1.

0 Introduction
This Work Execution Plan was developed as a minimum guideline for the installation of
gaskets in Plant Piping.
2.0 References
SAES-B-017 : Fire Water System Design.
SAES-L-050 : Construction Requirement for Plant Piping.
SAES-L-009 : Metallic Flanges, Gaskets & Bolts
ASME B16.20 : Ring Joint Gaskets and Grooves for Steel Pipes.
ASME-B31.3 : Process Piping
3.0 Selection Criteria :
3.1 Gasket materials shall be in accordance with ASME B31.3 and SAES-L-009.
3.2 Gaskets shall be suitable for the intended service and compatible with the flange
facing, the strength of the flange and bolting.
3.3 Gasket selection shall be in accordance with ASME B31.3 and the following;
3.3.1 Spiral wound type 316 stainless steel winding, flexible graphite filled with
carbon steel guide ring, per ASME B16.20, for raised face flanges in most
services, including steam and process hydrocarbons. Gaskets operating in
temperatures below minus 45 deg C, the guide ring shall be type 304
stainless steel material. Filler materials that deteriorate at elevated
temperatures, e.g. Teflon shall not be used in hydrocarbon services.
3.3.2 For Class 125 and 150 flat face flanges in non-hazardous services up to a
maximum temperature of 230 deg C, use compressed synthetic fiber with
oil resistant binder, 1.6 mm thick per ASME B16.21.
3.3.3 For plastic flanges, use full face gaskets of elastomeric material, 3 mm
thick with Shore A Durometer hardness between 50 and 60.
3.4 For untreated water services, such as seawater, raw water, wasia water and etc.,
use spiral wound gaskets or octagonal soft iron ring joint gaskets.
3.5 The PIKOTEK gaskets, or approved equal, with isolating sleeves and washers
shall be used for isolating dissimilar metal flanged joints and insulating joints for
cathodic protection.

4.0 Installation Procedure :

4.1 Ensure that gaskets are of the correct type, size and rating and it is in accordance
with the approved construction drawings.
4.2 Check/verify gasket for any scratches or damages.
4.3 Verify gasket color coding where applicable (See Table 1).
 4.4 The flange facing, particularly the seating area, shall be visually examined for
cleanliness and ensure that no damage, such as scratches exist.
4.5 When spiral wound gaskets are to be used, the gasket contact area shall not be
coated to ensure proper contact surface sealing purposes.
4.6 Align flanges and gasket then clamp securely in place.
4.7 Install all stud bolts and nuts hand tight.
4.8 Tighten the stud bolts using a calibrated torque wrench and in accordance with
SAES-L-050, Appendix A.
4.9 Ensure that gaskets are used only once and used gaskets shall be discarded.

5.0 Color Coding :

5.1 Spiral wound gaskets shall be marked with a color code that identifies the
windings and filler materials. A continuous color around the outer edge of the
centering ring shall identify the winding metal.
5.2 The color identifying the filler material for nominal pipe size 1” and larger shall
have four intermittent stripes approximately spaced 90 deg. apart on the outer
edge of the centering ring and for smaller sizes, gaskets shall have a minimum of
two stripes spaced 180 deg. apart.
5.3 The color coding shall be in accordance with Table 1 below.

6.0 Safety Requirements :

6.1 Elevated working platforms shall be in accordance with the construction Safety
Manual.
6.2 Work permit shall be obtained prior to the start of work..
6.3 Ensure that torque wrenches have valid calibration certificate.

6.4 Provide adequate lighting where required

5.1 Flange Jointing Practice

5.1.1 Alignment tolerances of mating flanges shall be per the applicable code and
the following:
 5.1.2 Flange “makeup” shall be done without the use of gasket sealing
compounds.

5.1.3 All flange bolting shall be assembled with thread lubricating compound.

5.1.4 Flanged pipe joints of cement lined type valves. If it is necessary to grind the
lining at the pipe ends to avoid interference with the action of the valve disc
(or plate), the lining shall be taper ground and coated with epoxy cement.

5.2 Additional Requirements For Piping Over 3 In. Nps (80 Mm) Connected To Rotating
Machinery.

5.2.1 A detailed piping erection procedure shall be prepared for each rotating
equipment machinery category to cover: a. Piping erection sequence b.
Flange alignment techniques Methodology shall cover initial and final “cold”
alignment, spring support adjustments, and “hot” alignment. The
procedures shall be submitted to the Client’s Engineer for approval. In
 addition, the AHS, machinery vendor, and Client’s Engineer shall mutually
agree procedures and the sequence of alignment for multi-casing
compressor trains.

5.2.2 During initial flange alignment:

5.2.2.1 Permanent spring supports shall be locked in “cold load” position
during piping erection and hydrostatic testing.
5.2.2.2 No unsupported piping shall be connected to the equipment nozzles.
5.2.2.3 For field-fabricated piping, the makeup of flanged or field welded
joints shall be done progressively away from the equipment nozzle.
5.2.2.4 If prefabricated piping sections are used, at least two welds shall be
left near the nozzle flanges for final fitting and alignment.
5.2.2.5 Piping shall be free of load-imposing temporary restraints that will
result in “cold springing” of the piping.
5.2.2.6 Final bolt tightening of piping flanges near the equipment nozzles
shall be done after initial alignment of the equipment nozzle flanges.
5.2.2.7 Local heating to correct minor misalignment is permitted on piping
that does not require postweld heat-treating.
5.2.2.8 Machined pins furnished with the mating flanges shall be used to
align flange bolt holes during field erection of the mating piping.

5.2.3 Equipment nozzle and mating flange alignment tolerances shall be within
the following maximum permissible limits:
5.2.3.1 For steam turbines and compressors other than reciprocating types,
1/64 in. (0.4 mm) for all alignment categories listed in 5.3.3.2 below.
[For nozzles greater than 24 in. NPS (600 mm), the machinery
vendor shall supply mating flanges.]
5.2.3.2 For centrifugal pumps and other rotating machinery
5.2.4 Final support adjustment. For liquid service, final adjustments of spring
support shall be made with the piping filled with process liquid.

5.2.5 During final “cold” alignment:

5.2.5.1 Piping and equipment nozzle flange alignment shall be verified after
the equipment has been aligned and grouted. Alignment checks will
be witnessed by the Client’s Engineer. Note: If the machinery train
includes a gear unit, the level, shaft parallelism, and tooth contact
pattern shall be checked prior to grouting the baseplate. Driver and
driven equipment shall be aligned to the gear unit.
5.2.5.2 The reverse indicator alignment method shall be used for “cold”
alignment checks of any special purpose equipment. Indicator
bracket sag shall be checked and recorded; and, final readings shall
include sag corrections.
5.2.6 During “hot” alignment:
5.2.6.1 Any of the following methods are acceptable for “hot” alignment
checks of equipment and equipment nozzle flange alignment: Dodd
Bars, Essinger Bars, and Optical Alignment.
5.2.6.2 Steam turbines. A preliminary “hot” alignment check shall be made
prior to start-up of the process unit. Operating procedures and
source for steam supply and discharge will be developed by the
Client’s Engineer. Any change in alignment greater than 0.002 in.
(0.05 mm) [0.004 in. (0.10 mm) in Total Indicated Reading (T.I.R.)] is
unacceptable. A final “hot” alignment check is required for special
purpose steam turbines, and on all general purpose steam turbines
with design operating temperatures over 300 degF (150 degC).

5.2.7 The Client’s Engineer shall witness “Cold” and “hot” alignment checks.

5.2.8 Records of pipe flange misalignment showing the effect of the piping
connections on the machinery shaft alignment shall be provided to the
Client’s Engineer. The following data are required:
5.2.8.1 Ambient temperature at which flange misalignment is measured.
5.2.8.2 Machine-to-driver shaft alignment: (readings before, during and after
flange bolt tightening).
5.2.8.3 Radial alignment: (maximum dial gage runout measured
perpendicular to the shaft on the rim of the coupling hub).
5.2.8.4 Axial alignment (maximum dial gage runout measured parallel to the
shaft on the face of the coupling hub near the rim).
5.2.8.5 Flange misalignment: (final “cold” alignment and “hot” alignment).
5.2.8.5.1 Vertical bolt hole offset
5.2.8.5.2 Horizontal bolt hole offset
 5.2.8.5.3 Rotational offset
5.2.8.5.4 Flange face parallelism
5.2.8.5.5 Flange face separation

5.2.9 Machinery-to-driver misalignment limits recorded during “cold” alignment of

piping shall be per the following:

Flange Joint

This presents Fiber Glass Systems recommendations for the proper use of fiberglass flanges.
The mounting of flanges on the pipe is addressed by the assembly instructions for the particular
joint
type and adhesive used.

7.3.3.1 Fiberglass flanges

(1) Flanges are used in pipe systems to connect appendages and equipment, or to make
connection
with other lines of similar or other material.

(2) It also gives the ability to divide a pipeline into several (prefabricated) sections making it easier to
install. Three types of flanges are available. Depending on the application and pressure one of
the below described flanges can be used.

7.3.3.2 Tooling, Gaskets, Bolt length

(1) Tooling

Check the presence and quality of joint material (bolt, nut, washer, gasket) and tooling. The
tooling
 and joint material listed below are, as a minimum, required to make a flanged joint. A torque
wrench and a ring spanner are required for proper assembly of fiberglass flanges.

● Level / Torque wrench / Ring spanner

● Flange square / Winches / Band clamp / Steel cross

(2) Gasket

● For hubbed flanges use a full-face gasket of a reinforced elastomer.

● For heavy duty flanges use a full-face or raised face gasket of a reinforced elastomer or
compressed fiber.

● For o-ring sealed stub end flanges use an o-ring. For flat faced stub end flanges use a
raised
face gasket of a reinforced elastomer or compressed fiber.

● When connecting to rubber lined valves, use either flat faced stub end flanges or insert a
spacer ring between valve and flange.

7.3.3.3 Bolt length

Note that flanges are thicker than metal flanges and require washers. This should be taken into
account when calculating the bolt length. For flange thickness, see the appropriate product
datasheet on dimension data.

7.3.3.4 Alignment, Connecting to other pipe systems

7.3.3.4.1 Alignment

(1) Flange joints shall be installed aligned and stress free. Never pull flanges together by
tightening the bolts.

(2) Leakage problems due to misalignment could be solved by using o-ring type gaskets.

FLANGE FACE TO FACE GAP

PIPE SIZE
(A)
< 300 mm 0
> 350 mm 3 – 5 mm
7.3.3.4.2 Connecting to other pipe systems

When pipe is connected to metal pipe systems, the interface should be anchored to prevent
movement or loads being transmitted to the pipe system.

7.3.3.5 Flange jointing

7.3.3.5.1 Place gasket

Place the gasket between the two flange faces.

7.3.3.5.2 Insert bolts

Insert the bolts and finger-tighten all nuts. Bolt threads must be clean and lubricated to attain
proper
torque. Use lubricated washers under both nuts and bolt heads to protect flange back face.

7.3.3.5.3 Tighten bolts

Tighten all nuts following the sequences shown under “tightening sequence”. After all bolts
have
been tightened to the recommended torque, re-check the torque on each bolt in the same
sequence,
since previously tightened bolts may have relaxed.

7.3.3.6 Tightening sequence