TFA Course for Foremen & QC Techn
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Transcript of TFA Course for Foremen & QC Techn
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Total Flange Assurance (TFA)Trainin for C Technician &
2/28/2013
Foreman
20 March 2012
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1) Purpose & goal TFA2) Roles & Responsibilities3) TFA Specification and Procedure3) Bolt UT - Why Bolt UT?
- Principles of Bolt UT- Bolt UT machine
Topics covered
- o t step- y-step- GMAX SoftwareTheory Test
4) PracticalPractical Training SessionPractical Test
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SHELL: No leaks!No fire, no injury, no shutdowns, no pollution
Contractor: No rework!More incentivesNo injury
Why TFA? Purpose & Goals
ess sco ngMore time to do other things
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TFA Procedure
Procedure Work Process - Differences
Roles and Responsibilities:- Authorized ForemanQC Technician
SEPL TFA Inspector
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TFA Organisation
ZONE 1 ZONE 2 / 3 / 4
FITTER FITTER FITTER FITTER FITTER FITTER
TFA Authorized TFA Authorized TFA Authorized
FOREMAN
TFA
QC TECHNICIANTFA
Executing Engineer
TFAExecuting Engineer
SEAL
SEAL
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TFA v5 Scope - PipingDefinitionCritical 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
Hy rocar on or Sour Service 316 eg. C 600 F , c ass 900, size 8 an 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
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Standard Flanges
Flanges that follow B16.5 (flanges 24)
Flanges that follow B16.47 (flanges >24) Series A or B Temperature at bolts 20% lower than process temperature unless flangeis insulated
Definition (cont.)
Non-standard Flanges
Flanges that DO NOT conform to B16.5 or B16.47
Temperature at bolts > 450C
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Selection of Bolt Tightening Method and QC ScopeFlange
Size150# 300# 600# 900# 1500# 2500#
1
1 12
3468
1012 2141618202426 428
303236 340424860
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Selection of Bolt Tightening Method and QC Scope(cont.)Zone Rating Service Method QC Scope Sealed by
1
1.1 Dn < 20, 150#
All Services Torquing Visual, ToqueSampling
AuthorizedForeman
Water,Compressed air ,
Steam,Nitrogen
Flogging Visual, SpannerSampling
1.2 Dn 4, 1500#
All Services Tensioning4.2 Dn > 3, 2500#
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TFA Zone 1Manual Tightening
Flange Size 150# 300# 600# 900# 1500# 2500#
1
1 12
3468
10
12 214
16182024
26 4283032
2 Fitters 2 Fitters 2 Fitters 2 Fitters 2 Fitters 2 Fitters 2 Fitters 2 Fitters 2 Fitters
Seal SealSeal
TFA Foremen
Seal SealSeal Seal SealSeal
TFA Foremen TFA Foremen
36
340424860
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TFA Zone 2
Tightening with Driven Wrenches
Flange Size 150# 300# 600# 900# 1500# 2500#
1
1 12
3468
10
12 214
16182024
26 4283032
2 Fitters
TFA Foremen Seal
2 Fitters 2 Fitters
QC Technician
Seal
Seal
Bolt-UTdatabase
36 340424860
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TFA Zone 3
Tightening with Driven Wrenches
Flange Size 150# 300# 600# 900# 1500# 2500#
1
1 12
3468
10
12 214
16182024
26 4283032
2 Fitters
TFA Foremen Seal
2 Fitters 2 Fitters
QC Technician
Seal
Seal
Bolt-UTdatabase
36 340424860
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TFA Zone 4Bolt Tensioning
Flange Size 150# 300# 600# 900# 1500# 2500#
1
1
123468
10
12 214
16182024
26 4283032
TFA Foremen Seal
Bolt-tensioning Crew
QC Technician
Special Services Provider
Bolt-UTdatabase
36 340424860
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FloggingOnly for Zone 1: Utilities Air, Water, N2, Steam
TorquingFor flanges in Zone 1 and Zone 2
Double Torquing (2 - Torque wrenches concurrently) -
Tightening Method
TensioningFor flanges in Zone 3: Critical and Zone 4 : All Service
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Visual, spanner (By Authorized FOREMAN) Visually check for F.L.A.N.G.E.Use spanner/hammer to test bolt tightnessOnly 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 tightnessOnl for Zone 1 All service exce t Utilities
QC Method
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
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TFATFA
11--seal approachseal approach
1 SealAuthorized TFA Foreman
TFA Tagging &1-seal ApproachZONEZONE
TFATFA
11--seal approachseal approach
Authorized TFA Foreman
execution under
# 1 # 2 / 3 / 4
-Execution-Responsible for the joint
SEPL TFA Inspector
sign-off EQCC to accept
1 SealQC Technician
has proper tech to check for properexecution
SEPL TFA Inspector
sign-off EQCC to accept
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Fitter (contractor)
Clean up the flange and prepare for inspectionSafely Break the Flange Joint
Works hand-in-hand with TFA Authorized Foreman
TFA Roles and Responsibilities
Execute Flange tightening as instructed by Authorized Foreman
,
Align Flange and hand tighten nuts
Prepare Bolts for Reference Reading
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Authorised TFA Foreman (AF) (contractor)
Inspect Flange Faces (report defects to QCT)
Works hand-in-hand with QC Technician & Fitter
TFA Roles and Responsibilities
Supervise safe breaking of Flange Joint
Execute Flange tightening as per given specZone 2, 3 and 4
Assist QCT for QC check of flanges for Zone 2 , 3 and 4
Check Lubrication of Nuts and Bolts
Ensure flange face checked
QC Check and Apply SEALforZone 1 Flanges- QC passed
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SEPL TFA inspector Project Engineer / Maintenance Engineer /Executing Engineer / Work Pack Leader
Maintain Log of Off-spec flanges
TFA Roles and Responsibilit ies
epor -spec anges o eer ng eamMaintenance Manager / Construction Manager Organize execution of Discovery works
Sign-offEQCCs following Equipment handover protocol
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1. Check flange faces2. Lubricate nuts and bolts
3. Check correct gasket install4. Install nuts and bolts hand tight (max 15% of studs to hold flange)
5. Tightening 1st pass
AF AF
AF AF
AF
Work Process : Zone 1
6. Tightening 2nd
pass7. Tightening 3rd pass8. Tightening Final pass9. QC Seal flange
AF AF AF AF
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1. Check flange faces2. Lubricate nuts and bolts
3. Check correct gasket install4. 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
AF AF
AF AF
AF
Work Process : Zone 2 & Zone 3
6. QC Reference measurement (3 / 6 Bolts)7. Tightening 1st pass8. Tightening 2nd pass9. Tightening 3rd pass
10. Tightening Final pass11. QC Check applied load @ 3 / 6 bolts12. QC Seal flange
QCT AF AF AF
AFQCTQCT
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1. Check flange faces2. Lubricate nuts and bolts
3. Check correct gasket install4. Install nuts and bolts hand tight (max 15% of studs to hold flange)
5. Prepare bolt ends for Bolt UT sandpaper/ filing: 6 bolts
AF AF
AF AF
AF
Work Process : Zone 4
6. QC Reference measurement (6 Bolts)7. Tightening for all Odd Studs8. Tightening for all EVEN Studs9. QC Check applied load @ 6 bolts
10. QC Seal flange
QCT AF AFQCT
QCT
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What is Ultrasonics?
Using ultrasound (sound above the range of human hearing) tomeasure distances
TFA Boltstress Ultrasonics
Ultrasonics: 1,000,000 - 5,000,000Hz (5Mhz)
Infrasound Sound Ultrasound
20Hz 20,000Hz
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What is Bolt Ultrasonics?
Using ultrasonics to measure the length of bolts in a very accurate way
TFA Boltstress Ultrasonics
Can measure a maximum distance of 1.5m
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Why do we use Bolt Ultrasonics?
By taking a reference value of the bolt length before the bolt istightened
TFA Boltstress Ultrasonics
tightened The two readings can be compared to determine elongation of
the bolt
elongationBolt before tighteningReference measurement
Bolt after tighteningFinal measurement
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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
TFA Boltstress Ultrasonics
So, if we know the elongation, we will know the bolt load
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What is the relationship between bolt load and bolt stress?
Bolt Stress = Area of Bolt
Bolt Load A
TFA Boltstress Ultrasonics
=
Area of bolt is dependent on diameter of bolt
F A
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So, how do we use Bolt UT?
Measure reference (before tightening)
Measure final (after tightening)
Gives uselongation
TFA Boltstress Ultrasonics
Calculate Bolt Stress
Compare Bolt Stress with Required Bolt StressIs it within 10%, +15% of required bolt load?If yes passIf no retighten
Calculated by Bolt UT computer
Input Bolt Effective Area
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Why do we use bolt stress instead of bolt load?
Bolt Stress(MPa / psi)
Bolt Load
(N)
vs
TFA Boltstress Ultrasonics
size, so stress is the sameacross different bolt sizes
larger bolt = larger load
Failure point of bolts aredependent on materialgoverned by stress
Unable to directly correlatefailure point with loadneed to convert to stress first
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Bolt material
100% Yield Stress
psi(lbf/in2)
MPa(N/mm2)
TFA Procedure
B7, L7, B16 105,000 724B7M, L7M 80,000 551
B8 Class 1 29,000 200B8 Class 2 80,000 551
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Required Bolt Stress (MPa)Bolt material Standard
FlangesNon-standard
Flanges
TFA Procedure
, ,
Depends oncalculation
B7M, L7M 275
B8 Class 2 275
Based on 50% Yield Stress
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Why Bolt UT?
Bolt Tightening MethodsUncontrolled Semi-controlled Fully ControlledFlogging Torquing
Double TorquingBolt UT
ens on ng Accuracy 50-80% 20-40% 10%Method of Control None Torque Actual Load
Weakness Highly inaccurate,no way to
determining actualload or torque
Conversion of torque intoactual bolt load is
affected friction, torquingmethod and lack ofproper lubrication eg.E9901 26, E99
None directmeasurement of bolt
load/stress ensures thatbolt load is exactly correctas required.
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Can we do better?
The tightening of Flanges wererejectedrejecteddue toINSUFFICIENT LUBRICATIONINSUFFICIENT LUBRICATION
MAKE SURE !
What was not done well so far? What was not done well so far?
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Stud/NutsTHREADSTHREADS are in good conditionLubricatorMOLYKOTE 1000MOLYKOTE 1000
Flange SurfaceFlange Surfaceis lubricated properly
Stud/NutsTHREADis lubricated
Nuts FACENuts FACEis lubricated
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Questions?
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