Bolting QA/QC Bulletin

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Timothy McCarthy
6 years ago
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Bolting QA/QC Bulletin M&TE Review 8-27-14 There have been several incidents over the past few months regarding torqueing methods, calibration procedures and verification of conversion charts

As most of you are aware, MPL has been developing and beginning to use Inspection Checklists to help clarify inspector s responsibilities when inspecting work activities (i.e. bolting, production welding, liquid epoxy coating application, etc.

All of the MPL Inspection Checklists are available for all inspectors to use and are included in the QCPDR and Inspection Checklist Workbook, which is available from your project leader, the M&TE

1 Bolting QA/QC Bulletin M&TE Review There have been several incidents over the past few months regarding torqueing methods, calibration procedures and verification of conversion charts matching serial numbers. While these mistakes are contractor errors, these issues could have been prevented with more robust inspection. As most of you are aware, MPL has been developing and beginning to use Inspection Checklists to help clarify inspector s responsibilities when inspecting work activities (i.e. bolting, production welding, liquid epoxy coating application, etc.). The MPL Bolting Inspection Checklist (attached) outlines the inspector s key responsibilities when inspecting bolting including verifying calibrations and torque charts. All of the MPL Inspection Checklists are available for all inspectors to use and are included in the QCPDR and Inspection Checklist Workbook, which is available from your project leader, the M&TE Inspection Coordinator and/or your inspection company. It is important that all inspectors adequately inspect each task they are assigned to inspect. Using the Inspection Checklists will help ensure that you complete all the necessary checks/inspections when overseeing a work activity.

2 (QCDPR) Quality Control Daily Progress Report MPL Inspector Quality Control and Progress Daily Report (QCPDR) Clea Inspector Name System Segment Facility Name / ROW # / Station # Project ID # Project Description Dig # Rehab Only Project Leader Weather Temp (Deg F) Activities Inspected/Completed Today (type an "x" next to each activity that was inspected today. Also complete corresponding inspection checklists and include with this daily report) x Anomaly Inspection Buffing (Grinding) Welded Sleeve Install Bolt-On Sleeve Install In-Service Welding Production Welding Bolting Hot Tapping Pipe Unloading Occurred Clearing Grading Ditching Excavation of Active Line Bedding, Padding, Backfilling Clean-up Blasting (Explosive) Boring or Crossing HDD Description of Non-Conformity Pipe Stringing Cold Bending Lowering-In Liquid Epoxy Coating Field Applied FBE Coating Air to Soil Interface and Span Coating Painting Pipe Support FRP Saddle Install Approx. Location / Station # Conventional Ground Bed Install Deep Anode Ground Bed Install Rectifier Install Test Station Install Hydrostatic Test In-Service Lowering Casing Removal or Modification Pipe Receiving and Damage Check Non-Conformity and Resolution Log (Use Inspection Checklists for common nonconformities; use a separate line for each non-conformity. Fill out for today's non-conformities, or non-conformities that are resolved today (i.e. weld cut-out)) Resolution

3 MPL Bolting Inspection Checklist Refer to TNLCON009 for further clarification, details, and specifications not listed here. Inspector Name System Segment Complete Not Applicable Non-Conformity Task ID Facility Name / ROW # / Station # Project ID # Project Description Dig # Rehab Only Responsibilities Project Leader Verify in-service bolted connections are not "hot bolted" unless approved in the CDR or other work plan. Verify the contractor removes old gasket material, dirt, grease, etc. and thoroughly cleans all mating surfaces. Verify the mating surfaces are not damaged. Verify the ID of the inner ring of the gasket > bore of the flange Verify all gaskets have the ASME rating stamped on the outer ring. Verify that new and undamaged gaskets (including ring type gaskets) are used for all flanged connections. Verify that gasket(s) are those specified on the project drawing or design. Verify no grease, sealant, or lubricant is applied to the flange or gasket surfaces. Measure all flanged connections at 12, 3, 6, and 9 o'clock positions and verify the centerline high low tolerance is 1/16". Note- completed before the bolts are tightened. Measure parallelism at all flanged connections by measuring the closest and farthest away positions of the flange mating surfaces. Verify the difference between closest and farthest measurements is 1/32". Note- up to 10% of max torque may be used to achieve parallelism. Verify the spacing between the flange mating services is <2x the thickness of the gasket Note- up to 20% of max torque may be used to achieve proper spacing. Verify all flanged connections two hole tolerance and verify the holes are within 1/8" of perfect alignment. Inspect studs and nuts for thread damage. Nuts must turn on stud by hand. Verify any damaged components are not installed. Verify studs and nuts are properly code stamped (Typically B7 for studs, 2H for nuts) and match Verify that studs and nuts are the correct size as specified on the project drawing or design. Verify anti-seize lubricant is applied to studs threads and nut washer face (that touches flange) before installation. Verify the male thread pitch matches the female thread pitch before tools are used to tighten connections. Verify all torque wrenches (hand or hydraulic powered) have been calibrated with the manufacturer's recommended time frame. For hydraulic torque wrenches, verify that the pressure/torque conversion chart serial number matches the serial number of torque wrench. Verify that all bolted connections are tightened per the torque increments and pattern as shown on GSTD P. Verify that all bolted connections are tightened to the final torque range as specified in Tables 7-10 attached to TNLCON009. After 100% of final torque is achieved, verify the contractor checks each nut (sequentially in a clockwise pattern) and verify that no nut rotation occurs. Verify studs fully extend through the nuts and have at least 2 thread protrusions after tightening is completed. Mark across flange gap with paint stick/marker to indicate that the connection has been properly torqued. Documentation Comment on all non-conformities that happened today or that were worked on the MPL Inspector Quality Control and Progress Daily Report (QCPDR tab). Complete as-built drawing of bolted connections.

4 of calibration Serial number of item calibrated to match tool being used ISO ISO 6789

5 Above we have provided an example of a calibration certificate and what to look for to verify it matches the tool and has been calibrated by an accredited company. For manual torque wrenches a calibration cert needs to be with the wrench onsite for the inspector to verify. The serial number on the calibration needs to match the serial number on the wrench. Calibration to ISO 6789 or ASME B specifications. For hydraulic torque wrenches a calibration chart needs to accompany the torque head and needs to reference the serial number on the torque head. The chart may adjust how much pressure is required to achieve a certain torque. The power unit needs to have a calibrated gauge to ensure that the pressures are accurate. Both calibrations are required for hydraulic torque tools. Labs who calibrate hydraulic torque tools should be certified to ISO 17025

WELD PLATE GAUGE TOOL INSTRUCTIONS

WELD PLATE GAUGE TOOL INSTRUCTIONS Introduction The weld plate gauge tool has been developed in order to verify that upon reception and installation of the weld plate they are within acceptable tolerance.