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History
Revisio Revision
Page
n
date
07-MAY00
2012

Doc No: SA-JERTFAAA-PSCL506504_rev.00

Scope of Revision
ISSUED FOR
REVIEW

Title: GASKET
INSTALLATION AND BOLT
TORQUING PROCEDURE
FOR RTR UNDERGROUND

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-

Title: GASKET

TFAAA-PSCL506504_rev.00

INSTALLATION AND BOLT


TORQUING PROCEDURE
FOR RTR UNDERGROUND

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
Docshall
No: SA-JERTitle:
GASKET
Piping
be Ceramic
Coated.
TFAAA-PSCLINSTALLATION AND BOLT
Page 4
506504_rev.00
TORQUING PROCEDURE
6. Gasket
and Bolt installation
of 6
FOR RTR UNDERGROUND

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-

Title: GASKET

TFAAA-PSCL506504_rev.00

INSTALLATION AND BOLT


TORQUING PROCEDURE
FOR RTR UNDERGROUND

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-

Title: GASKET

TFAAA-PSCL506504_rev.00

INSTALLATION AND BOLT


TORQUING PROCEDURE
FOR RTR UNDERGROUND

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.

bed 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

uty 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.

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

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

Alignment

Reinfor Compre Steel


Oced
ssed
Rein- Ring
Flange joints shall be installed
aligned
and Fiber
stress free.
Never
pull anges together by tightening the bolts.
Range
Elasto
forced
(stub
See table below
allowance.
mer for maximum misalignment
end)
Rubber
Table
Maximum misalignment allowance 100
1 2:
- 12
16 bar 20 bar 50 bar
Inch
Flange A B Size Range mm mm 1 bar
14 - 24
75
- 16 Inch 1162 bar
18 - 40
4 bar
16 Inch
bar 240
Inch
bar

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 the

Assembly 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

Wi
thout delay, slowly push the Quick-

Assembly of

Quick-Lock Flanges
Lock ange onto the Quick-Lock
spigot

Ctnd

Photo 6 - Push ange onto spigot


Photo 7 - Check bolt holes alignment

Photo 8 - Final seating

Photo 9 - Check alignment of ange face

in a straigh
forward
motion. D
not rotate o
jiggle
th
ange.

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 14 - Check boltholes alignment

Photo 13 - Push ange onto spigot

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

C
heck the alignment of the ange face

Assembly of
using a ange square, or by
using a

Taper/Taper Flanges

level and a measuring


tape.
Photo 17 - Check alignment of bolt holes
Photo 18 - Cure the adhesive joint

Ctnd

Photo 16 - Check alignment of ange face

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

Initial
Torque

Torque
Full
Pressure
Seal
10 Nm
30 Nm
20 Nm
40 Nm
30 Nm
70 Nm
Initial
Torque
Torque
Full
Pressure
Recommended Bolt Torques
Seal
Table 3: Hubbed Flanges
10 Nm
30 Nm
NmInch 60 Nm
Flange Size 2 - 4 Inch 6 - 12 Inch 1420
- 16
80 Nm
Table 4: Heavy Duty Flanges 30 Nm
50 Nm
150 Nm
Flange Size 1 - 1,5 Inch 2 - 4 Inch 6 - 8 Inch 10 - 14 Inch 16 Inch 18 - 20 Inch 22 - 40 Inch
100
250 Nm
Table 5: Stub end Flanges
Nm
Flange Size 1 - 4 Inch 6 - 12 Inch 12 - 16 Inch 18200
- 24 Inch 26 - 40 Inch
400 Nm
Nm
250
500 Nm
Nm
Initial
Torque
Torque
Full
Pressure
Seal
20 Nm
60 Nm
50 Nm
100 Nm
100
200 Nm
Nm
200
400 Nm
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 Headquarters
Ameron 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.ameronfpg.com

Centron International, Inc.


Ameron B.V.
P.O. Box 490 FiberglassComposite 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