boxing up of high pressure flange joints

8/18/2019 Boxing Up of High Pressure Flange Joints

1/20

BOXING UP OF HIGH

PRESSURE FLANGE

JOINTS


2/20

WHAT IS FLANGE JOINT ?

FLANGE JOINT IS A FLEXIBLE JOINT USED TO JOIN PIPES OR VALVES OR VESSELS WITH IN A

FLUID HANDLING SYSTEM IN ORDER TO HAVEACCESSIBILITY & FLEXIBILITY. A FLANGE JOINT

MUST FULFILL THE FOLLOWING CRITERIA :

IT IS TO BE LEAK FREE.

IT MUST BE ABLE TO WITHSTAND THESYSTEM PRESSURE & TEMPERATURE.


3/20

WHAT IS FLANGE JOINT ?

IT IS A FLEXIBLE JOINT WHICH CAN BEOPENED & BOXED UP AS & WHEN

REQUIRED.

FLANGE JOINT IS A STATIC SEAL IN THEFLUID HANDLING SYSTEM.


4/20

CLASSIFICATION OF JOINTS

FLANGE JOINT IS CLASSIFIED BASED ON THE SYSTEMPRESSURE. THE MOST COMMON TERMINOLOGY USEDIS THE POUND REFERENCE WHICH WE NORMALLY

CALL AS CLASS.

DIMENSIONS OF THE CLASS RATING IS FURTHERDEPENDENT ON DESIGN STANDARDS I.E. ANSI OR API.

FLANGE JOINTS ARE ASLO CLASSIFIED BASED ON THE

TYPE OF GASKET USED I.E. RTJ AND NON-RTJ.


5/20

DESIGN STANDARDS

ANSI STANDARD (ANSI B16.5)

CLASS 1!"# $!!"# %!!"# !!"# 1!!" &

'!!".

API STANDARD (API 6A, 6B & 6BX)

MAINLY MORE OR ABOVE CLASS '!!!".

THE DIFFERENCE BETWEEN API & ANSI FLANGES IS THE

MATERIAL FROM WHICH THEY ARE FABRCATED AND THEHIGHER WORKING PRESSURE AT WHICH API FLANGES MAY BEOPERATED. THESE ARE NOT INTERCHANGEABLE.

WE HAVE ONLY ANSI FLANGE & THEREFORE OUR DISCUSSIONWILL BE LIMITED TO ANSI FLANGES ONLY.


6/20

SEALING PRINCIPLE

NON-RTJ JOINT RTJ JOINT

IN CASE OF NON-RTJ

JOINT SEALING IS

ESTABLISHED DUE TOSURFACE CONTACT

BETWEEN GASKET

FACE & FLANGE FACE.

FOR RTJ JOINT SEALING

IS ESTABLISHED DUE

TO LINE CONTACTBETWEEN GASKET

(RING) FACE & FLANGE

FACE.


7/20

INTEGRITY OF THE JOINT

INTEGRITY OF THE FLANGE JOINT ISDEPENDENT ON THE FOLLOWING :

CLEANLINESS OF THE FLANGE SURFACE.

NO DAMAGE ON THE FLANGE FACES. NO DAMAGE ON RING GASKET FACES.

EQUAL TIGHTENING ON EACH STUDS ( NUTS.

STAGE WISE APPLICATION OF TORQUE.

COMPATIBLE METALLURGY OF FLANGES (

STUDS ( NUTS.


8/20

SHAPE OF RTJ GASKETS

OVAL TYPE (ANSI B 16.20) THIS TYPE IS THE ORIGINAL JOINT DESIGN.

CONTACTS FLANE FACE AT THE CURVED SURFACEAND PROVIDES A HIGH RELIABILITY SEAL.

OCTAGONAL TYPE (ANSI B 16.20) MORE ACURATE IN DIMENSIONS AND SURFACE

FINISH THAN OVAL SHAPE TYPE BECAUSE IT

CONSISTS OF STRAIGHT SURFACES ONLY.

MORE TORQUE LOAD IS REQUIRED TO FLOW THE

GASKET MATERIAL INTO IMPERFECTIONS ON THEFLANGE FACINGS.

OTHER TYPES )BX & RX* ARE FOR API DESIGNFLANGES AND NOT IN USE IN OUR REFINERY.


9/20

IDENTIFICATION OF RINGS

MATERIALS IDENTIFICATION

SOFT IRON D

LOW CARBON STEEL S

Cr. STEEL F5TYPE 30 S 30

TYPE 3!" S 3!"

TYPE 3# S 3#

TYPE !0 S !0


10/20

SIZE OF RING GASKETS

RINGS ARE IDENTIFIED WITH UNIQUENO. ACCORDING TO FLANGE ( PIPE SI+E& PRESSURE RATING ALONG WITHMETALLURGY OF THE SAME.

FOR EXAMPLE “R51 D” INDICATES RINGFOR , X '!! " CARBON STEEL FLANGE.

FOR EXAMPLE “R51 S16” INDICATES RINGFOR , X '!! " SS $1% FLANGE.


11/20

HARDNESS

$ATERIAL FLANGE

($IN BHN)

RING

($A% BHN)SOFT IRON !!0 &0

LOW CS !0 !'0TYPE 30 L 3!" L !0 !'0

!Cr TO 5Cr !50 !30

TYPE 30 3!" 3# !"0 !0


12/20

BOLTING MATERIALS

FLANGE STUDS NUTS

A!05 A!&3 GR. B# A!& GR. 'H

A!05 (NACE) A!&3 GR. B#$ A!& GR. 'H$

A!' GR. F5 * F& *

F!! * F''

A!&3 GR. B!" A!& GR.

A!' GR. F 30 * 3!"L

* 3'! * 3'!H

A!&3 GR. B# A!& GR. 'H

A 5!5 GR. "D A 30# GR. B GAL+. A 30# GR. B GAL+.

A!' GR. F 30H *

3'! (H')

A 53 GR. ""0 CL. A A 53 GR. ""0 CL. A

A!' GR. F 3'!H

(HOT CATALYST)

A 53 GR. ""0 CL. A A 53 GR. ""0 CL. A


13/20

TIGHTENING DEVICE

NON!RT" "OINT

HAMMERING.

RT" "OINT HAMMERING.

HYDRAULIC TORQUE WRENCH.)ELECTRICALLY ( PNEUMATICALLYOPERATED*

BOLT TENSIONER.


14/20

CORRECT TORQUE

APPLYING CORRECT TORQUE IS ONE OF THE MOSTIMPORTANT FACTOR TO ENSURE LEAK PROOF &

SAFE JOINT BECAUSE OF THE FOLLOWING

REASONS: OVER TORQUE MAY DAMGE THE GASKET FACE ( FLANGE

GROOVE FACE.

UNDER TORQUE MAY NOT BE SUFFICIENT TO HOLDSYSTEM PRESSURE AT REQUIRED TEMPERATURE.

THEREFORE CORRECT TORQUE APPLIED WITH

CORRECT PROCEDURE CAN ONLY ENSURE LEAK

PROOF JOINT.


15/20

CARE OF RING GASKETS

STORE RING GASKET ON FLAT SURFACE WITH

CARDBOARD OR HEAVY PAPERS TO SEPARATE

EACH GASKET FOR SURFACE PROTECTION

DO NOT HANG RING GASKETS ON PEGS OR NAILS.

DO NOT STORE GASKETS ON THEIR EDGES. NEVER SHIP RING GASKETS LOOSE OR IN SACKS.

PROTECT THE GASKETS DURING SHIPMENT BY

WRAPPING EACH IN PAPER# FOIL OR IN BOXES IN

ORDER TO PREVENT DAMAGE TO THE GASKETSURFACE.


16/20

PRECAUTIONS FOR RTJ

JOINTS ENSURE PROPER CLEARANCE.

CHECK FOR HYDRO-CARBON PRESENCE.

OPEN CROSS - BOLTS ( NUTS.

RTJ RING TO BE TAKEN OUT CAREFULLY. ENSURE PROPER MATCHING OF THE JOINING

SURFACE.

ENSURE NO LAPPING COMPOUND IS LEFT OUT.

ENSURE SAFETY )PROPER HANDLING* OF RTJRING WHILE BOXING UP.


17/20

USE SOFT MATERIALS )ROPE(CLOTH* FOR

TEMPORARY HANGING OF RINGS.

ENSURE SURFACE CLEANLINESS OF GROOVES &

RINGS BY USING DIESAL(KEROSENE.

BEFORE BOXING UP RE-CHECK THAT RING IS

NOT DAMAGED.

TIGHTENING OF CROSS BOLTS ( NUTS SLOWLY.

ENSURE UNIFORM GAPS ALL AROUND THE

FLANGE FACES.

USE PROPER TORQUE AS DIRECTED BY UNIT

ENGINEER.

PRECAUTIONS FOR RTJ

JOINTS


18/20

APPLY TORUE VALUE IN STAGES.

MAINTAIN RECORDS AS PER INSTRUCTION OF

UNIT ENGINEER FOR FUTURE REFERENCE.

ENSURE THAT TWO THREADS ARE PROJECTEDON EITHER SIDE OF THE NUTS.

ENSURE PROPER SI+E & TYPE OF STUDS &NUTS HAVE BEEN USED.

ENSURE PROPER METALLURGY OF RING#STUDS & NUTS W.R.T. FLANGE.

PRECAUTIONS FOR RTJ

JOINTS


19/20

EXPERIENCE SHARING

DA#AGE RING.

#ETALLURGY #IX.

S$ORT BOLTING. GREASING O% RINGS.

UNDER SIE GAS'ET (NON!

RT"). UNDERSIE BOLTS.


20/20

T HA

N K Y O U

boxing up of high pressure flange joints

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