OPERATIONAL EXCELLENCE
MANAGEMENT SYSTEM
(OEMS)
Refining ＆ Trading
MRCSB
Engineering
Administrative
Procedure
06 Physical Asset Management
06_03_02-L3 PSM-MI-20433 BFJA JIT Management
Procedure
03 Maintenance Management
02 Maintenance Planning, Scheduling ＆
Execution
PSM-MI-20433 BFJA JIT Management
Document Ref. No.:
MRCSB-06_03_02-L3-017746
Revision:
7
Published:
1 August, 2022
Next revision date:
1 August, 2025
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OPERATIONAL EXCELLENCE
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Engineering
06 Physical Asset Management
Administrative
Procedure
06_03_02-L3 PSM-MI-20433 BFJA JIT Management
TABLE OF CONTENTS
1.
PURPOSE .......................................................................................................... 3
2.
SCOPE ............................................................................................................. 3
3.
PERFORMANCE MEASUREMENTS ........................................................................... 4
4.
PROCEDURE ...................................................................................................... 6
5.
ROLES AND RESPONSIBILITIES .......................................................................... 14
6.
DEFINITIONS .................................................................................................. 18
7.
LINK WITH OTHER DOCUMENTS ......................................................................... 20
8.
ATTACHMENTS ................................................................................................ 20
9.
DOCUMENT HISTORY ........................................................................................ 22
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OPERATIONAL EXCELLENCE
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06 Physical Asset Management
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06_03_02-L3 PSM-MI-20433 BFJA JIT Management
1. PURPOSE
This document is a major revision of previously issued PSM-MI-20433 Joint Integrity (JIT)
Management procedure. It consolidates and streamlines all previously issued MI procedures for
Bolted Flange Joint Assembly (BFJA/JIT) works as listed below. These MI procedures are
combined into this document and the below document will be removed.
a. PSM-MI-20401 Bolt Tensioning
b. PSM-MI-20405 Assembling Flanges (Flange Make-up)
c. PSM-MI-20407 Blinding/De-blinding for Isolation/Normalizations including First
Break
d. PSM-MI-30401 Re-Torquing and Leakage Control
e. PSM-MI-30414 Control Torquing
This procedure provides requirement in managing the integrity of a bolted joint assembly works,
from identification of joints to selection of bolt tightening method, detail execution and result
documentation.
2. SCOPE
This procedure shall apply to
2.1
2.2
All nominal pipe diameter of bolted flange joint assemblies.
All equipment girth flanges and nozzle flanges as per clause 2.1 unbolted for
maintenance activities or energy isolation purposes.
2.3 All INTERNAL JOINTS for C1 Criticality Equipment as per OEM requirements. OEM BFJA
manual/specification shall be referred to.
For e.g., Catalyst Transfer Pipe (CTP) for CCR UOP Reactors R-23201/2/3/4 which have specific
OEM / Licensor requirement.
The guideline provided shall be followed for joint making on piping flanges and process
equipment during routine maintenance activity and plant modification project work in MRCSB
including Major Turnaround work executed by TA Planning team.
It is also applicable for battery limit blinding and process blinding activity
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06_03_02-L3 PSM-MI-20433 BFJA JIT Management
3. PERFORMANCE MEASUREMENTS
SAFETY
Prior to starting the work, Assigned Person shall ensure all necessary safety precautions have
been carried out and it is safe to execute the BFJA/JIT works in accordance to all safety
requirements specified in the this procedure, Permit To Work (PTW) and all relevant HSEMS
procedures.
Observe and identify hazards involved with the works. If necessary, Job Hazard Analysis (JHA)
shall be conducted prior to execution. All hazards information shall be communicated and
understood by all parties involved prior to work execution.
Consider the requirements for special Personal Protective Equipment (PPE) such as heat
resistance suit and gloves, SCBA, chemical suit, splash goggle, or others for
blinding/deblinding work and Re-Torquing or Leakage Control Works.
Caution
The close proximity of the stud and self-reinforced nozzles shown below had
cause SERIOUS hand injury during prior tightening activity. As such, GAPS
SHALL BE made available to allow ring spanner application for any tightening
works.
Special considerations for Re-Torquing and Leakage Control Works
As these works are performed while equipment or piping is in operating condition, High
Pressure and/or High Temperature hazards should always be observed and identified prior to
work execution.
All Leakage Control Works performed on hydrocarbon/toxic services may require usage of
breathing apparatus (SCBA) during work execution as specified in JHA.
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06_03_02-L3 PSM-MI-20433 BFJA JIT Management
The gasket material of the joint shall be determined prior to execution. Compressed, nonasbestos gasket (NAF) shall never be Re-Torqued due to its rubber content which degrades
and hardens. Re-Torquing can cause gasket failure due to fracture.
Teflon based gasket will deformed after being re-torqued as these are soft at elevated
temperature. Re-Torquing of these gaskets shall only be done after process cycle while the
equipment or piping is cooled.
PERSONNEL
Only trained and competent Assigned Person’s JIT Inspector and Assigned Person MRCSB
trained by TCU are allowed to perform the BFJA/JIT management works as specified in this
document.
JIT Inspector trained by TCU after undergoing JIT training are allowed to perform the BFJA/JIT
management works and to lead joint making and bolt tightening works. He/She can be
MRCSB staff or contractor staff.
Only Competent Contractor Fitter confirmed by TCU after passing ECCA assessment are
allowed to perform joint making and bolt tightening works.
Only trained and competent HTW and HBT operators are allowed to perform joint making and
bolt tightening activities using these machines.
TOOLS AND EQUIPMENT
All necessary hand tools shall be prepared, inspected and tested prior to the execution of
BFJA/JIT works. Correct sizes of tools to be used must be correctly pre-determined to avoid
any damages or injuries. Sufficient numbers of JIT Tags and JIT Record Forms shall be
prepared and filled correctly. For equipment with frequent routine maintenance works, JIT
Record Book shall be used in-lieu of the JIT Record Form.
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All JIT tools (MTW, HTW & HBT) need to be inspected and calibrated before starting of job.
The power and control unit of the hydraulic torque wrench and bolt tensioning machine shall
be inspected to ensure ability to provide required pressure during tightening. Calibration
sticker for measuring gauge shall be valid and the hydraulic unit shall have inspection sticker
validated by MRCSB. These requirements are necessary prior to work.
All tools shall be non-sparking and of industrial standards. Modified or self-fabricated tools
shall not be used.
4. PROCEDURE
PREPARATION
Prior to executing any BFJA/JIT works, a walkabout shall be carried out by Assigned Person with
Area Operation Technician (OTF) to identify the correct joint(s) to be blinded/de-blinded,
assembled and tightened. The blinding list (either EIS-Equipment Isolation Sheet or PIS-Process
Isolation Sheet) shall be obtained from Area Operation and approved by Area Owner. These
joint(s) shall be correctly marked in the blinding list and subsequently tagged with JIT tag with
reference number to the blinding list upon site verification.
Evaluate site condition for height and space restrictions to ensure safe execution of work.
Identify requirement for scaffolding for working at heights, and clear working area for any
obstructions.
BFJA/JIT Management Workflow (Attachment A) provides guidance in the execution of BFJA/JIT
Management works in accordance with this procedure and the correct utilization of JIT Tag, JIT
Record Form and/or JIT Record Book.
Assigned Person shall obtain the recommended bolt tightening method and required torque
value for each joint from respective tables in Attachment E. For non-standard joints, torque
value shall be obtained from respective Mechanical Static Engineer.
Method Selection for Flange Tightening (Table 1) and Recommended Torque Tables (Attachment
E) shall be used as reference.
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Table 1 : Method Selection for Flange Tightening
Note:
1) If HBT is not practical at site e.g., tool restriction due to clearance around nut and fillet
geometry, switching to HTW will be under approval of Technical Authority and with proper
documentation
Note: Refer to Attachment U for HBT Exception List
2) Critical Joints are defined as per item 6.0 Definitions
3) For oxygen service piping/flanges shall follow as per stipulated in Attachment Q
New bolts and nuts that will be used for JIT activity shall have marking. In case of missing
marking or new bolts and nuts without any marking, contractor shall mark the bolts & nuts with
permanent marking.
For proper bolt and nuts arrangement, contractor shall provide container or storage after bolts
cleaning activity.
All incoming materials (gaskets, bolts, nuts etc.) shall be inspect and verify by competent
personnel.
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Any deviation from approved specification, shall notify MRCSB personal in charge and CAF shall
be raised for documentation purposes.
Personal’s Responsibility
Responsibility
Actions
Assigned Person
4.1
and Area
Identify the bolted flange joint from P&ID and EIS as
reference.
Production
Technician (OTF)
4.2
Perform site verification of BFJA/JIT joints. Sign the White
Section of JIT tag and attached it on the joint.
Assigned Person’s
4.3
Inspector
Verify correct tightening method and recommended torque
value per Tables in Attachment E. Torque values for nonstandard joints shall be obtained from Mechanical Static
Engineer.
Assigned
4.4
Fill in Section I of JIT Record Form.
4.5
Perform the Flange Break activities in accordance with
person/JIT
inspector
Attachment G: Blinding/De-blinding for
Isolation/Normalization including First Break and HSEMS20050 (LOTO)
Caution:
First break of flange shall be done under SCBA / Air line
for Hydrocarbon, Nitrogen environment, service contain
H2S and with the presence of the Assigned Production
Personnel (reference: PRD-OPP-CP-022 Equipment
Isolation and Blinding /De-Blinding).
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To review JIT list prepared by contractor during the
Assigned Person
4.6
planning stage
4.7
Conduct Assessment on the joint faces, studs and nuts in
and JIT Inspector
accordance to Attachment H: Bolt Joint Assembling Flanges
(Flange Make-up). Fill and sign section II of JIT Record
Form.
Assigned Person
4.8
Perform flange repairs (if any) in accordance to approved
repair procedure.
Assigned Person
4.9
and JIT Inspector
Perform BFJA/JIT make-up work in accordance to
Attachment H: Bolt Joint Assembling Flanges (Flange Makeup).
Ensure correct tightening method is used.
Refer to Attachment I: Control Torquing for tightening
works using MTW and HTW.
Refer to Attachment J: Bolt Tensioning for tightening works
using HBT.
Record the tightening details in Section III of JIT Record
Form
Assigned Person
4.10
Measure and record the flange gap and alignment and
conduct joint inspection after tightening activity. Sign the
Green Section of JIT tag.
Assigned Person
and JIT Inspector
4.11
Fill Section IV of JIT Record Form.
4.12
Perform pressure/leak test (if required).
4.13
Upon acceptance pressure/leak test and BFJA/JIT works,
Sign Section V of JIT Record Form.
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Assigned Person’s
4.14
MRCSB
Assigned Person
Verify completion and acceptance of BFJA/JIT works and
Sign Section V of JIT Record Form
4.15
Remove JIT Tag from the joint and attach to its JIT Record
Form.
Attach copy of JIT Record Form (Attachment C) to
completed MWO before TECO for Routine Maintenance
Work. Include JIT Record Form (Attachment C) for final
project document for plant modification work.
Tasks 4.17 to 4.22 are only applicable for BFJA/JIT that requires Re-Torquing or Leakage
Control Works.
Assigned Person
4.16
Obtain the initial JIT Record Form (Attachment C) of the
joint.
Assigned Person
4.17
Perform the BFJA/JIT Re-Torquing and/or Leakage Control
Works in accordance with Attachment K: Re-Torquing and
Leakage Control Works.
Record tightening details and process parameters in Section
VI of JIT Record Form (Attachment C)
4.18
Measure and record the flange gap, alignment and conduct
joint inspection after tightening activity. Fill Section VII of
JIT Record Form.
4.19
Upon acceptance of works, sign Section VIII of JIT Record
Form.
Attach JIT Record Form (Attachment C) to completed MWO
before TECO for Routine Maintenance Work. Include JIT
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Record Form (Attachment C) for final project document for
plant modification work.
Assigned Person’s
4.20
Verify completion and acceptance of BFJA/JIT Re-Torquing/
Leakage Control Works and Sign Section VIII of JIT Record
MRCSB
Form.
Area Production
4.21
Supervisor OTF/PE
Verify acceptance of BFJA/JIT Re-Torquing/ Leakage Control
Works and Sign Section VIII of JIT Record Form
SUSD
Tasks from 4.23 is only applicable for BFJA/JIT for Frequent Routine
Maintenance Work [Frequency of once (1) a month or more].
AMT Manager &
4.23
Operation Engineer
To develop Area Specific Routine Maintenance Task List
(Attachment W)
To develop Equipment Isolation Sheet (EIS) with running
number & fixed Joint Number
Area Static
4.24
Engineer (MTS)
Area Manager &
Maintenance Task List
4.25
Principal Static
Assigned Person &
To review and endorse Area Specific Frequent Routine
To review and approve Area Specific Frequent Routine
Maintenance Task list
4.26
Identify bolted flange joints for all equipment in the Area
Area Operator
Specific Frequent Routine Maintenance Task List using P&ID
(OTF)
and EIS as reference.
Assigned Person
4.27
Perform site verification of BFJA/JIT joints.
4.28
Fill in Attachment D for all the BFJA/JIT joints for every
equipment’s declared
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Assigned Person
4.29
Verify and approve the filled Attachment D forms.
Maintenance work
4.30
To maintain filing for the approved Area Specific Frequent
Coordinator (MWC)
Routine Maintenance Task List and Attachment D forms
4.31
Communicate & brief on BFJA/JIT requirements based on
the filled in Attachment D form to the manpower performing
the tasks at site.
4.32
Attach the respective Attachment D form to the PTW for the
assigned task
Assigned Person &
4.33
Supervisor
Fill in Attachment D (JIT Completion Sheet) after work
completion and approval by Supervisor
ACCEPTANCE CRITERIA
For all BFJA/JIT and Re-Torquing works, the following conditions shall be met after final
torquing:
a.
No movement of nut at target torque value or 100% of tensioning.
b.
Flange gap shall be uniformed and any difference in gap shall be within 0.5 mm
measured across any diameter
c.
Flange lateral misalignment shall not exceed the following values
Table 2 – Maximum Lateral Misalignment for BFJA/JIT
NPS (DN)
Maximum Misalignment
≤4” (100)
2mm
>4” (100)
3mm
d. No leaks at joints during pre-commissioning and commissioning.
For Leakage Control Works, all conditions below shall be met
a. No leaks
b. No movement of nut at final torque value
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c. Flange gap shall be uniformed and any difference in gap shall be within 0.5 mm
measured across any diameter.
d. Flange misalignment shall not exceed values in Table 2 above.
e. Gasket centering metal ring is not pressed or compressed. (Flanges using Spiral Wound
Type Gaskets)
Prohibition
a.
Metal jacketed gasket is not allowed to be used at any joints.
b.
Usage of torque multiplier is not recommended. If still require to be used, Contractor
Shall get approval from MRCSB’s technical authority.
APPROVED LUBRICANT
For common / standard carbon steel flanges
MOLYKOTE 1000™
;
µ= 0.13 (Coefficient Of friction), K=0.17 (Nut Factor)
DRY
;
µ= 0.16 (Coefficient Of friction), K=0.20 (Nut Factor)
For stainless steel flanges in extremely high temperature (> 350 Deg C),
P37
;
µ= 0.14 (Coefficient Of friction for thread), K=0.18
;
µ= 0.09 (Coefficient Of friction for head), K=0.13
Or equivalent and suitable which is chemically compatible with the bolt/nut/washer materials
and the process fluid. Particular care should be taken to avoid lubricant chemistry that could
contribute to stress corrosion cracking, galvanic corrosion, oxygen auto-ignition, etc.
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5. ROLES AND RESPONSIBILITIES
BFJI Execution Personnel Work Matrix
Roles
Technical Capability Unit (TCU)
Responsibilities
Responsible to provide JIT training and assessment.
Upon successful completion of relevant training courses
and subsequent passing of mandatory tests, contractor
candidates will be confirmed as JIT Competent Person by
issuance of JIT Visa card. TCU also responsible to
conduct assessment under Contractor Competency
Assurance to confirm as Competent Contractor Fitter.
TCU is responsible to train contractor experience fitter to
become JIT supervisor.
Maintenance Planner or Project
Responsible in ensuring the preparedness of the team
Engineer
prior to work and provide the correct tools and
specifications. He shall ensure the availability of flange
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repair contractor to repair the flange gasket face(s) in
the event of any damage or out of tolerance is found. He
shall also ensure that MTW/HTW/HBT Torqueing Team
presents or possess certificate.
Area Production Technician (OTF)
Responsible to identify correct bolted flange joint as per
Equipment Identification Sheet (EIS), Equipment
Drawings, ISO and P&ID. During tagging exercise, he
shall sign the MRCSB (OPERATIONS) section of JIT Tag
(WHITE Part).
Area Production Supervisor (OTF/PE
Responsible to ensure safe working conditions before any
SUSD)
BFJA/JIT works is executed. He shall acknowledge and
sign Section VIII of JIT Record Form upon completion of
Re-torquing or Leakage Control Works.
Shall provide information on operating parameters
Operation (Facility SUSD)
(pressure and temperature) of the equipment and piping
flanges.
Mechanical Static Engineer (MTS)
Shall review technical information of the joint making
Note: Engineer scope only for non-standard flange. Torque
works with advice from Technical Professionals. He shall
values for standard flanges shall be retrieved from Tables in
Attachment E.
specify the correct bolt tightening method in accordance
with Method Selection for Flange Tightening (Table 1)
and verify correct torque value for each joint per
Manufacturer’s Data Book, Supplier Data Book, P-Bolt
Calculation and/or Recommended Torque Table supplied
as Attachment E of this document.
Fitter
Responsible to execute, disassembly and assembly of the
joint as well as control torquing using Manual Torque
Wrench (MTW). He/she must have undergone
Engineering Contractor Competency Assurance (ECCA)
assessment by TCU and be confirmed with ECCA green
sticker on safety visa by TCU. He/she responsible to fill
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up Section II & III of JIT form and, at least 1 pax shall
be available in each fitter team.
Control Bolting Technician Level 1
For HTW Activities
Responsible to execute, disassembly and assembly of the
joint as well as control torquing using Hydraulic Torque
Wrench (HTW). He/she must have undergone Control
Bolting Technician Assessment (CBTA). For control
bolting technician level 1, at least 1 pax shall be
available in the team for HTW activities. He/she
responsible to fill up Section IV, VI and VIII of JIT form.
Control Bolting Technician Level 2
For HBT Activities
Responsible to execute, disassembly and assembly of the
joint as well as control torquing using Hydraulic Torque
Wrench (HTW) and Hydraulic Bolt Tensioning (HBT).
He/she must have undergone Control Bolting Technician
Assessment (CBTA). For control bolting technician level
2, at least 1 pax shall be available in the team for HBT
activities. He/she responsible to fill up Section IV, VI and
VIII of JIT form.
JIT Inspector (Staff/Contractor)
Responsible to supervise the joint execution/final
torquing works and certify joint completion as
Contractor’s representative. Upon joint completion, he
shall sign the JIT Supervisor section (Joint Completion,
Joint Set-up and Tightening) of the JIT Tag (GREEN Tag).
In JIT form, He/she shall fill up and sign Section I until
IV and also Section VIII. During Turnaround / Shutdown,
He/she is from Contractor side while during normal
routine whereby Contractor is not involved, JIT
Supervisor shall be Mechanical Technician.
Assigned Person / JIT Verifier
A person that will verify the work done by JIT
(Staff)
Supervisor. Assigned Person is also a JIT Supervisor if it
is done internally by MRCSB staff. He/she must be
trained as JIT Competent Supervisor thru JIT Supervisor
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assessment. He/she shall sign Section V and VIII. He/she
is competent to provide inspection report and
recommendation in accordance with ASME PCC I
acceptance criteria and competent to provide Nonstandard joint calculation. He/she shall be able to verify
the JIT work vs requirement in PSM-MI-20433 Bolted
Flange Joint Assembly (BFJA/JIT) Management
Procedure. During outside office hour (On-call) job,
Assigned Person will be also act as Assigned Person’s
Supervisor.
JIT Verifier Leader (Staff)
Shall be competent to lead and coordinate JIT verifier
team, review inspection report and recommendation in
accordance with ASME PCC I acceptance criteria. He/she
shall be competent to lead Non-standard joint calculation
and lead the JIT work vs requirement in PSM-MI-20433
Bolted Flange Joint Assembly (BFJA/JIT) Management
Procedure.
JIT Manager/ Assigned Person’s
Responsible to ensure that the Assigned Person is
Inspector (Staff)
competent and trained to perform the work and certify
the completion of the joints. He shall ensure the correct
materials and tools are available and used throughout
the execution of BFJA/JIT works. He shall sign Section V
of JIT Record Form upon acceptance of BFJA/JIT works
and Section VIII upon acceptance of Re-Torquing or
Leakage Control Works.
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6. DEFINITIONS
The following definitions apply for the purpose of this procedure.
Terms
Definitions
Bolted Flanged Joint
Pressure-boundary flanged joints with ring-type gaskets that are
Assembly (BFJA/JIT)
entirely within the circle enclosed by the bolt holes and with no
contact outside this circle
Manual Torque Wrench
Wrench with positive (Click) indication when required torque is
(MTW)
achieved.
Hydraulic Torque Wrench
Two of the most common means of tightening large bolts, where
(HTW) and Hydraulic Bolt
high bolt loads are required.
Tensioning (HBT)
machine provide the tension by the amount of rotational force
Hydraulic fluid pressure in HTW
applied on the bolt while Bolt tensioning machine applies preload
to a bolt by stretching it axially.
Re-Torquing
Proactive mean by retightening of bolts to maintain tightening
force of the bolts during the process of temperature increase or
after a certain relaxation period has passed.
Re-Torquing shall
be performed on all flanges in high temperature service
(operating temperature above 200oC) having Leak History. ReTorquing work shall be carried out twice, at 50% and 75% of the
operating temperature.
Leakage Control Works
Reactive mean by tightening joints when leaks occur during
operation due to thermal expansion, inherent vibration, reduced
gasket properties, damaged sealing surface or other situations
where unit shutdown is not planned, or items not taken out of
service.
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Routine Maintenance Work
A set of mechanically regular activities that is carry out at
minimum
Bolt
frequency of once (1) in a month.
Term refers to all type of threaded fastener that may be used in
a pressure-boundary BFJA such as a machine bolt, stud bolt, etc.
Working Surfaces
The term “working surfaces” refer to those interfaces between
fastener components and/or fasteners and flanges that slide past
one another during tightening or loosening
Critical Joints (Touched or
Untouched)
Critical Joints are defined by the following criteria:
i.
Flanged Joints with leak history as per Critical Flange
Management Procedure ref: PRD-OPP-CP-052
First Break
ii.
Joints with RTJ flange & gasket
iii.
Operating temperature above 350 deg
iv.
Joints with special gasket or OEM proprietary design
Opening of piping flange or equipment flange. See PRD-OPP-CP022 Equipment Isolation and Blinding /De-Blinding for definition
of First Break flange for Normal Operation or Partial Shutdown,
OR during Turnaround.
WARNING: Not allowed to
break joint without JIT tagging
in place.
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7. LINK WITH OTHER DOCUMENTS
The JIT Record Form shall be duly completed for each BFJA/JIT works.
Reference
ASME PCC-1-2013
Document Name
Guidelines for Pressure Boundary Bolted Flange
Joint Assembly
PTS 12.00.03
Workshop Equipment and Mechanical Tools
Petronas Technical Paper
Joint Integrity Technical Sharing Presentation
by PGTS (to define…)
M-46-BP-7 Revision 4
Phillips 66 Recommended Best Practice for
Joint Make-up
Technical Paper by Gary Sears from
Guidelines for the Management of Integrity
Hydratight Sweeney
Pipe Joints
PTS 12.00.60
PTG – 12.00.06
Bolted Flange Joint Assembly
(Amendments/Supplements to ASME PCC-1)
Guideline for Bolted Flange Joint Integrity
(BFJI)
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8. ATTACHMENTS
A
BFJA/JIT Management Workflow
A1
BFJA/JIT Joint List Registration Flow
A2
BFJA/JIT Workflow for Turnaround (TA)
B
Joint Integrity (JIT) Tag - 4 colors
C
Joint Integrity (JIT) Record Form
D
Joint Integrity (JIT) Record Form for Routine Maintenance Work
E
Recommended Torque Tables
F
RACI Chart
G
Blinding/De-blinding for Isolation/Normalization including First Break
H
Bolt Joint Assembling Flanges (Flange Make-up).
I
Control Torquing
J
Bolt Tensioning
K
Re-Torquing and Leakage Control Works
L
Sample of JIT/BFJA Execution Team Organization Chart
M
Best Practice for Stud Bolt and Lubricant Application
N
Sample of Blinding List
O
Original Equipment Manufacturer (OEM) Specific Torque Value
P
JIT Component Strategy
Q
JIT Inspection report
R
Oxygen Service Piping
S
JIT Personnel Competency Development Plan Guideline
T
Scope Demarcation
U
HBT Exception List
V
PSR-1 P-Bolt Summary
W
X
Area Specific Routine Maintenance List
DIGITAL FLANGE INTEGRITY TOOLS (DIGI-FIT)
Y
Audit check list form for (BFJA)
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9. DOCUMENT HISTORY
Attachment : Revision History
Revision
No.
Revised By
Approved
By
Approval
Date
Description
0
MZAR
AE
30/1/2015
These MI procedures are combined into
this document and the below document
will be removed.
a. PSM-MI-20401 Bolt Tensioning
b. PSM-MI-20405Assembling Flanges
(Flange Make-up)
c. PSM-MI-20407 Blinding for Isolation
including First Break
d. PSM-MI-30401 Re-Torquing and
Leak Control
e. PSM-MI-30414 Control Torquing
Improvement on responsibility person.
Scope includes plant modification.
Add requirement to attach JIT Form to
SAP prior to TECO or in Final project
document for plant modification project
work.
Additional requirement to check flange
flatness prior to flange make-up
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1
MZAR
AE
10/8/2015
Additional responsibility for Maintenance
Planner/Project Engineer
Additional responsibility for Technical
Capability Unit (OEX), Assigned Person,
Additional requirement in Sect II of
Sample of Joint Integrity (JIT) Record
Form
Additional information in Attachment H
: Bolt Joint Assembling Flanges (Flange
Make-up) [Guideline]
Added up Attachment L : JIT/BFJA
Execution Team Organization Chart
Scope includes Major Turnaround
Scope includes battery limit blinding
and process blinding activity.
Area Production Supervisor; replace
accepted with acknowledge
Scope of assigned person during On-call
Improvement on JIT tag look
Improvement on Attachment C: Joint
Integrity Record Form
Improvement on Attachment D: Joint
Integrity Record Form for Routine
Maintenance Work
Improvement on Attachment E:
Recommended Torque Tables
New attachment:
-
-
-
Attachment L: JIT/BFJA
Execution Team Organization
Chart
Attachment M: Best Practice for
stud bolt and lubricant
application
Attachment N: Sample of
Blinding List
Attachment O: Original
Equipment Manufacturer (OEM)
Specific Torque Value
Overall, replace certified with trained
or confirmed
Additional requirement Attachment A:
Joint Integrity (JIT) Workflow
Additional requirement in Sect 9
PREPARATION
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Removal of AIM from procedure
Attachment J: Bolt Tensioning
[Guideline]
1.0 Procedures
Include in 2.4 and 2.9
Assemble the bolts to the flange
with extra thread length (1D)
protruding above the hexagon
nuts on the side of the flange on
which the tools are to be used.
Addition and Update; Attachment E:
Recommended Torque Tables
2
MFFMF
ARAR
21/6/2016
Additional responsibility for Assigned Person
Additional requirement added in workflow
Attachment A: Joint Integrity (JIT) Workflow
Updated JIT Tag to include flange size and rating
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3
MFS
EAA
5/1/2017
Revised responsibility for Area Production
Supervisor, Assigned Person and Assigned
Person Supervisor
Included new definitions for Bolt, Working Surfaces
and Critical Joints
Amended torqueing method selection for H2S
service, more than 1.5 inch, class rating should be
above 600# for HBT application
Included disclaimer for downgrading HBT to HTW
Amended final flange gap acceptance criteria
Section 11
Improved flow chart for TA to include instructions
to remove sections of JIT tag upon activity
completion
Amended JIT Tag to include Gasket Specifications
Included new JIT tag with distinct color and
required signature for Critical and Normal Joints for
TA
New improvised JIT form
New JIT sheet
Included new torque table for Gr. 660 bolt
Amended Att. H, 3.1 to use soft brass wire brushes
Included new para. for graphite residual
acceptance Att. H, 3.1
Added paragraph for guide on inspection after
breaking flange Att. H, 3.2
Added notes for flange gap alignment prior
tightening Att. H, 3.4
Added statement on approved lubricant for
stainless steel flanges in extremely high
temperature Section 12
Added para. and Caution notes for bolt reuse Att.
H, 3.2
Added clause for lubricant Att. H, 3.3
Added clause and sample picture of prohibited use
of masking tape for gasket adhesive
Added caution for application of graphite tape Att.
H,3.7
Added statement for method to gauge
misalignment in flanges Att. H, 3.11
Revised and removed old appendix on Attachment
H
Added note for minimum HTW tool on critical joints
Att. I, 2.6
Added note and sample numbering sequence for
split ring type joint tightening sequence
Improved clause for final pass of tightening Att. I,
2.14
Added clause for leakage control Att. I, 2.16
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Added new note for torque value for low yield
strength bolts Att. I ,2.5
New revised figure for bolt numbering sequence
and table for legacy tightening Att. I, 4.0
Added clause for information required for HBT Att.
J, 1.0
Revised clause for percentage of bolt tightening
Att. J, 2.1
Updated PTS numbering and name reference
Aligned final acceptance criteria per Section 11 for
Att. K, 4.14
Added reference for torque table for re-tightening
Att. K, 4.15
Added recommended manpower loading Att. I, Org
Chart
Revised bolt replacement criteria Att. M
Amended unit for minimum torque value to ft.lb Att.
O
4
EAA
MNIK
23/5/2017
Added First Break definition and Flange Break
activity for blinding/de-blinding for Normal
operation and Partial shutdown taking excerpt from
PRD-OPP-CP-022 Equipment Isolation and
Blinding/De-Blinding Procedure requirement to
have mandatory presence of Production Personnel
during activity. Recommended Action from Incident
Investigation First Aid Case due to contact with
Flushing Diesel at E-21256B/C on 10 Feb 2017.
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5
HA
MAR
17/11/2017
Replaced PP(M)SB with MRCSB.
Revised responsibility of Mechanical Static
Engineer, JIT Supervisor, Assigned Person/JIT
Verifier and introduced responsibility of Competent
Fitter Level 1&2, Control Bolting Technician Level
1&2 and JIT Verifier Leader.
Added requirement for first break.
Added Oxygen Service and Critical/Thermal Shock
in 'Method Selection for Flange Tightening'.
Added Procedure of Handling Oxygen
Piping/Flanges included in 'Attachment Q'
Removed JIT Tag – 2 colours.
Added approved lubricant that can be used for
stainless steel flanges in extremely high
temperature.
Additional info and some amendment in JIT
Inspection form.
Amended recommended torque value for Table
E5, E8 and E9.
Added Recommended Value Table E16, E17, E18
& E19.
Included JIT Inspection Report as per 'Attachment
P'.
Added workflow for Attachment A1: BFJA/JIT Joint
List Registration Flow.
Added pre-check requirement for critical joint
added in JIT Form.
Added Non-Standard Joint in 'Attachment E:
Recommended Torque Table Summary'.
Amended value for 1" Stud size for 'Table E1Recommended Torque Values at 60% Bolt Yield'
Amended RACI Chart in 'Attachment F'.
Added clear statement for bolt size and its
requirement for round 5 of bolt tightening.
Added Attachment P: JIT Components Strategy
Added Attachment S: JIT Personnel Competency
Development Plan
Added Attachment T: Scope Demarcation
6
MB
MNIK
13/11/2018
Added HBT Exception List & PSR-1 P-Bolt
Summary Attachments
7
MB
MNL
3 Apr 2020
1.
2.
3.
4.
Added Tasks 4.23 – 4.34 for Routine
Maintenance BFJA/JIT Tasks
Amended Attachment D Form for Routine
Maintenance
Added Attachment W for Area Specific
Equipment List with Routine Maintenance
Amended Table E1 – E11 to follow latest PTG
BFJA JIT
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8
MB/ HA / ARAR
Revision
No.
9
Revised By
MB/HA
MNL
28 May 2020
Approved
By
Approval
Date
MNIK
19.3.2022
1.
SCOPE: ADD scope of Internal joints as per
INC/2019/RA/0151-09-01 CCR Action item.
2.
ITEM 4 PREPARATION: REPLACE Table 1 :
Method Selection for Flange Tightening with
MRCSB MI table because more
comprehensive as it based on MRCSB
experiences in actual site application and
Lesson Learnt.
3.
ATTACHMENT E: REMOVE "Table
Summary" in Attachment E. To follow PTG
new recommendation.
4.
ATTACHMENT E: ADD Table E19 Recommended Torque Values for Bolts used
at SPM CALM Buoy (Spiral Wound Gasket
and Hoses as per PTG new recommendation
Description
1.
2.
3.
4.
5.
6.
Amended Attachment C on JIT Form section 1 add
item (AFC Plug material)
Improvement on responsibility person suit to OER2
Amended Table E4 with latest correct bolt load
calculation based on bolt coefficient for lubricant
P37 with approved lubricant that can be used for
stainless steel flanges in extremely high
temperature.
Add new revised recommended torque value for
from Table E1, till 11 for bolt size 13/8’’ nut size
55mm
Add new deployment strategies for digital flange
management (Digi Fit)
Add new attachment Y Audit check list form for
(BFJA)
Document Authorisation
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Author:
Mukhriz B Badarudin (ENG/MRCSB)
Date:
14 July, 2022
Reviewer:
Eddy Azrai B Ariffin (ENG/MRCSB);
Date:
22 July, 2022
Approver:
M Nasrul Islam B Kupordin (ENG/MRCSB)
Date:
1 August, 2022
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Supporting Document Link
No.
1
2
3
4
Supporting Documents
PSM-MI-20433 BFJA JIT-MB-signed
PSM-MI-20433 MRCSB Joint Analysis Summary List_2019.7.31 (002)
PSM-MI-20433 P Bolt Summary TA 2018
PSM-MI-20433 BFJA JIT Management
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