HIAP SENG ENGINEERING LIMITED

• LEAK FREE WORK PLAN

FOR 2019 CRU EVENT (Rev. 1)

• SRC CRU REVAMP PROJECT

• VENUE: Area F or POA Meeting Room
Ground Level, SRC CRU Revamp Project for
LFWP Training.

25 October 2018 1
Training Objectives
Objectives
➢ SRC’s goal is to achieve a Leak-Free Operation necessary to
achieve an Incident and Injury Free (IIF) work place.

➢ To elaborate the importance of flange tightening to ensure “Leak-

Free” flanges during start-up.

➢ To ensure participants are familiar with the requirements for flange

tightening of piping and equipment.

➢ To explain the scope for leak-free, torque card system, gasket

specifications, tightening pattern and QC check on flanges.

25 October 2018 2
Flange leaks can be very serious

“The cost of preventing a leak is far less

than the cost of fixing a leak”
Flange leaks can result in Plant Shutdowns

Fire: May 1990

HCU-2
Fire: Apr 2003 Fire: May 2003
Past leak incidents
• Packing leak on high pressure valves during HCU-2 start-up.

• Hydrocarbon gas leak from ring joint gasket on 303-C vent line flange
during HCU-1 start-up.

• Hydrocarbon leak from plug of orifice flange tapping 351-B inlet pass
during HCU-1 start-up.

• There are cases of incorrect gaskets used or work quality issues during
every TARs.

• There is a need to improve tightening process for flanges to ensure no leak

after start-up.

• The approach is to carry out thorough checks on the flange surface and
gasket and Manual Torque instead of flogging

25 October, 2018 5
Manual Torquing Vs Manual tightening (flogging)

Stud Loads Set by PSC During 1/01 #4CU S/D on Edwards Bypass Valves E-1585B Floating He ad Final Torque , Clad Gaske ts, Ne w Studs, No Washe r
100,000 60,000
Average Bolt Stress 29,500
90,000 Stud Load Target Targeted Bolt Stress 33,500

80,000 50,000

70,000
Apply torquing for a more evenly
distributed loading on the flanges
Stud Load in PSI

60,000 40,000

50,000

Stud Load in PSI

40,000
30,000

30,000

20,000
20,000

10,000

0
10,000
1

8
4

4
s

s
s

s
s

s
as

as

as

as

as

as
as

as

as

as

as

as

as
as

as

as

as

as
,P

,P

,P

,P

P
,P

,P

,P

,P

,P

,P

,P
0,

0,

0,

0,

0,

0,

0,
A

0B

0B
B

16

16

16

16

16

16

16
00

00

00

00

00

00

00

00

00

10

10
1

1
11

11

11

11

11

11

11

11

11

F-

F-

F-

F-

F-

F-

F-

-1

-1
F-

F-

F-

F-

F-

F-

F-

F-

F-

F
ve

ve
0
al

al
V

1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
41
43
45
47
49
51
53
55
57
59
61
63
l

l
tro

tro
on

on

Stud Number
C

Flogging Manual Torquing

25 October 2018 6
Gasket Application
Spiral Wound

Gasket Types and their respective colour coding are

based on the applicable Pipe Classes.

25 October 2018 7
8 QC INSPECTION

9.9 Gasket Application colour Code

2. Gasket Winding, Filler, Ring and Rating Colour Code

25 October 2018 8
CVX Torque Table for Piping & Equipment

25 October 2018 9
CVX Torque Table for Special Piping

25 October 2018 10
Torque Cards
➢ Hiap Seng to prepare and issue Torque Cards to Contractors for
placement at site.

➢ To use Hydraulic Torquing if torque value ≥ 1000 ft-lb OR bolt size ≥

46mm.

➢ All equipment manholes that require Hydraulic Torquing, will still use the
Equipment Torque Card but Torquing is to be carried out by a
specialized contractor.

➢ The same is applicable for Control Valve flanges and Relief Valves
flanges.

➢ HS Fitters/Foreman and QC Supervisor to sign on the Torque Cards after

completing the tightening.

➢ Tag Torque Card and install tightening inspection wire with seal.

25 October 2018 11
 Piping Torque Card

Piping Torque Card

Blind Location #:
Date : Prepared by :

Torque Load (100%) : ft-lb Torque Load (80%): ft-lb

➢ HS to prepare and issue Torque Cards for placement at site by HS

QC/Supervisors.

➢ After completion of tightening and accepted by HS QC Inspector , torque

cards to be provided for piping and equipment flanges. HS/JES/SRC QC to
make sure torque cards have tag and install inspection wire with seal for all
flanges after completing the tightening.

25 October 2018 12
Equipment Torque Card

Equipment Torque Card

Equipment # : W/O # :
Date : Prepared by :

Torque Load (100%) : ft-lb Torque Load (80%): ft-lb

Description :

Hydraulic Torquing : Y / N Performed by :

The followings to be checked by fitter / QC Supervisor

Gasket checked

Flange surface checked

Bolt and nut checked

Flange alignment checked

Fitter name :

QC Supervisor Name :
Tightening Sequence
* Leave 1" of empty space
1st Pass torque all studs to 80% in Star Pattern
2nd Pass torque all studs to 100% in Circular Pattern
Return the torque card to Maintenance when done
3rd Pass torque all studs to 100% in Circular Pattern

25 October 2018 13
 Heat Exchanger Torque Card
EXCHANGER TAG, available from the Dublin Forms Control Center

Plant:
Exchanger # W/O#
Bundle Weight: Date:
Hydrotest Pressures:
Shell Side: Tube Side:

Gasket Type: Gasket Type: Gasket Type: Gasket Type:

Tube Side / Shell Side

# of Studs: # of Studs: # of Studs:

# of Studs:

Stud Diameter: Stud Diameter: Stud Diameter: Stud Diameter:

Stud Length: Stud Length: Stud Length:

Stud Length:
Final Stud Load Final Stud Load Final Stud Load Final Stud Load
(fp or PSI?): (fp or PSI?): (fp or PSI?): (fp or PSI?):
Gasket Surface Inspected By: Gasket Surface Inspected By: Gasket Surface Inspected By: Gasket Surface Inspected By:

Gasket Installed By: Gasket Installed By: Gasket Installed By: Gasket Installed By:

NEW Studs Lubed Both Ends By: NEW Studs Lubed Both Ends By: NEW Studs Lubed Both Ends By: NEW Studs Lubed Both Ends By:

Hardened Washers Installed By: Hardened Washers Installed By: Hardened Washers Installed By:
Hardened Washers Needed? Y / N
Installed By:
Initial Torquing Done By: Initial Torquing Done By: Initial Torquing Done By: Initial Torquing Done By:

Hot Torque 200-300F Done By: Hot Torque 200-300F Done By: Hot Torque 200-300F Done By:
Floating head stud loads are set high
to compensate for relaxation.
Channel Cover Channel to Shell Floating Head Shell Cover

Return this tag to When Done!

MFG-7255 (8/98)

➢ NO change to current practice for using manual torquing for all heat exchanger
joints using Kamprofile gaskets.
➢ To use hardened washer on both sides of the stud bolts for heat exchangers only
25 October 2018 14
Torque Cards
➢ In Summary, contractor fitters and QC
supervisor are to check and sign on all
the torque cards.

➢ SRC QC to collect all torque cards and

check for completeness before signing
off the Progress Chart.

➢ All torque cards to be passed to SRC

Engineers for safekeeping.

25 October 2018 15
 Tightening Sequence
Piping and Equipment
1st pass – Torque all studs to 80% in Star pattern
2nd pass – Torque all studs to 100% in circular pattern
3rd pass - Torque all studs to 100% in circular pattern (2nd round)

25 October 2018 16
 Tightening Sequence
Heat Exchangers
1st pass – Torque 4 studs to 100% torque value
2nd pass – Torque all studs to 100% in circular pattern
3rd pass – Torque all studs to 100% in circular pattern (2nd round)
NO Need to apply Star pattern for heat exchangers

25 October 2018 17
Hot Torquing
For Heat exchangers only
➢ Hot torquing is required for selected heat exchangers, it is
NOT required for Piping and Equipment manholes.

➢ For Heat Exchangers with operating temperature >120°C,

it is recommended to carry out the hot torquing between
120°C to 205°C.

➢ Close coordination with OPN is required during plant

start-up to maximize hot torquing before 205°C, without
causing any delay in start-up.

➢ For Heat Exchangers with operating temperature <120°C,

hot torquing is not required.

25 October 2018 18
Installation of System and Equipment Blinds

6209
62-05 -C 03

System blind (Green Tag). Equipment Blind (Green Tag).

For both Blinding and De-blinding, For Blinding ONLY, Spiral Wound gasket to be
the use of gasket will depend on used. For De-blinding, the use of gasket will
the applicable line class/spec. depend on the applicable line class/spec.

25 October 2018 19
Quality Check on Flanges
➢ HS Fitter/Foreman to check on
the following four pointers for
every flange joint:-
1. Gasket flange surface
2. Condition of the new gasket
3. Condition of the stud bolts including
finger test
4. Any mis-alignment or warping of flange

➢ HS fitter / QC supervisor to
report to SRC personnel if the
following site conditions are
found during opening of flanges
so that action can be taken at an
early stage:
➢ Damage on gasket surface
➢ Warped flange
➢ Misalignment of flanges

25 October 2018 20
Flange Checklist
➢ To use the “Flange Checklist” where Fitters and HS QC need to sign
after completing the tightening.

➢ Hiap Seng to prepare the “flange checklist” and pass it to Contractors

before work commences. Contractors are to keep the list inside the
permit plastic folder at site.

➢ Contractors to sign off the flange checklist upon completion of

Blinding / De-blinding.

➢ SRC/JES QC/Piping Engineer, Opn Supervisor to check the

completeness of the flange checklist before Mechanical handover.

➢ Physical knocking on the nuts using inspection hammer will then be

carried out on-site to check if the requirements are met.

25 October 2018 21
Stud replacement
➢ DO NOT recommend mandatory replacement of stud bolts, only to replace
if it fails the ‘finger test’, regardless of stud bolt diameter. Replacement is
based on the condition of the stud bolts.

➢ To report to the HS Supervisor on bolts that fail ‘finger test’ in advance so

that they can prepare the new stud bolts before boxing up.

➢ Studs preferably to have two threads exposed past the nut, flushed with
nuts is acceptable.

25 October 2018 22
QC Inspection

QC Records and Reports:

• After completion of Inspection and accepted by HS QC Inspector , the QC
records/Reports shall be signed by all parties and records to be maintained.

25 October 2018 23
Safe Use of Torque Wrench (Before Job)

➢ Select best suited capacity torque

wrench. As a recommendation,
use a torque wrench in the middle
(50% of the overall capacity of
the tool).

➢ Properly inspect your torque

wrench before using. Make sure it
is not damaged or defected in
any way. Ratchet mechanism
may slip or break if dirty.

➢ Pay special attention to the jaws

on the sockets when inspecting
torque wrenches. Ensure they are
still sharp, otherwise slippage
may occur.

25 October 2018 24
Safe Use of Torque Wrench (Before Job)

➢ Do not use sockets or fasteners

showing wear or cracks.

Varying length of sockets

➢ Select the correct socket such
that it fits fully onto the nut.

➢ As most torque wrenches are

length specific, always grasp the
torque wrench in the center of the
Poor fitting (left) and good fitting (right)
handle. If two hands need to be
used, place one hand on top of
the other.

25 October 2018 25
Safe Use of Torque Wrench (During Job)

➢ Safety glasses or goggles PPE

should be worn at all times when
using any hand tool.

➢ Ensure socket is fitted properly

onto the nut before torqueing.

➢ Always PULL, DO NOT PUSH, to

apply torque. Adjust your stance to
prevent a fall.

➢ Apply torque in a slow, methodical

manner and avoid sudden, “jerking”
movements.

➢ Stop pulling wrench IMMEDIATELY

when target torque is reached

25 October 2018 26
Example For Tag Torque Card

25 October 2018 27