Professional Documents
Culture Documents
2nd edition
An IP Publication
Energy Institute
e: pubs@energyinst.org.uk
www.energyinst.org.uk
May 2007
Second edition
Published by
ENERGY INSTITUTE, LONDON
The Energy Institute is a professional membership body incorporated by Royal Charter 2003
Registered charity number 1097899
Endorsed by
Oil & Gas UK, HSE OSD and the ECITB
The Energy Institute gratefully acknowledges the financial contributions towards the scientific and
technical programme from the following companies:
BG Group
BHP Billiton Limited
BP Exploration Operating Co Ltd
BP Oil UK Ltd
Chevron
ConocoPhillips Ltd
ENI
ExxonMobil International Ltd
Kuwait Petroleum International Ltd
Maersk Oil North Sea UK Limited
CONTENTS
Page
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Criticality assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 Assessing the risks with bolted joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
21
21
21
21
22
22
22
22
27
27
28
29
Contents Cont....
Page
Management of leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Engineering risk assessment of leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Stages at which leaks occur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Corrective actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Definition and detection of leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6 Managing leaks and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7 Learning from leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
31
31
32
32
32
34
34
In-service inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Risk assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Degradation mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 Inspection techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5 Defect mitigation measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
37
37
37
37
38
vi
FOREWORD
The first Issue version of this document has its roots set in the upstream oil and gas industry being part of the
HSE/industry drive to reduce the incidence of hydrocarbon leaks on offshore installations. Leaking joints have been
the main cause of hydrocarbon releases on the UKCS offshore sites and there exists similar concern for the vast
number of facilities handling petrochemical and other hazardous material on main land sites.
In 2005, the UKOOA (now Oil & Gas UK) led Installation Integrity Working Group (IIWG) requested that the
Energy Institute manage the review and revision of the Joint UKOOA/IP Guidelines for the management of the
integrity of bolted pipe joints first issued in June, 2002. This project required the formation of a cross-industry Work
Group (WG) many of whom were from that used to compile Issue One. Others included those from the parent IIWG
members, consultants and representation from the industry training organisation, ECITB.
The revision exercise was part of the programme of work undertaken by the IIWG which included development and
promotion of industry good practices and suitable performance measures. The principal deliverables of this Work
Group were an Asset Integrity Tool Kit and review and revision of guideline documents one of which was for the
management of integrity of bolted pipe joints. It is therefore considered that this Guideline will provide valuable
advice to assist operators manage plant integrity for any installation employing bolted joints.
During the review process, the WG elected to widen the scope to include bolted joints used within pressurised
systems and not just pipe joints as is the case for Issue One, and to ensure that the document is applicable to onshore
industries as well as offshore oil and gas.
This document has been compiled as guidance only and is intended to provide knowledge of good practice to assist
operators develop their own management systems. While every reasonable care has been taken to ensure the
accuracy and relevance of its contents, the Energy Institute, its sponsoring companies, section writers and the Work
Group members listed in the Acknowledgements who have contributed to its preparation, cannot accept any
responsibility for any action taken, or not taken, on the basis of this information. The Energy Institute shall not be
liable to any person for any loss or damage which may arise from the use of any of the information contained in any
of its publications.
This Guideline will be reviewed in the future and it would be of considerable assistance for any subsequent revision
if users would send comments or suggestions for improvements to:
The Technical Department,
Energy Institute,
61 New Cavendish Street,
London
W1G 7AR
e: technical@energyinst.org.uk
vii
viii
ACKNOWLEDGEMENTS
As Work Group members, the Institute wishes to record its appreciation of the work carried out by the following:
Sub Group Champions, who have managed the coordination and compilation of designated sections through
leadership of their respective volunteer sub-groups and through providing authorship expertise:
Stuart Brooks
Rod Corbet
Anderson Foster
Jim MacRae
Robert Noble
Sub Group members, who have provided valued input into their designated sections:
Blair Barclay
Keith Dunnett
Bill Eccles
Alan Gardner
Tim Jervis
Gary Milne
Phillip Roberts
Ravi Sharma
Mike Shearer
Lawrence Turner
Mark Williams
Pat Wright
ECITB
CNR International
Bolt Science (Hytorc)
Consultant
Shell Exploration & Production
Hydratight
Shell Exploration & Production
HSE
Lloyds Register EMEA
Shell Exploration & Production
Klinger UK Ltd
RGB Ltd.
Assistance was also provided by the following other Work Group members:
Gwyn Ashby
Peter Barker
Arunesh Bose
Martin Carter
Kevin Fraser
Norrie Hewie
Gavin Smith
Roy Smith
Jan Webjorn
Mitsui Babcock
Marathon Oil
Lloyds Register EMEA
BHP Billiton
IMES
Hess Corporation
Novus Sealing
Hytorc
Verax
ix
Andrew Pearson
Chris Boocock
Bob Kyle
ODL
The revision/review project was coordinated and managed by Keith Hart FEI, Energy Institute, Upstream Technical
Manager.
The Institute also wishes to recognise the contribution made by those who have provided comments on the Draft
document which was issued during an industry consultation period.
1
INTRODUCTION
for bolted joints in pressurised systems. Individually the
sections of this document provide details of what is
considered good practice in the key areas of ensuring
joint integrity. Together they provide the framework for
a management system.
This document is not intended as a design guide for
bolted joints, but as a guide to how to manage joints
during construction and commissioning phases and
through their operational life. It provides a framework
to achieve this based on working with a correctly
designed joint.
ANALYSIS,
LEARNING AND
IMPROVEMENT
OWNERSHIP
MANAGEMENT
OF LEAKS
TECHNOLOGY
AND PRACTICE
IN-SERVICE
INSPECTION
CRITICALITY
ASSESSMENT
RECORDS, DATA
MANAGEMENT
AND TAGGING
TRAINING AND
COMPETENCE
GUIDELINES FOR THE MANAGEMENT OF THE INTEGRITY OF BOLTED JOINTS FOR PRESSURISED SYSTEMS
In-service Inspection
Learning from both positive performance and
incidents is important. A management system
should include the means for gathering relevant
data on joints which are successful and those that
have incidents or leakage issues. These should be
collected by everyone involved in bolted joints, and
periodically reviewed and analysed to establish
trends, issues and improvement opportunities.
Management of Leaks
The objective of a correctly designed and installed
bolted joint is to provide a long-term tight seal and
prevent ingress or egress of fluids through the joint.
However, leaks can occur and managing the
investigation and repair of the leak is essential to
avoid recurrence. It can also provide useful data for
prevention on other projects.
Criticality Assessment
The range of services, pressures and conditions
which bolted joints experience varies considerably.
Each joint should undergo a criticality assessment
which will determine the levels of inspection,
assembly control, tightening technique, testing,
assurance and in-service inspection relevant to the
joint.
2
BOLTED JOINT TECHNOLOGY
AND PRACTICE
Pipework and pressure systems are designed to
meet varying operational conditions. In order to avoid
failure, it is very important that the relevant piping
specifications for materials and components are adhered
to in full.
There are many types of bolted joint and only some
of the more commonly used are mentioned here but as
mentioned previously, the basic reliability parameters
and procedures applied are the same for all.
2.1 OVERVIEW
This section gives a brief outline of how joints work and
provides guidance on the safe and efficient assembly
and disassembly of flanged joints and clamps. It also
discusses basic proposals for integrity testing. The
scope of these Guidelines covers all pressure-containing
joints including pipelines, pressure vessels such as
reactors and heat exchangers, associated valves and
other pressure-containing equipment. Due to operating
conditions with heat exchangers and reactors,
particularly temperature gradients, different metal joint
components and thermal and pressure cycling, a higher
level of control and assurance of bolt load is generally
required compared to, for example, piping joints
subjected to static pressure only. The principles set out
are generic in nature and not exclusive to pressure
containment applications; they can be applied to bolted
joints subjected to other service conditions such as
fatigue, vibration and structural loading.
The flanged joint is deceptively simple yet, in
common with the welded joint, its integrity relies on a
number of parameters including the basic design,
structural and metallurgical quality of its components
and achieving the required design clamp force on
assembly. Important to meeting these assembled design
objectives is the selection of suitable installation
procedures and tools that are applied by competent
operators.
The importance of planning the joint assembly,
preparation of all components, procedures, tooling and
ensuring application of the correct methodology is
essential.
Flange joints
GUIDELINES FOR THE MANAGEMENT OF THE INTEGRITY OF BOLTED JOINTS FOR PRESSURISED SYSTEMS
2.2.2
2.2.3
Compact flanges
Clamped connectors
Hub
Clamp
Seal
ring
Kammprofile
This is a solid metal ring having a serrated tooth
form profile on both faces. A covering layer of
graphite or PTFE is applied which compresses into
the serrated surface as the gasket is loaded. These
are used increasingly for heat exchanger flanges
(see Figure 2.5 on page 7).
2.3.2.3 Metallic
These are made from one or a combination of metals in
a variety of shapes and sizes for high temperature and
pressure usage. The metal ring fits into grooves that
have been machined into the flange faces. Due to the
high application pressures, the seating stresses and
corresponding bolt tension are necessarily large to give
sufficient deformation to overcome flange surface
imperfections and distort against the groove surfaces so
as to overcome high service pressures. Oval and
octagonal types (see Figure 2.7 on page 7) are
commonly used in oil and gas applications under ASME
B16.20 and API 6A. RX rings are perceived to be selfenergising whilst the BX type are designed to fit into a
recess that allows metal to metal contact when the
flanges are tightened.
2.3.2.1 Non-metallic
These are made from elastomers, cork, compressed
fibres, plate minerals and PTFE. Usually the material
sheet is cut to the shape of the flange sealing face. They
are generally used for low to moderate pressures and
temperatures and see wide chemical service including
acid and alkaline applications.
2.3.2.2. Semi-metallic
These combine a combination of non-metallic filler for
compressibility and metal for strength. They are
typically used for higher temperature and pressure
applications compared to the non-metallic types.
Common types include:
Spiral wound
These gaskets are constructed with spirally wound
metal and soft filler (see Figure 2.6 on page 7). A
wide range of metals can be used for the winding
strip and support rings as well as various filler
materials. On raised face flanges, the gaskets have
an outer support ring which locates inside the bolt
PCD. They can also be supplied with an inner ring
for higher pressure system usage. The inner ring is
also used where high process flow rates or abrasive
media are found; the inner ring reduces turbulence
at the pipe bore. On spigot or recess flanges a
simple sealing element gasket is used with no
additional support rings.
Metal jacketed
These clad gaskets have been traditionally used on
heat exchangers. A variety of metals can be used to
encase a soft filler material. It should be noted that
some heat exchanger flanges have stress raising
'nubbins' on one face and the non-seamed face of
5
GUIDELINES FOR THE MANAGEMENT OF THE INTEGRITY OF BOLTED JOINTS FOR PRESSURISED SYSTEMS
Bolting
Ensure that:
Components and flange faces are clean and
undamaged and of the correct surface finish.
Nuts and bolts are clean and free running but not
sloppy on threads.
Gaskets are clean and free of damage.
2.4.3
GUIDELINES FOR THE MANAGEMENT OF THE INTEGRITY OF BOLTED JOINTS FOR PRESSURISED SYSTEMS
2.4.4
Alignment
1.
2.
3.
4.
Breakout
3 mm
1 mm
Angular offset
Centre-line offset
2.5.1.2 Tightening
Torque tightening should be carried out sequentially, in
stages to 100% of specified full torque, using the crossbolt tightening method. Typically three stages of 30%,
60% and 100% are used. It is important that the flange
is brought together evenly to prevent overloading of the
gasket at any point and this should be monitored at all
times during the process. Once the first 100% level has
been achieved a check pass should then be carried out
on all bolts using a clockwise pass to ensure all bolts are
at the final torque level. If a bolt load assurance system
is used then the final tightening cycle or check is
measured by bolt load. It is possible that the use of a
bolt load assurance method can reduce the number of
intermediate, pre-torque cycles.
The joint will continue to settle under load and
the number of passes at 100% will be influenced by the
type of joint and its gasket type. For example, cut
gaskets and most ring type joints can be considered as
'soft' joints whereas metallic gaskets such as spiral
wound types can be considered as 'hard' joints. A soft
joint may require more torque passes to reach the
required bolt load in all bolts.
Figure 2.10 shows cross bolt torque tightening
sequences from ASME PCC1.
2.5.1.1 Lubricant
Regardless of the torque tool used, lubricant has a
significant effect on the achieved bolt load or stress for
a given torque. A known good quality lubricant, suitable
for service and of proven coefficient of friction must be
used. It is recommended that where possible sites adopt
a single lubricant policy; this avoids the opportunity for
confusion.
Extra care needs to be taken with high friction
surface coatings.
4 Bolt
Flange
6
2
3
2
9
5
8 Bolt
Flange
12
16
16 Bolt
Flange
14
13
11
10
15
GUIDELINES FOR THE MANAGEMENT OF THE INTEGRITY OF BOLTED JOINTS FOR PRESSURISED SYSTEMS
2.5.2
Reliability factors
B
A
B
B
2.6.3
Bolt tightening
GUIDELINES FOR THE MANAGEMENT OF THE INTEGRITY OF BOLTED JOINTS FOR PRESSURISED SYSTEMS
2.6.5
GUIDELINES FOR THE MANAGEMENT OF THE INTEGRITY OF BOLTED JOINTS FOR PRESSURISED SYSTEMS
2.7.1
14
2.7.2
Test recording
Safety Note
Strength testing is almost always carried out using
liquids (hydrostatic or hydraulic testing). Although
pressure testing using a liquid is not without risk, it is
by far the safer method and should be used wherever
practicable. Pressure testing using air, steam or gas
(pneumatic testing) is more dangerous because of the
higher energy levels involved.
The energy released during a total failure of
equipment containing compressed air can be up to 200
times the energy released by the same test if water was
used as the test medium. Pneumatic strength testing
should never be carried out using flammable gas.
Pneumatic leak testing to 10% of design pressure
can be used to find small but significant leaks in
equipment which will contain flammable gases and/or
liquids.
Caution should also be taken when carrying out
hydrostatic testing at low ambient temperatures (<7C)
to avoid the risk of brittle fracture.
Refer to the HSE Guidance Note GS4 'Safety in
pressure testing' and the associated research report for
further details.
2.7.3
2.7.4
15
GUIDELINES FOR THE MANAGEMENT OF THE INTEGRITY OF BOLTED JOINTS FOR PRESSURISED SYSTEMS
16
3
CRITICALITY ASSESSMENT
safety and environmental aspects of the local and distant
environment.
For onshore, this will often be part of the Control of
Major Accident Hazard (COMAH) assessment for the
site.
For offshore, Safety Case, PFEER and Pipeline
Safety Regulations will apply. The UK Health and
Safety Executive OIR/12 database contains useful
information to enable offshore industry operators to
develop their risk assessment.
Risk may also occur with joints containing
harmless fluids e.g. water, which would damage
building fabric or product, or risk interaction with
electrical installations if they leaked.
There are a number of areas which will affect the
criticality of the joint. These can be grouped as follows:
3.1 INTRODUCTION
There is a variety of bolted joints involved in
pressurised systems, ranging from low pressure joints
containing water or compressed air to high pressure
joints containing steam, hydrocarbons or explosive or
poisonous gases. Although every joint should be
designed and installed to safely contain the pressure and
contents specified, it is logical that joints at higher
pressure or with hazardous contents will require
additional vigilance due to the potential consequences
of failure.
The criticality of a joint may have an effect on a
number of areas addressed in the management system
including:
Choice of tightening method.
Choice of personnel assembling and tightening the
joint.
Level of bolt load assurance.
Level of records and data stored against the joint.
Level of inspection and testing prior to entering
into service.
Level of testing and inspection in service.
3.2.1
Leak potential
17
GUIDELINES FOR THE MANAGEMENT OF THE INTEGRITY OF BOLTED JOINTS FOR PRESSURISED SYSTEMS
3.2.2
3.2.4
Service fluid
Local factors
3.2.5
Hydrocarbon.
Corrosive.
Explosive.
Poisonous or noxious.
Radioactive.
High temperature.
Environmental contaminant.
Expensive.
Loss potential
Problem
Cyclic temperature
Untested joints
Exception on joint
Flange face marked, piping load, history of leakage with root cause
unidentified
18
CRITICALITY ASSESSMENT
Table 3.2: Joint criticality Examples of criteria used and controls applied
Joint Criticality
Low
3.2.6
Controls
Joint identified and recorded in database
Assembly not witnessed but carried out to a procedure by trained and competent
contractor
Bolt loads taken from database
Controlled tightening applied by use of hand torque wrench or torque wrench
Tightening carried out by competent personnel (see Section 4)
Integrity test by local arrangement
In-service testing includes visual inspection
Medium
High
GUIDELINES FOR THE MANAGEMENT OF THE INTEGRITY OF BOLTED JOINTS FOR PRESSURISED SYSTEMS
3.2.7
3.2.8
Risks to personnel
20
4
TRAINING AND COMPETENCE
maintain joints, or to supervise or assess such
work.
Includes a process to assure that third party vendors
and contractors can demonstrate that their
personnel are managed using equivalent systems to
equivalent competence standards.
4.1 INTRODUCTION
All personnel carrying out work on bolted joints should
be trained and competent to a level appropriate to the
required technical skills and failure risks of the joint
involved. Similarly, supervisory personnel and assessors
should also be trained and competent to ensure they are
aware of the issues involved in achieving a leak-free
joint.
4.3 TRAINING
The skill levels that individual companies use will
depend on a number of variables. For example, a
company with a large number of personnel may decide
on a number of skill levels appropriate to the type of
work an individual may perform. Other companies may
decide to train all their personnel to a higher level as a
matter of course. This approach is particularly relevant
to remote sites where it is imperative to have personnel
with the necessary skills available at all times. As such,
the training specifications for the following Engineering
Construction Industry Training Board (ECITB)
TECSkills units have become the benchmark standards
for the UK offshore oil and gas industry:
PF010
PF015*
PF018
PF019
21
GUIDELINES FOR THE MANAGEMENT OF THE INTEGRITY OF BOLTED JOINTS FOR PRESSURISED SYSTEMS
22
GUIDELINES FOR THE MANAGEMENT OF THE INTEGRITY OF BOLTED JOINTS FOR PRESSURISED SYSTEMS
Table 4.1: Competence requirements for authorised bolt tightening personnel (contd)
Ability to:
Recognise and rectify faults with torque or tensioning equipment
Interpret joint or flange manufacturer identifying marks
Identify defects, distortion and surface irregularities on flange sealing faces and threads
24
ID No
Installation
Date
This is to certify that the Technician named above has produced satisfactory leak-free mechanical joints of
the types indicated below within the past 12 months.
Joint Type
Satisfactory
Performance
Requires Training
Date
Signature
Comments
RTJ
Raised face
Insulating gasket
Compact
Clamp connector
Taper-Lok
Kidney
Other (installationspecific)
Note:
1. This record does not replace a recognised NVQ but certifies a Technicians ongoing competence in
making a specified mechanical joint.
2. It is recognised that certain installations do not have all types of joints.
Supervisor
(Position)
Verified
(Position)
Name:
Name:
Signature:
Signature:
Date:
Date:
25
GUIDELINES FOR THE MANAGEMENT OF THE INTEGRITY OF BOLTED JOINTS FOR PRESSURISED SYSTEMS
26
5
RECORDS, DATA MANAGEMENT AND
TAGGING
should be securely attached to the joint and may hold no
other data than the unique tag number. In selecting a
permanent tag, consideration needs to be given to the
attachment method, the temperature of the flange and
tag and security device material, the permanence of the
tag markings, and avoidance of corrosion spots due to
dissimilar metals or water traps.
5.1.2
Temporary tags
Permanent tag
Control competence.
Assist in the preparation of work permits.
Provide cross-shift communication of job status.
Assist job completion confirmation.
27
GUIDELINES FOR THE MANAGEMENT OF THE INTEGRITY OF BOLTED JOINTS FOR PRESSURISED SYSTEMS
28
5.2.1
Recommended data
5.3 REVIEW
5.2.1.3 Joint history
Starting at the construction stage: Records of
assembly, break out, reassembly, inspections and
controlled tightening. Including personnel
involved, equipment and procedures used. Results
and measurements taken where appropriate.
Records of inspection and testing of the joint.
Records of subsequent disassembly, inspection,
assembly, tightening and testing during operation
29
GUIDELINES FOR THE MANAGEMENT OF THE INTEGRITY OF BOLTED JOINTS FOR PRESSURISED SYSTEMS
30
6
MANAGEMENT OF LEAKS
However, there are a significant number of industries
where good business practice or regulatory requirements
make it essential to formally assess loss of containment
events and determine root cause and measures to
prevent recurrence.
When a leak or incident occurs, a common
approach to manage such situations is an engineering
risk assessment which utilises the collective skills
within the organisation to address three fundamental
questions:
6.1 INTRODUCTION
The objective of a correctly designed and installed
bolted joint is to provide a long-term tight seal and
prevent ingress or egress of fluids through the joint.
However, leaks can occur and the Duty Holder or
operator has overall responsibility to manage this
situation. This section introduces some important
features that may be required of the management system
for pressurised systems after joint make-up. These
include:
31
GUIDELINES FOR THE MANAGEMENT OF THE INTEGRITY OF BOLTED JOINTS FOR PRESSURISED SYSTEMS
6.3.1
Leak test
A leak test is not a replacement for correct joint makeup and tightening; rather, it is merely part of the
assurance process. Where a joint is just failing a leak
test it is tempting to increase bolt load. However if the
bolt load was correctly applied in the first instance,
increasing the bolt load could be hiding a problem, e.g.
a nipped gasket or grit on the gasket, which will
manifest as a service leak later.
6.3.3
Gas leaks:
A release that will cause a hand-held gas detector
10cm 'downwind' of the release source to indicate
20% Lower Explosive Limit (LEL).
The most likely method of detecting a leaking bolted
joint is observation by operations and maintenance
personnel or inspection personnel during routine
operation in the plant. There is no substitute for 'line
walking' as most leaks are of relatively small
magnitude. The more significant leaks may also be
detected by plant safety systems such as gas detectors
or, in extreme cases, by the process control system.
All leaks should be tagged and entered in the
maintenance system for repair and the record and data
management system as soon as is reasonably practical.
It may also be reportable.
An emission from a joint with a lower release rate
than a leak is described as a seep. These too should be
tagged and periodically checked to ensure they have not
worsened, and be entered into the maintenance system
for repair at the next scheduled service for that item. It
should also be recorded in the records and data
management system.
Service testing
Leaks occurring
operation
during
start-up
or
32
MANAGEMENT OF LEAKS
START
PASS OR FAIL?
PASS
FAIL
Joint failure leakage
rate above the target
acceptance criteria
Is this
a single failure
or are there numerous
failures in the
system?
SINGLE
NUMEROUS
TIME OUT
YES
Technical review
required
Is there a
common style of joint that
is failing?
NO
YES
Is the
leakage rate above
the maximum acceptance
criteria?
NO
NO
Is the technical
authority willing to approve
the leakage result?
Is the
torque/tension
applied to the joint
correct for this application?
(Check procedure and all
assumptions made)
NO
YES
YES
Correctly apply
the torque/tension
in the field
NO
Has the
torque/tension
been correctly applied
in the field?
YES
Break the joint and
investigate failure mode.
Apply rigorous checks.
Reassemble and retighten
joint to approved method.
SUCCESS
33
GUIDELINES FOR THE MANAGEMENT OF THE INTEGRITY OF BOLTED JOINTS FOR PRESSURISED SYSTEMS
34
MANAGEMENT OF LEAKS
Figure 6.3: Encasement clamp repair on a 24 in. seawater line to stop leak on stub of composite flange
35
GUIDELINES FOR THE MANAGEMENT OF THE INTEGRITY OF BOLTED JOINTS FOR PRESSURISED SYSTEMS
36
7
IN-SERVICE INSPECTION
Flange orientation, particularly blind flanges
installed horizontally, allowing water to collect in
the holes. Stud bolts in blind flanges in firewater
mains have suffered this form of damage.
7.1 INTRODUCTION
In-service inspection of bolted joints is an integral
activity to ensure the continued integrity of the joints
and as such should be built in to all relevant inspection
programmes. This section looks at the possible damage
that can occur, the inspection methods available for
detection of defects and the mitigation measures that
can be put in place to minimise such degradation.
A summary of the key issues addressed in this
section is included in Table 7.1.
7.4.1
Non-destructive testing
GUIDELINES FOR THE MANAGEMENT OF THE INTEGRITY OF BOLTED JOINTS FOR PRESSURISED SYSTEMS
Typical
conditions
Exposed areas
Galvanic corrosion
Dissimilar metals
flanges, bolts, gaskets
Localised bolt
corrosion
Crevice corrosion
Fatigue
Creep
Stress corrosion
cracking
Hydrogen
embrittlement
Flange face
corrosion
Pipework containing a
corrosive medium,
dissimilar materials
Inspection
technique
Visual, sample removal,
Cylindrical Guided Wave
Technique
Visual
Intrusive visual, UT
Mitigation
measures
Material selection, thread
protectors, coatings
Material selection, gaskets,
bolt/flange insulating kits,
weld overlay
Material selection
Material selection
Pipework design
Material selection, ASME
SA-453
Material selection
7.4.2
Destructive testing
IN-SERVICE INSPECTION
Coatings
Bolts can be supplied with a variety of life
extending surface treatments such as hot dip spun
galvanising, which research shows offers the best
long term protection. Zinc, PFTE or electroless
nickel are also used.
Cathodic protection
Used for underwater applications. However, there
is usually a need to apply coating to the pipework
and flange joints to minimise the risk of hydrogen
embrittlement.
Thread protectors
Neoprene, polyethene and aluminium are common.
However, the potential for loss of thread
engagement strength needs to be assessed.
Flange protection
Gaskets (material selection is important to avoid
galvanic corrosion), flange protectors, coatings.
39
GUIDELINES FOR THE MANAGEMENT OF THE INTEGRITY OF BOLTED JOINTS FOR PRESSURISED SYSTEMS
40
IN-SERVICE INSPECTION
41
GUIDELINES FOR THE MANAGEMENT OF THE INTEGRITY OF BOLTED JOINTS FOR PRESSURISED SYSTEMS
42