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SAUDI ARAMCO ID/PID - 24-Mar-2016 - REV. 2015.09.01 (Standards Cutoff - September 6, 2015) Rev. 2015.09.

01 6-Sep-15
SATR NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO TEST REPORT
Flange Joint Tightening Inspection Report SATR-L-2001 24-Mar-16 MECH
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

EQUIPMENT ID NUMBER(S) or LINE NUMBER FLANGE JOINT NUMBER/S Test Pack No. SYSTEM ID. PLANT NO.

LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.

SCHEDULED TEST DATE & TIME ACTUAL TEST 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
TEST PROCEDURE ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-TEST DATE
No.
A General Requirements

The flange joint assemblers shall be qualified by independent SAEP-351,


A1
accreditation organization. section 5.1

After successfully completing the required training courses, a record


shall be maintained to demonstrate the technician’s competency.
(Skills training course shall be recent for the date of perfoming
flange bolt and torqueing activities. See note)
SAEP-351,
A2 (Note: Hydrocarbon release incident data for oil and gas industry
section 5.2
indicate that poor bolted flange assembly is a major cause of leaks. A
review of historical causes confirms that the skills and practices used
have not assured leak-free joint. Therefore, any technician working
on a flange assembly shall be trained and assessed as component
to perform the task.)

Tightening tools shall be checked for adequacy, performance and SAEP-351,


A3
calibration. The tools accuracy should not exceed ±5%. section 8.2

B Bolt Tightening & Torqueing

Table of Torque values tabled according to flange rating, bolt size, SAEP-351,
B1
type of gasket, and the lubricant’s friction factor. section 10

Tightening shall have a minimum of four passes (33%-66%-100%-


SAEP-351,
B2 100%) to achieve the required torque load. (Records of torque values
section 9.2
of every flange joint are tabled for reference.)

Flange load factor shall be considered when using bolt tensioner less
SAEP-351,
B3 than 100%. (Records of torque values of every flange joint are tabled
section 9.3
for reference.)

Saudi Aramco: Company General Use


SAUDI ARAMCO ID/PID - 24-Mar-2016 - REV. 2015.09.01 (Standards Cutoff - September 6, 2015) Rev. 2015.09.01 6-Sep-15
SATR NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO TEST REPORT
Flange Joint Tightening Inspection Report SATR-L-2001 24-Mar-16 MECH
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
TEST PROCEDURE ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-TEST DATE
No.

Bolt Tensioning Method when approved. (i.e.: HYDRATIGHT - 50% Tensioning Method)
C
NOTE: Items listed below shall be verified against the project approved bolt tensioning procedure for conformance.
HYDRATIGHT
C1 Mark bolts in 2 Sets, Set 'A' & Set 'B', alternatively. Procedure or
Equivalent

HYDRATIGHT
C2 Tensioners are fitted to every other bolt of Set 'A'. Procedure or
Equivalent

HYDRATIGHT
Pressurize the tensioners to pre-determined "Pressure A" per the
C3 Procedure or
approved procedure. (This is repeated 2 more times.) Equivalent

Transfer tensioners to Set 'B' bolts and pressurize to pre-determined HYDRATIGHT


C4 "Pressure B" and tighten nuts. This is repeated 2 more times. Procedure or
(NOTE: Pressure B is lower in value than Pressure 'A') Equivalent

After tensioning, Break Loose Pressure (BLP) is verified to be greater


than or equal to Pressure B by the following steps:
a) Fit tensioner to one of the tensioned bolts in Set 'A'.
HYDRATIGHT
b) Pressurize slowly until the nut is loosened using a Tommy Bar
C5 Procedure or
and socket. Equivalent
c) Once the nut moves, stop pressurizing and record the
achieved pressure. This is the Break Loose Pressure.
(NOTE: If BLP < Pressure B, Tensioning is a Fail. )

Bolt Tensioning Method (i.e.: HYDRATIGHT-100% Tensioning Method)


D
NOTE: Items listed below shall be verified against the project approved bolt tensioning procedure for conformance.
HYDRATIGHT
D1 Tensioners are fitted to ALL bolts. Procedure or
Equivalent

HYDRATIGHT
Pressurize the tensioners to pre-determined "Pressure A" per the
D2 Procedure or
approved procedure. (This is repeated 2 more times.) Equivalent

After tensioning, Break Loose Pressure (BLP) is verified to be greater


than or equal to Pressure A by the following steps:
a) Fit tensioner to one of the tensioned bolts in Set 'A'.
HYDRATIGHT
b) Pressurize slowly until the nut is loosened using a Tommy Bar
D3 Procedure or
and socket. Equivalent
c) Once the nut moves, stop pressurizing and record the
achieved pressure. This is the Break Loose Pressure.
(NOTE: If BLP < Pressure A, Tensioning is a Fail. )

E Findings are recorded in Bolt Tightening Report Form in Attachment 1

REFERENCE DOCUMENTS:
1. SAES-L-350 - Construction of Plant Piping, (11 March 2014)
2. SAEP-351, Bolted Flange Joints Assembly, (01 December 2013)
3. ASME B31.3, ASME Code for Pressure Piping_Process Piping (2010 Edition)
4. Schedule Q, Contractor's Quality Requirements
5. Recommended Tensioning Procedure-By HYDRATIGHT
6. SAES-L-450 - Construction of On-Land & Near Shore Pipelines, (10 November 2012)
7. ASME PCC-1 Guidelines for Pressure Boundary Bolted Flange Joint Assembly (2013 Edition)

Contractor / Third-Party Saudi Aramco


Technician Performing Test* PMT Representative
Name, Title, Department, Test Performed Successfully and Results are Acceptable: T&I Witnessed QC Record Reviewed Work Verified
Company, Initials and Name, Initials and Date:
Date:
QC Inspector PID Representative
Witnessed Test 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:
Saudi Aramco: Company General Use
SAUDI ARAMCO ID/PID - 24-Mar-2016 - REV. 2015.09.01 (Standards Cutoff - September 6, 2015) Rev. 2015.09.01 6-Sep-15
SATR NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO TEST REPORT
Flange Joint Tightening Inspection Report SATR-L-2001 24-Mar-16 MECH
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
TEST PROCEDURE ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-TEST DATE
No. Quality Record Approved:
Name, Organization,
Name, Sign and Date:
Initials and Date:

*Person Responsible for Implementation of Test and Analysis of Results Y = YES N = NO F = FAILED

Saudi Aramco: Company General Use


SAUDI ARAMCO ID/PID - 24-Mar-2016 - REV. 2015.09.01 (Standards Cutoff - September 6, 2015) Rev. 2015.09.01 6-Sep-15
SATR NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO TEST REPORT
Flange Joint Assembly & Gasket Installation Report SATR-L-2001 24-Mar-16 MEC
EQUIPMENT ID NUMBER(S) or LINE NUMBER FLANGE JOINT NUMBER/S Test Pack No. SYSTEM ID. PLANT NO.

LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.

SCHEDULED TEST DATE & TIME ACTUAL TEST DATE & TIME QUANTITY INSP. MH's SPENT
SAUDI ARAMCO
SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER W

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

Attachment 2 - FLANGE JOINT INSPECTION & TIGHTENING REPORT


Pre-Inspection of Flange Joint Assembly Completed and Checklist, SAIC-L-2014, signed: YES Q
NO
Torque Method used :

Lubricant applied ____________ Friction Factor______________ Torque Corr Factor____________

Bolt Tensioning Method used: 50% Tensioning / 100% Tensioning. Break Loose Pressure verified:

Applied
Flange Details Gasket Details Bolting Details
Torque (Note: Add columns s
stages of
Sr.
No
1St Stage
Winding
@33% of
ID-No Size/Type Rating Rating -filler Material Length Size
Inner/Oute Reqd
Mtl
r Ring Torque
Material
1

10

11

12

RESULT:

REMARKS:

Contractor / Third-Party Saudi Aramco


Technician Performing Test* PMT Representative
Name, Title, Department, Test Performed Successfully and Results are Acceptable: T&I Witnessed QC Record Reviewed
Company, Initials and Name, Initials and Date:
Date:
QC Inspector PID Representative
Witnessed Test Work / Rework May Proceed T&I Witnessed QC Record Reviewed
Name, Initials and Date: Name, Initials and Date:

QC Supervisor Proponent and Others


Saudi Aramco: Company General Use
Quality Record Approved: T&I Witnessed QC Record Reviewed
Name, Organization,
Name, Sign and Date:
Initials and Date:

*Person Responsible for Implementation of Test and Analysis of Results

Saudi Aramco: Company General Use


QR NUMBER

MECH
PLANT NO.

/ PMCC / MCC NO.

TRAVEL TIME
SAUDI ARAMCO USE ONLY
WORK PERMIT REQUIRED?

QR # ______

YES
NO

Applied Torque / Tension Values

Torque (Note: Add columns should contractor offered more Tension


stages of torqueing) Pressure
4th
2nd 3rd Stage
Final w/ in
Stage Stage Re-
±5% of Tension
@66% of @100% torque
Reqd. Pressure
Reqd of Reqd @100%
Torque
Torque Torque of Reqd
Torque

Saudi Aramco

Work Verified

Work Verified

Saudi Aramco: Company General Use


Work Verified

Y = YES N = NO F = FAILED

Saudi Aramco: Company General Use

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