 3: Hubbed Flanges Flange Size 2 - 4 Inch 6 - 12 Inch 14 - 16 Inch Table 4: Heavy Duty Flanges Flange Size 1 - 1,5 Inch 2 - 4 Inch 6 - 8 Inch 10 - 14 Inch 16 Inch 18 - 20 Inch 22 - 40 Inch Table 5: Stub end Flanges Flange Size 1 - 4 Inch 6 - 12 Inch 12 - 16 Inch 18 - 24 Inch 26 - 40 Inch Initial Torque Torque Full Pressure Seal 10 Nm 30 Nm 20 Nm 40 Nm 30 Nm 70 Nm Initial Torque Torque Full Pressure Seal 10 Nm 30 Nm 20 Nm 60 Nm 30 Nm 80 Nm 50 Nm 150 Nm 100 Nm 250 Nm 200 Nm 400 Nm 250 Nm 500 Nm Initial Torque Torque Full Pressure Seal 20 Nm 60 Nm 50 Nm 100 Nm 100 Nm 200 Nm 200 Nm 400 Nm 300 Nm 600 Nm Troubleshooting If the assembled ange joint leaks, loosen and remove all bolts, nuts, washers and gasket. Check for alignment of assembly. Rebuild to correct alignment as required. Check the gasket for damage. If damaged, discard and replace it with a new, undamaged gasket. Check anges for seal ring damage. In particular, check the condition of the inner seal rings. Flanges with damaged inner seal rings must be removed and new, undamaged anges installed. If leaks occur as a result of deciencies in non-berglass components of the piping system, consult the manufacturer of the defective components for recommended corrective procedures. Clean and re-lubricate old threads and washers before rejoining. Repeat the joining procedure outlined above. After corrective action has been taken, retest the joint. Safety Wear suitable protective clothing, gloves and eye protection at all times. Photo 22 - Safety gear Important Notice This literature and the information and recommendations it contains are based on data reasonably believed to be reliable. However, such factors as variations in the environment, application or installation, changes in operating procedures or extrapolation of data may cause different results. Ameron makes no representation or warranty, express or implied, including warranties of merchantability or tness for purpose, as to the accuracy, adequacy or completeness of the recommendations and information contained herein. Ameron assumes no liability whatsoever in connection with this literature or the information or recommendations it contains. Written comments regarding this document are invited. U.S.A. Ameron International Corporation 1004 Ameron Road P.O. Box 878 Burkburnett, Texas 76364 U.S.A. Phone: +1 940 569 1471 Fax: +1 940 569 2764 Group HeadquartersAmeron International Corporation - Fiberglass-Composite Pipe Division 9720 Cypresswood Drive, Suite 325 - Houston, Texas 77070 - U.S.A. Phone: +1 832 912 8282 - Fax: +1 832 912 9393 E-mail: marcom@ameronfpd.com Website: http://www.ameron-fpg.com U.S.A. EuropeCentron International, Inc. Ameron B.V. P.O. Box 490 Fiberglass-Composite Pipe 600 FM 1195 South P.O. Box 6 Mineral Wells - Texas 76068 4190 CA Geldermalsen U.S.A. The Netherlands Phone: +1 940 325 1341 Phone: +31 345 587 587 Fax: +1 940 325 9681 Fax: +31 345 587 561 E-mail: info@centrongre.com E-mail: info@ameron-fpg.nl Asia Ameron (Pte) Ltd. No. 7A, Tuas Avenue 3 Jurong Singapore 639407 Phone: +65 6861 6118 Fax: +65 6862 1302/6861 7834 E-mail: info@ameron.com.sg