Document DvvjmzDEQbzrQ51NKjvpX6824

ENGINEERING INSTRUCTIONS general BOLTING UP PRACTICE Purpose & Scope Responsi bility 1. This Instruction covers the prescribed practice for bolting up all * types of flanged joints on Refinery equipment. .2 The Foreman in charge is responsible for the proper direction of * all work and for close adherence to this Instruction. Unusual mea sures such as the building up of imperfect flanges by welding, re facing of distorted flanges, and heating and bending of pipe for proper alignment shall be applied only under his direction.! He shall report unusual conditions to the Lead Engineer, Designs Section, and shall procure his approval to proceed whenever the corrective measures required are at variance with accepted practice. Tools for Bolting Up Proper wrenches are supplied by Central Tool Room. Wrenches longer* than the standard issue shall not be used. Ten pound hand hammers are permissible, but only with hammer wrenches as Issued by Central Tool Room. Other tools, such as impact wrenches, longerfwtenches, heavy hammers, etc., shall be used in bolting up only when approved by the Foreman in charge. Tools for Dismantling The use of an impact wrench, a hand hammer, sledge, or long wrench * Is permissible in all cases of dismantling. Unless specifically approved by the Foreman in charge, use of a length of pipe for addi tional wrench length shall not be used because of the danger of straining the wrench and the personnel hazards involved. Selecting and In stalling Gaskets Prepara tion of Flange Faces 5. Engineering Instruction R-506, "Selecting and Installing Gaskets" should be used as a reference in connection with this Instruction although much of the material of Instruction R-506 has been Included here for convenience. PREPARATION OF FLANGE FACES j i Clean the flange faces thoroughly with a wire brush or metal scraper before bolting together. In cases where flanges cannot be separated enough to permit the use of a wire brush, use a thin scraper to re move any foreign matter that might have accumulated on the flanges. On tongue and groove and on ring type flanges, particular care must be exercised to see that the groove is clean, To clean the groove, use a special scraper tool. Inspec tion After cleaning, inspect the flanges for pits and defects In the * gasket faces. Repair minor imperfections by truing up with a file; or in severe cases build up by electric welding and finish with a file, grinding wheel, or portable flange facing tool. Sometimes ORJ flange grooves may be satisfactorily trued by hand lapping With an ORJ gasket. 9-28-62 (Replaces 8-1-41) CHEVBB 0002626 R-800-1 ENGINEERING INSTRUCTIONS GENERAL BOLTING UP PRACTICE Repairing Distorted Flanges 8. Flanges often show a distortion near the outer circumference caused * by excessive stress applied to the bolts. Unless corrected, this will in time prevent the tongue from forming a seal with the gasket, due to the outer edge of the flanges coming in contact before the tongue engages the gasket. Such n condition may be corrected by grinding the flange faces outside the bolt circle, removing! enough metal to provide clearance between the flange faces when the flanges are bolted up as outlined in Item 14. In extreme cases thej flanges may be refaced, where the thickness of the flange permits. | Cases of serious flange distortion shall be referred to the Lead Engineer, Designs Section. Chipping Goggles or Safety Spectacles 9. Chipping goggles or safety glasses shall be worn at all times by * mechanics who are scraping or^wire brushing a flange^face of who are refacing a flange either with~a~Ti1e, grinding wheel^ orflange facing tool. See Richmond Refinery Instructions 314, Appendix I, pages 5 and e. r-i i New Gaskets 10. If available, a new gasket shall always be used. Reusing Old Gaskets 11. On specific approval by the Foreman in charge, an old gasket may be * reused' only if: | (a) Significant shutdown time can be saved; or (b) New gasket is not readily available; or (c) Old gasket isvirtually as good as new. i j Installing 12. After cleaning the flanges for make-up, as described above, jinsert * Gaskets the gasket dry. Normally, placement of gasket gives no trouble. Composition gaskets of the proper dimension are centered by the flange bolts. Metal jacket gaskets for tongue and groove or male and female face joints shall be placed with the seam in the!bottom of the groove or on the bottom of the female facing. j BOLTING UP PIPINGFLANGES j Lubri cation 13. To permit easy tightening of bolts and also to provide for dis mantling without undue effort, all bolts and nuts must be thoroughly cleaned and lubricated before assembling joints. Use one of the special thread pastes specified in Appendix I for this purpose. Special attention should be given to the nut surface coming!in con tact with the flange. Lubrication of this surface preventsjseizure of the two metals when tightening up. ; 9-28-62 (Replaces 8-1-41) chevbb 0002627 R-800-2 ENGINEERING INSTRUCTIONS GENERAL BOLTING UP PRACTICE Flanges in Alignment 14. When flanges are in alignment, both horizontally and vertically, and faces are parallel, install all bolts, with the exception of one or two, and tighten the nuts hand-tight. In one of thp holes left open, insert a spud bar and use it as a lever to raise or lower either flange as required to insure proper alignment> and on tongue and groove flanges, the proper entering of the tongue into the groove, and on ring joints, the proper seating of the ring into the groove. When this is accomplished, tighten one bolt sufficiently to keep the tongue and groove engaged, or the ring seated, and then tighten the opposite bolt a like amount. This will result in a parallel facement. Remove the spud bar and install the retaining bolts, tightening them by gradually working around the flange until all bolts are tight with equal tension on each bolt. Flanges Out of Alignment 15. When flanges are out of alignment, either vertically or horizontally, pry the ends of the lines over or up until a spud bar can b|e Inserted * in the corresponding hole of each flange, after which proceed as in Item 14. In the event it is not possible to line up lines without excessive strain, corrective measures shall be taken either by heating the pipe or making alterations, as directed by the Foreman in charge. Correct flange misalignment at machinery as required to avoid any significant strain on the machinery. Flange Faces Net Parallel 16. When flanges are in alignment but the faces are not parallel, if this condition is not too serious and a run of line sufficient for deflection exists on either side of the flanges, proceed as in Item 14, except that the first bolts to be tightened should be on the side -of the flange where the greatest opening exists. When flanges are drawn up parallel, all bolts can be tightened to the same approximate degree of tension, and then gradually increased around the bolt circle until all are tight. Heating to Align Pipe 17. If the flanges cannot be drawn parallel without too great a! strain * on the bolts, the pipe, if carbon steel, may be heated to a tempera ture sufficient for bending as directed by the Foreman in charge. While at this temperature, bolt the flanges together, as outlined above, and anneal the pipe later to relieve any existing strain. After the pipe has been allowed to cool, unbolt the flanges for inspection, and if strains still exist, repeat the procedure. I 18. Where chrome nickel pipe and/or fittings are involved, the Lead Engineer, Designs Section, shall be consulted for instructions. Cold Pull Up Flanges in Alignment Jy. When flanges are in alignment hut require a cold pull-up to ; lake care of expansion during operation, bolting up can be accomplished in two ways, i.e., by the use of special bolts or chain blocks. 9-28-62 (Replaces 8-1-41) CHEV BB 0002628 R-800-3 ENGINEERING INSTRUCTIONS Special Long Bolts GENERAL BOLTING UP PRACTICE I 20. Special bolts should be of a length great enough to engage the two flanges plus the cold pull. Use at least two bolts to pro vide equal tension on each side of the flange, and by tightening up these bolts alternately, bring the flanges together. The correct length of bolts shall then be substituted for the special bolts. Tightening of both the special and the regular bolts must b^ done by one man with the proper length wrench. This will assure that no overs tress in the flanges will occur. j Chain Blocks .21 In using chain blocks, the blocks are lashed to the pipe and the two flanges brought together and bolted up as prescribed in|Item 14. All cases of cold pull-up in excess of 4", and such cases where un usual effort is required to bring the flanges together, shall be referred to the Lead Engineer, Designs Sections, for instructions. Cold Pull-up Flanges Not Lined Up .22 When a cold pull-up is necessary and flanges do not face, pull the flanges together as described in Items 20 or 21 and bolt-up as described in Item 16. BOLTING UP COVER PLATES AND VESSEL AND EXCHANGER HEADS 23. The directions given in Item 13 regarding lubrication shall;be followed in all cases when bolting up cover plates and vessel or ex changer heads. In most instances facing of cover plates and heads will be normal, and the directions given in Item 14 above can be followed. Where any distortion or misalignment occurs, the matter shall be referred to the Lead Engineer, Designs Section, for Instruc tions. Special Cases TORQUE WRENCHES I 24. In critical services and in other special cases the work requisi tion may specify the use of a calibrated torque wrench. This type * of wrench is carried in the Central Tool Room and may be j procured in the usual manner. When used, the required torque will be specified. j - - - oOo - - - | Attachment \ Appendix I j 9-28-62 (Replaces 8-1-41) CHEVBB 1002629 R-800-4 GENERAL ENGINEERING INSTRUCTIONS APPENDIX I BOLTING UP PRACTICE SPECIFICATIONS FOR PASTE FOR USE ON BOLT THREADS The following bolt thread pastes are available in the Central Tool Room; 1. For temperatures up to 400F, mixed as follows: Graphite Grease 35# (1 - 35# pail ) Flake Graphite 30# (6 - 5# pkgs.) White Lead 50# (2 - 25# pails) Rod Engine Oil 15 Gals. Approximate cost: 20c per lb. 2. For temperatures 400F to 600F, mixed as follows: Molybdenum Disulphide Powder 1 part by vol. Chevron Filter Coat Oil 1 part by vol. Approximate cost: $1.55 per lb. j The following bolt thread pastes are carried in stock by the Storehouse: 3. General Service Led-Plate (anti-seize compound) #250 ! (Contains metallic lead) Stock #54-4490 Approximate cost: 89c per lb. 4. For Monel Bolts Where Lead is Detrimental ; i ! j Jet-Lube (copper anti-seize compound, lead-free, for temperatures up to 1200F) SS-30 Stock #54-1520 I Approximate cost: $1.82 per lb. CHEV BB 0002630 9-28-62 (Replaced 8-1-41) R-800-5