Total Flange Assurance (TFA)

Training for QC Technician &

Foreman
20 March 2012

2/28/2013

Topics covered
1) Purpose & goal TFA
2) Roles & Responsibilities
3) TFA Specification and Procedure
3) Bolt UT
- Why Bolt UT?
- Principles of Bolt UT
- Bolt UT machine
- Bolt UT step-by-step
- GMAX Software
Theory Test
4) Practical
Practical Training Session
Practical Test

Why TFA? Purpose & Goals

SHELL:

No leaks!
No fire, no injury, no shutdowns, no pollution

Contractor:

No rework!
More incentives
No injury
Less scolding
More time to do other things

TFA Procedure

Procedure

Work Process - Differences

Roles and Responsibilities:
Authorized

QC

Foreman

Technician

SEPL

TFA Inspector

TFA Organisation
ZONE 1
FITTER

ZONE 2 / 3 / 4

FITTER

FITTER

FITTER

TFA Authorized
FOREMAN

TFA Authorized
FOREMAN

FITTER

TFA Authorized
FOREMAN

SEAL

TFA
Executing Engineer

FITTER

TFA
QC TECHNICIAN

TFA
Executing Engineer

SEAL

Definition

TFA v5 Scope - Piping

Critical Service

Bolt Joints in following operating condition to be identified as a critical bolt Joints

Highly hazardous chemical service as defined in CFR 1910.119 (OSHA PSM rule),
Lethal Service as defined in the ASME Section VIII Divisions 1 and 2 Codes
Category M Fluid Service as defined in ASME B31.3.
Hydrogen Service above 316 deg. C (600 F), class 600, size 10 and greater
Hydrocarbon or Sour Service 316 deg. C (600 F), class 900, size 8 and greater
Hydrocarbon or Sour Service 316 deg. C (600 F), class 1500, size 6 and greater
Hydrocarbon or Sour Service 316 deg. C (600 F), class 2500, size 4 and greater
Joints subjected to cyclic temperature

Definition (cont.)
Standard Flanges

Flanges that follow B16.5 (flanges 24)

Flanges that follow B16.47 (flanges >24) Series A or B

Temperature at bolts <450C

Note: Temperature at bolts are typically >20% lower than process temperature unless flange
is insulated

Non-standard Flanges

Flanges that DO NOT conform to B16.5 or B16.47

Temperature at bolts > 450C

Selection of Bolt Tightening Method and QC Scope

Flange
Size

150#

300#

600#

900#

1500#

2500#

1
1

2
3
4
6
8
10
12

14
16
18
20
24
26

28
30
32
36
40
42
48
60

Selection of Bolt Tightening Method and QC Scope (cont.)

Zone

Rating

1.1

Dn < 20, 150#

Service

Torquing

Visual, Toque
Sampling

Water,
Compressed air ,
Steam,
Nitrogen

Flogging

Visual, Spanner
Sampling

Torquing

Visual, Toque
Sampling

Torquing

Bolt-UT, 3 samples

Dn <12, 300#

All Services

1.3

Dn < 6, 600#

All Services

2.1

Dn 20, 150#

2.2

10 < Dn < 36, 300#

4 < Dn < 26, 600#

All Services
All Services,
except critical

Dn <20, 900#
2.4

Bolt-UT, 6 samples
Bolt-UT, 3 samples
Torquing

Critical services

2.5

Dn <6, 1500#

Torquing

2.6

Dn <4, 2500#

All Services,
except critical
All Services,

2-wrench
Torquing

Critical services

Tensioning

All Services,
except critical

2-wrench
Torquing

Critical services

Tensioning

All Services,
except critical

2-wrench
Torquing

Critical services

Tensioning

All Services

Tensioning

3.2

3.3

Dn > 32, 300#

Dn > 24, 600#

Dn >18, 900#

4.1

Dn > 4, 1500#

4.2

Dn > 3, 2500#

Authorized
Foreman

Bolt-UT, 3 samples

6 < Dn < 20, 900#

3.1

All Services,
except critical

Sealed by

Torquing

Critical services
2

QC Scope

All Services

1.2

2.3

Method

Bolt-UT, 6 samples

Bolt-UT, 3 samples
QC
Technician

Bolt-UT, 6 samples

Flang
e Size

150#

300#

600#

900#

1500#

2500#

TFA Zone 1
Manual Tightening

2
3
4
6
8
10

12
14
16
18
20
24

26
28
30
32

36
40
42
48
60

2 Fitters

2 Fitters

2 Fitters

2 Fitters

TFA Foremen

Seal

Seal

2 Fitters

2 Fitters

2 Fitters

TFA Foremen

Seal

Seal

Seal

2 Fitters

2 Fitters

TFA Foremen

Seal

Seal

Seal

Seal

Flang
e Size

150#

300#

600#

900#

1500#

2500#

TFA Zone 2

Tightening with Driven Wrenches

2
3
4
6
8
10

12
14
16
18
20
24

26
28
30
32

36
40
42
48
60

2 Fitters

2 Fitters

2 Fitters
Seal

TFA Foremen

QC Technician

Seal

Seal

Bolt-UT
database

Flang
e Size

150#

300#

600#

900#

1500#

2500#

TFA Zone 3

Tightening with Driven Wrenches

1
2
3
4
6
8
10

12
14
16
18
20
24

26
28
30
32

36
40
42
48
60

2 Fitters

2 Fitters

2 Fitters
Seal

TFA Foremen

QC Technician

Seal

Seal

Bolt-UT
database

Flang
e Size

150#

300#

600#

900#

1500#

2500#

TFA Zone 4

Bolt Tensioning

2
3
4
6
8
10

12
14
16
18
20
24

26
28
30
32

36
40
42
48
60

Bolt-tensioning Crew

Bolt-UT
database
TFA Foremen

Special Services Provider

QC Technician

Seal

F.L.A.N.G.E.
Every flange needs to be visually checked for:

Faces

No damage, no scratches, clean

Lubricant

Sufficient Molykote 1000 on threads and nut faces

Alignment Parallelism and OD alignment to spec

Nuts & Bolts Not corroded, cleaned, min. 2 threads protruding
Gasket Correct size, rating, material, not damaged
Enough Bolt Load Using QC method to determine adequate
bolt tightness

Tightening Method
Flogging
Only for Zone 1: Utilities Air, Water, N2, Steam
Torquing
For flanges in Zone 1 and Zone 2
Double Torquing (2 - Torque wrenches concurrently)
For flanges in Zone 3: Non-critical
Tensioning
For flanges in Zone 3: Critical and Zone 4 : All Service

QC Method
Visual, spanner (By Authorized FOREMAN)
Visually check for F.L.A.N.G.E.
Use spanner/hammer to test bolt tightness
Only for Zone 1: Utilities Air, Water, N2, Steam
Torque wrench (By Authorized FOREMAN)
Visually check for F.L.A.N.G.E.
Use torque wrench (set at 90% of torque value) to check tightness
Only for Zone 1 All service (except Utilities)
Bolt UT, 3 samples (By QC Techinician)
Visually check for F.L.A.N.G.E.
Reference reading : 3 bolts; Final Reading : 3 bolts for QC check
For Zone 2 Non-Critical services
Bolt UT, 6 Samples (By QC Techinician)
Visually check for F.L.A.N.G.E.
Reference reading : 6 bolts; Final Reading : 6 bolts for QC check
For Zone 2 Critical services; Zone 3 & 4 : All Service

TFA Tagging &1-seal Approach

#1

ZONE

#2/3/4

TFA
1-seal approach

TFA
1-seal approach

1 Seal
Authorized TFA Foreman

Authorized TFA Foreman

-Execution
-Responsible for the joint

execution under
instruction of QC Technician

1 Seal
QC Technician
has proper tech to check for proper
execution

SEPL TFA Inspector

SEPL TFA Inspector

sign-off EQCC to accept

sign-off EQCC to accept

TFA Roles and Responsibilities

Fitter

(contractor)

Works hand-in-hand with TFA Authorized Foreman

Safely Break the Flange Joint

Clean up the flange and prepare for inspection
Prepare Nuts and Bolts, Lubricate adequately
Align Flange and hand tighten nuts
Prepare Bolts for Reference Reading
Execute Flange tightening as instructed by Authorized Foreman

TFA Roles and Responsibilities

Authorised TFA Foreman (AF)

(contractor)

Works hand-in-hand with QC Technician & Fitter

Supervise safe breaking of Flange Joint

Inspect Flange Faces (report defects to QCT)
Prepare Correct Gasket
Check Lubrication of Nuts and Bolts
Ensure flange face checked
QC Check and Apply SEAL for Zone 1 Flanges - QC passed
Execute Flange tightening as per given spec Zone 2, 3 and 4
Assist QCT for QC check of flanges for Zone 2 , 3 and 4

TFA Roles and Responsibilities

Authorised QC Technician (QCT)

(contractor)

Works hand-in-hand with TFA Foremen

1:3
QCT vs. TFA Crew
ratio

Ensure flange face checked

Brief TFA Foremen on Tightening scope and QC scope
Ensure F.L.A.N.G.E. checked
Take Bolt UT Reference Reading
Re-set torque value on the 3rd pass based on 4 bolts
Measure final stress value reading
Seal flange (Zone 2, 3 and 4) QC passed

TFA Roles and Responsibilities

SEPL TFA inspector

Project Engineer / Maintenance Engineer /

Executing Engineer / Work Pack Leader

Maintain Log of Off-spec flanges

Report Off-spec flanges to TA Steering Team /
Maintenance Manager / Construction Manager
Organize execution of Discovery works
Sign-off EQCCs following Equipment handover
protocol

Work Process : Zone 1

1.
2.
3.
4.
5.
6.
7.
8.
9.

Check flange faces

Lubricate nuts and bolts
Check correct gasket install
Install nuts and bolts hand tight
(max 15% of studs to hold flange)
Tightening 1st pass
Tightening 2nd pass
Tightening 3rd pass
Tightening Final pass
QC Seal flange

AF
AF
AF
AF
AF
AF
AF
AF
AF

Work Process : Zone 2 & Zone 3

1.
2.
3.
4.

Check flange faces

Lubricate nuts and bolts
Check correct gasket install
Install nuts and bolts hand tight
(max 15% of studs to hold flange)
5. Prepare bolt ends for Bolt UT sandpaper/ filing: 3 / 6 bolts
6. QC Reference measurement (3 / 6 Bolts)
7. Tightening 1st pass
8. Tightening 2nd pass
9. Tightening 3rd pass
10. Tightening Final pass
11. QC Check applied load @ 3 / 6 bolts
12. QC Seal flange

AF
AF
AF
AF
AF
QCT
AF
AF
AF
AF
QCT
QCT

Work Process : Zone 4

1.
2.
3.
4.

Check flange faces

Lubricate nuts and bolts
Check correct gasket install
Install nuts and bolts hand tight
(max 15% of studs to hold flange)
5. Prepare bolt ends for Bolt UT sandpaper/ filing: 6 bolts
6. QC Reference measurement (6 Bolts)
7. Tightening for all Odd Studs
8. Tightening for all EVEN Studs
9. QC Check applied load @ 6 bolts
10. QC Seal flange

AF
AF
AF
AF
AF
QCT
AF
AF
QCT
QCT

TFA Boltstress Ultrasonics

What is Ultrasonics?

Using ultrasound (sound above the range of human hearing) to

measure distances

Human hearing: 20Hz 20,000Hz (20kHz)

Ultrasonics: 1,000,000 - 5,000,000Hz (5Mhz)

Ultrasound

Sound

Infrasound
20Hz

20,000Hz

TFA Boltstress Ultrasonics

What is Bolt Ultrasonics?

Using ultrasonics to measure the length of bolts in a very accurate

way

Accuracy of measurement: 0.001mm

Can measure a maximum distance of 1.5m

TFA Boltstress Ultrasonics

Why do we use Bolt Ultrasonics?

By taking a reference value of the bolt length before the bolt is

tightened

And taking a final value of the bolt length after the bolt is
tightened

The two readings can be compared to determine elongation of

the bolt

Bolt before tightening

Reference measurement
Bolt after tightening
Final measurement

elongation

TFA Boltstress Ultrasonics

Why do we use Bolt Ultrasonics?

A bolt is like a spring when you tighten the bolt, it stretches

Like a spring how much the bolt stretches or elongates is

directly proportional to how much load is in the bolt

So, if we know the elongation, we will know the bolt load

TFA Boltstress Ultrasonics

What is the relationship between elongation and bolt load?

Bolt Load = Spring constant x Elongation

F = k x L
Spring constant is dependent on material of bolt

TFA Boltstress Ultrasonics

What is the relationship between bolt load and bolt stress?

Bolt Stress =

Bolt Load
Area of Bolt
F
A

Area of bolt is dependent on diameter of bolt

TFA Boltstress Ultrasonics

So, how do we use Bolt UT?

Measure reference (before tightening)

Gives us elongation

Measure final (after tightening)

Calculate Bolt Load

Input Bolt material

Calculate Bolt Stress

Input Bolt Effective Area

Calculated by Bolt UT computer

Compare Bolt Stress with Required Bolt Stress

Is it within 10%, +15% of required bolt load?
If yes  pass
If no  retighten

TFA Boltstress Ultrasonics

Why do we use bolt stress instead of bolt load?

Bolt Stress

vs

Bolt Load

(MPa / psi)

(N)

Bolt Stress is normalised to bolt

size, so stress is the same
across different bolt sizes

Bolt Load varies with bolt size

 larger bolt = larger load

Failure point of bolts are

dependent on material
governed by stress

Unable to directly correlate

failure point with load 
need to convert to stress first

TFA Boltstress Ultrasonics

Plastic
Range

Bolt Failure

Yield Point

Ultimate Tensile Strength

Tensile Point

Stress

Elastic
Range

Strain

TFA Procedure

100% Yield Stress

Bolt material

B7, L7, B16

psi
(lbf/in2)
105,000

MPa
(N/mm2)
724

B7M, L7M

80,000

551

B8 Class 1

29,000

200

B8 Class 2

80,000

551

TFA Procedure

Required Bolt Stress (MPa)

Bolt material

Standard
Flanges

B7, L7, B16

360

B7M, L7M

275

B8 Class 2

275

Based on 50% Yield Stress

Non-standard
Flanges
Depends on
calculation

Why Bolt UT?

Bolt Tightening Methods
Uncontrolled

Semi-controlled

Fully Controlled

Flogging

Torquing

Bolt UT

Double Torquing
Tensioning
Accuracy

50-80%

20-40%

10%

Method of Control

None

Torque

Actual Load

Weakness

Highly inaccurate,
no way to
determining actual
load or torque

Conversion of torque into

actual bolt load is
affected friction, torquing
method and lack of
proper lubrication eg.
E9901 26, E99

None direct
measurement of bolt
load/stress ensures that
bolt load is exactly correct
as required.

Can we do better?
What was not done well so far?

The tightening of Flanges were rejected due to INSUFFICIENT LUBRICATION

MAKE SURE !

Stud/Nuts THREADS are in good condition

Lubricator MOLYKOTE 1000
Flange Surface is lubricated properly
Stud/Nuts THREAD is lubricated
Nuts FACE is lubricated
February 28, 2013

37

Thank you
Questions?

February 28, 2013

38