Flange Management Procedure IFU

Document Title: Flange Management Procedure
COPI Doc No.: ID-N-SB-LL0-PRO-ST-00-0001
Originator: PT. Wijaya Karya (Persero). Tbk

COPI Group Owner: Engineering-O
Area: Suban
Location: Suban Station
System: General
Document Type: Flange Management Procedure
Discipline / Subdiscipline: Piping / Piping
Old COPI Document No.:
0B IFA 12 Okt 2012 Issued for Approval GP ZR AGN MER / HS AIB

0A IFC 18 June 2012 Issued for Comment AR FAD AGN MER / HS AIB
Prepar Check OEE / Project Unit Owner

Rev Status Issue Date Reason for Issue Approval
ed ed Approvals
Printed initials in the approval boxes confirm that the document has been signed.
The originals are held within Document Management.
Procedure/Work Instruction/Job Note: ID-N-SB-LL0-PRO-ST-00-0001
Flange Management Proceure
ConocoPhillips Indonesia Page 2 of 32
Revision Sheet
ConocoPhillips Indonesia Inc. Ltd
REVISION DATE DESCRIPTION OF CHANGE
0A 18 June 2012 Issued for Comment

Refer to COPI Specification or Procedure ID-G-BU-00000-00000-
0B 12 Okt 2012
01548 In-Service Flange Integrity Guidline.
Table of Contents
Table of Contents....................................................................................................................................... 3
1 Introduction............................................................................................................................ 4
1.1 Purpose................................................................................................................................... 4
1.2 Scope...................................................................................................................................... 4
1.3 References.............................................................................................................................. 4
2 Definition................................................................................................................................ 5
3 Flange Management Requirement and Procedure.............................................................5
3.1 Flange Joints Disturbance Procedure......................................................................................5
3.1.1 Reference Documentation....................................................................................................... 5
3.1.2 Breaking Flange Joints............................................................................................................ 5
3.1.3 Making Joints........................................................................................................................... 6
3.1.4 Tagging Procedure.................................................................................................................. 6
3.2 Flange General Requirements................................................................................................. 9
3.2.1 Bolting..................................................................................................................................... 9
3.2.2 Thread Lubricants and Preservatives......................................................................................9
3.2.3 Flange Faces......................................................................................................................... 10
3.2.4 Gaskets................................................................................................................................. 10
3.2.5 Insulation Gasket Sets and Specialty Gasket........................................................................10
3.3 Tightening.............................................................................................................................. 11
3.3.1 Tightening Methods............................................................................................................... 11
3.4 Hot Bolting and Preventative Bolting.....................................................................................13
3.4.1 Hot Bolting Requirement........................................................................................................ 13
3.4.2 Hot bolting procedure............................................................................................................ 14
3.4.3 Preventative Maintenance Bolting......................................................................................... 14
3.4.4 Preventative Maintenance Bolting Procedure........................................................................15
4 Flange System Records...................................................................................................... 15
5 Responsibilities...................................................................................................................... 15
1 Introduction
Widely used in piping installation flange connection type that must be properly installed according to
existing standart. It is necessary to be a procedure that can be used as a reference for instating the flange
connection
1.1 Purpose
This document is intended as a guide on how to install flanged joints in service for plant and facilities. It
provides a framework to achieve this based on working with correctly designed joints.
This document also provides guideline when works disturb a flanged joint (repair/replacement) to ensure
integrity and quality requirements are met upon reinstatement.
In order to avoid failure it is very important that the relevant specifications for materials and components
are adhered to in full.
1.2 Scope
This guideline shall be applied within COPI facility when works disturb flange joints (interference from
original conditions) for the following type of asset:
 all piping flange bolting
 all flange bolting of connecting piping to flanged equipment (pressure vessel, heat exchanger,
valve, pipeline and tank)
This document doesn’t cover the following:

 Cast Iron flanges
 Glass-line vessels and piping flanges
 Plastic pipe flanges
 Other non standard flanges
1.3 References
1. API 570, Inspection, Repair, Alteration, and Rerating of In-service Piping Systems
2. API 510, Pressure Vessel Inspection Code: In-service Inspection, Rating, Repair and Alteration
3. API 574, Inspection Practices fro Piping System Components
4. API 572, Inspection of Pressure Vessels
5. ASME PCC-1 Guidelines for Pressure Boundary Bolted Flange Joint Assembly
6. COPI document ID-G-BU-00000-00000-01548 In-service Flange Integruty Guideline,
2 Definition
Hot Bolting – The sequential removal and replacement of individual fasteners on piping flanges with the
system still “live”. Existing fasteners are removed in a predetermined diametrically opposed sequence,
are examined for condition and then either cleaned, lubricated and re-fitted, or replaced by a correctly
specified fastener. Each refurbished or new fastener is then installed and tightened by controlled means
before the next fastener in the sequence is removed.
Preventative Bolting - The practice of checking for looseness and where necessary re-tightening
fasteners in flanged joints on a live (on-line) system. Tightening shall be done by controlled means even if
the bolt is equipped with a load-monitoring device (e.g. Rotabolt).
Tightening - The making tight of a flanged joint by torquing or tensioning the flange bolts.
Torquing - The loading of flange bolts using manual or hydraulic torque equipment
Tensioning- The loading of flange bolts usually using hydraulic equipment.
3 Flange Management Requirement and Procedure

Flange management work flow process is attached in Appendix A. These requirements apply when flange
joints are disturbed for maintenance, repair and/or replacement works.
3.1 Flange Joints Disturbance Procedure

3.1.1 Reference Documentation
Determine the type, size and class of the flange to be bolted. Determine the relevant specification number
of the flange joint. Check the material, coating and size of the stud bolts. Check the type, pressure rating
and size of the gasket. The stud bolts and gasket specifications for the flanged joint must always match
the descriptions in the following documents:
 Piping specification: isometric, line index, etc
 Pressure vessel specification: data sheet, drawing, MDR, etc.
 P&ID (as built drawings)
 Heat exchanger specification: data sheet, drawing, MDR, etc.
 Tank specification: data sheet, drawing, MDR, etc.
 Pipeline specification: data sheet, drawing, MDR, etc.
 Valve specification: data sheet, drawing, MDR, etc.
Note: if in doubt contact the COPI Asset Engineering for guidance.
3.1.2 Breaking Flange Joints

1. Before commencing work ensure that the permit to work and risk assessments are valid for the
job in hand, and that the correct protective clothing/equipment is worn. Ensure that all safety
precautions and work permit instruction set out in ID-G-BU-00000-00000-00462 Permit to Work
are in place and are strictly adhered to.
2. Confirm that the line has been isolated, drained/vented or purged as appropriate before
attempting to break a joint. Ensure beyond all doubt that the line or piece of equipment being
worked upon has been correctly isolated and vented to atmospheric pressure and flushed and
purged if appropriate. the isolation requirement set out in ID-G-BU-00000-00000-00404 Lock Out
– Tag Out must be accomplished through an isolation certificate
3. Ensure that the correct tools for the job are available and are used. HSE document# ID-G-BU-
00000-00000-00391 – Hand Tools shall be complied.
4. The tagging system is used starting from breaking flange joint.
5. When attempting to break a joint, avoid standing directly alongside or underneath the joint.
Always break the bolt that is furthest away from you first, preferably the bottom furthest bolt.
6. Continually check for leakage, seepage or signs of pressure in the line – a hissing sound, a smell
of gas, etc. Use a pair of wedges away from you to determine this.
7. If at any stage there is a sign of pressure in the line, stop work immediately. Re-tighten the joint to
contain the leak, if safe to do so, and then report the situation to the maintenance supervisor or
raise alarm. The line isolation will then have to be checked.
8. Never remove nuts from studs until you have ascertained that the considered pipe/equipment is
depressurized and empty.
9. Before finally parting a joint, always assess the forces on the pipe. Will the joint spring apart? Is
one half of the joint unsupported? Temporary supports or restraints may be required.
3.1.3 Making Joints

All personnel carrying out work on bolted joints should be competent to a level appropriate to the required
technical skills. Similarly, supervisory personnel and assessors should also be competent to ensure they
are aware of the issues involved in achieving a leak free joint. This includes a process to assure third
party vendors and contractors can demonstrate that their personnel are managed using equivalent
competence standards.
1. Before starting, check that the permit to work/risk assessment is valid for the job in hand and that
the correct protective clothing/equipment is worn. Ensure that all safety precautions and work
permit instruction set out in ID-G-BU-00000-00000-00462 Permit to Work are in place and are
strictly adhered to.
2. Check if these are procedure in place for carrying out the intended work – and if so follow the
procedure. This includes using the Flange Disturbance Register and the use of flange
disturbance tags as detailed in section 3.1.4 below.
3. Determine the type, size and class of the flange to be bolted. Determine the referenced
document/specification as described in section 3.1.1 of the concerned joint. Check the material,
coating and size of the stud bolts. Check the type, pressure rating and size of the gasket. The
stud bolts and gasket specifications for the flanged joint must always match the descriptions in
the specification document (as mentioned in section 3.1.1).
4. Only use the correct materials for the job. Never use damaged materials and always uses a new
gasket when making up a joint. It is recommended that nuts/bolts are also renewed, however,
where this is not possible a visual inspection of these parts should be completed prior to
installation.
5. It does not allow to use cut from sheet gasket.
6. Ensure that the correct tools for the job are available and are used. HSE document# ID-G-BU-
00000-00000-00391 – Hand Tools shall be complied.
7. Ensure the joint faces are clean and properly aligned before inserting the gasket.
8. Visually check the flanges for equal gap. If a larger gap appears on one side of the flange, tighten
the bolt which corresponds with the larger gap first.
9. Ensure the flanges are parallel after tightening.
3.1.4 Tagging Procedure
Each disturbed flange shall be ’tagged’ prior to assembly, only one flange tag per flange/joint will
be fitted. The tags are double-sided and comprise four distinct sections, the outer three sections
being perforated to allow tear off (all four sections of the tag are pre-printed with a unique
number). Tag should be made from water proof material e.g. plastic.
Flange disturbance tagging is given in Appendix B.

Section 4 Section 3 Section 2 Section 1
 Section 1 (Flange Not Disturbed)

 Section 2 (Flange Not Tightened)
 Section 3 (Flange Not Tested)
 Section 4 (Main body of tag which will initially remain on the flange)
When Section 4 has been completed (on both sides), the tag indicates that the flange has been
assembled and tightened competently.
The tag should be fitted using a suitable tie and in a position adjacent to or on the joint.
Section 1 is removed and returned to the Maintenance Supervisor/Work leader to indicate that
flange has been disturbed. Person who disturbs the flange shall fill date and his/her name
complete with Permit work Number.
Section 2 is removed and returned to the Maintenance Supervisor/Work Leader to provide a

visual indication that the flange has been tightened and ready to be leak tested. The Work Lead
responsible for the tightening operation shall advise the Maintenance Supervisor/Work Leader of
the name of the technician tightening each flange and be responsible for the return of Section 2 to
the Construction/Maintenance Supervisor.
Section 3 is removed and returned to the Maintenance Supervisor/Work Leader to provide a

visual indication that the flange has been leak tested. The supervisor responsible for the leak test
operation shall advise the Maintenance Supervisor/Work Leader of the name of the technician
performing the test and be responsible for the return of Section 3 to the
Construction/Maintenance Supervisor. If the result of the leak test is failure due to a leaking
flange, a new tag should be assigned to the joint prior to rework.
Section 4 of the tag will remain on the flange until such time that further maintenance is carried
out, only then will the existing tag be removed and replaced with a new tag. This shows visually
that both operations have been completed upon that flange.
PSSR shall be performed before joints back to online and operation should perform site
verification to check tagging system.
Side A: This side of tag is completed by the Worker/Technician assembling the flange. The
worker/technician shall print his name and confirm the acceptable condition of the;
a) Flange face cleanliness

b) Flange alignment - Acceptance criteria given in relevant specification.
c) Material and length of the bolts - Acceptance criteria given in relevant document described in
section 3.1.1.
d) Size and material of the gasket.- Acceptance criteria given in document relevant document
described in section 3.1.1.
e) Correctly Lubricated. – See section 3.2.2
Side B: When the flange is ready for bolt tensioning/torquing, the Worker/Technician shall check
Side A of the tag to confirm the flange had been assembled correctly. The Worker/Technician can
then proceed to tighten the flange.
When bolt tightening is completed, the Worker/Technician shall print his name and confirm;
a) System Number
b) Line Number
c) The torque or tension applied. – Measured using hydraulic pressure gauges mounted on the
torque/tensioning machinery or set point on manual torque wrenches.
On completion of the above, Section 2 of the tag is removed and returned to the
Operation/Maintenance Supervisor/Work Leader who will retain it in the work pack for close out
audit.
A similar process is utilized after the flange has been leak tested (for information on leak testing
refers to Pressure and Leak Testing Guidelines.
The leak tests (service tests) are carried out with the pressure system in service, normally during
start-up. The test is normally carried out (but not necessarily always) at maximum normal
operating pressure using the process fluid as the test medium, supplemented by water or inert
gas from an external source if necessary.
When the flange has successfully passed a test, the Leak Test Technician shall confirm and write
on Side B Pressure and date of test then remove Section 2 of the tag and return it to the
Maintenance Supervisor/Work Leader who will insert the perforated ticket in the work pack for
close out audit.
On completion of testing the permit to work should be signed off as complete before handover
back to the operations department.
When all flanges have been tightened and tested the remaining portion of the tag should be kept
at disturbed flanges for at least 3 months after the start-up is complete. After that it is at the
discretion of the Facility Management as to how long the tags are kept.
3.2 Flange General Requirements

3.2.1 Bolting
To ensure consistent performance, it is essential that nuts and bolts are supplied with the precise
specification for tolerance and fit. Studs/Nuts shall be the correct material and size/length for the
application and free of corrosion, damage, dirt and grit.
Confirmation of the above is required to complete Section 4 of Side A of the flange tag.
Bolt Length – Bolts should extend completely through their nuts.
Re-use of Bolts/Studs
Studs and or nuts can only be reused, subject to the following conditions:
 There is no noticeable degradation.
 They are free from obvious defects (corrosion, cracks, etc.).

 There is no sign of yielding (i.e. deformed threads, stud shaft, etc).
 Nuts must run freely by hand on the bolt.
If a stud or nut is found to be unsuitable for re-use, it shall be scrapped
immediately.
For joint assemblies on the critical path of a maintenance or shutdown program (or where tight
time schedules are to be adhered to), it is recommended that replacement bolting be made
available in case the existing bolting is found to be unfit to return to service.
It is essential that when choosing fasteners for a flanged joint the grade of stud and nut used are
compatible and compliant with the piping specification. Matching stud and nut grades are given in
Table below:
Table-3 Stud and Nut Compatible
Stud Compatible Nut

ASTM Material Marking ASTM Material Marking
A193 Grade B7 B7 A194 Grade 2H 2H
A193 Grade B7M B7M A194 Grade 2HM 2HM
A193/A320 Grade B8 Class 2 B8 A194 Grade 8 8
A193/A320 Grade B8M Class 2 B8M A194 Grade 8M 8M
A193 Grade B16 B16 A194 Grade 4 4
A320 Grade L7 L7 A194 Grade 4 or 7 4 or 7
3.2.2 Thread Lubricants and Preservatives
1. The torque/tensioning values given in Appendices F as a general guidance. If required the

calculation should be made by using ASME PCC-1 for a specific flange
2. The use of lubricants with a lower coefficient of friction can lead to excessive bolt stress being
applied and failure of flanges or bolts may result.
3. Friction coefficient (COF) of some preservative lubricant can be referred at Appendix D.
4. When bolt tensioning is complete, to prevent corrosion a liberal coating of lubricant should be
applied to the nuts up to the back of the flange, and to the stud ends protruding from the nuts.
Copperslip, Densotape or nut/thread protectors are considered to be suitable for this purpose.
5. The above information is required to complete Section 4 of Side B of the flange tag.
Note: this is particularly important where low alloy bolts are used on unpainted stainless steel
flanges. Marinel material bolting should not be lubricated.
3.2.3 Flange Faces
Prior to assembly the flanges should be inspected to ensure the faces are in good condition
(particularly with respect to radial scoring), clean, parallel and axially aligned.
Pipe flange alignment tolerances shall comply with the relevant pipe fabrication/erection
specification.
Any deviation of tolerances shall be put in IAAN process.

Flange alignment is critical to the performance of the bolted joint. No excess pressure should be
exerted to align the bolt holes for the insertions of bolts without engineering approval. Excess
pressure used to assist with the insertion of bolts on flanges on rotating equipment could have
damaging effects on seals, shafts and bearings. For specific information on pipe alignment on
rotating equipment see API 686. General piping alignment specifications can be found in ASME-
PCC-1.
Every effort shall be made to align the joint. Applying large forces, through mechanical devices or
bolting, to align flange joint is bad practice and not permitted. Joints found in this condition should
be reported and seek consultation with COPI Asset Engineering prior to re-commissioning.
The above information is required to complete Section 4 of Side A of the flange tag.
If in doubt contact the COPI Asset Engineering for guidance.
3.2.4 Gaskets
A new gasket/RTJ/Seal Ring shall be used whenever joints are made or remade.
Gaskets shall be suitable for the operating conditions and remain flexible under a varying load
due to fluctuations in pressure and temperature. The type of gasket used shall comply with the
Pipe Specification. Where spiral wound gaskets are utilized, extra care shall be taken to protect
the face of the gasket.
When installing the gaskets, ensure the flange and gasket faces are clean and dry. Gaskets
should be of the correct type and correctly positioned. Note that it is not possible to mix and
match gaskets between proprietary clamped connectors (e.g. Graylok/Techloc & Galperti).
3.2.5 Insulation Gasket Sets and Specialty Gasket
Where identified, it is imperative that insulation kits are fitted correctly. The purpose of the
insulation kit is to prevent undesired conductivity between dissimilar materials and corrosion
issues occurring. Insulation kits generally require a lesser bolt load to create an effective seal as
a result of the specially designed gasket, with spacers and washers playing an integral role. It is
essential that all components of the insulation kit are fitted to ensure the integrity of the joint and
that the manufacturer’s recommendations are followed when tightening the joint.
Note: A lower torque must be used for insulation kits to avoid cracking. If cracks or
damage occur whilst tightening the insulation kits must be replaced as they are no longer
usable.
3.3 Tightening
3.3.1 Tightening Methods
The following table is general rule for selection of tightening method:
Table-4 Torque/Tension Guidance based on bolt size and flange class
Bolt Size Flange Class Tension Torque Comments

1 ½ and larger 900# and above Yes Tension whenever possible,
torquing may be utilized only if
tensioning is not possible
1 ½ and larger Below 900# Yes Yes Tension whenever possible,
Below 1 ½ 900# and above Yes Tension whenever possible,
Bolt Size Flange Class Tension Torque Comments

Below 1 ½ Below 900# Not Yes
Required
The equipment must have a valid calibration certificate.

3.3.1.1 Conventional Spanners/Wrenches
Flange bolts may be tightened by hand torque wrenches Conventional spanners/wrenches may
be used on Class 150 Non-Severe System piping systems only.
Note: the flogging of bolts in hydrocarbon systems is not permitted.
3.3.1.2 Torque Wrenches
Flange bolts shall be tightened by torque wrenches on all hydrocarbon systems (all pressure
ratings), and utility systems rated at Class 300 and above.
Controlled torque wrenching shall be carried out using either manual or hydraulic torque
wrenches that are calibrated and “in certification”. The method chosen is dependent upon bolt
loading, access, clearance and tooling availability, which will be determined by the site personnel.
When the bolt loading requires a torque figure greater than 500 lbf.ft (678 Nm) to be applied, the
use of a hydraulic torque wrenches is recommended.
Note: if torque equipment cannot be applied due to access restrictions then the
Operation/Maintenance Supervisor/Lead shall be advised and a Risk Assessment
completed detailing the additional controls required to ensure joint integrity, this may
include using conventional spanners and joint make up verification by a second
Worker/Technician.
3.3.1.3 Torquing Procedure
Figure 1 Tightening Sequence

To achieve joint tightness it is important that the following procedure is adhered to:
(1) Check and ensure that the general requirements of Section 3.2 have been satisfied.
(2) To achieve uniform joint load/stress distribution the bolts shall be tightened in three stages,
representing 30%, 60% and 100% of the torque values stated in Appendices F. At each
stage of tightening, bolts shall be tightened in a controlled sequence as follows:
(3) Finally the bolts shall be chased round using the 100% torque value stated in Appendices F,
until uniform tightening has been achieved. Note: If tightening an RTJ, a second 100% chase
round shall be completed.
3.3.1.4 Hydraulic Jack Bolt Tensioning Equipment
Where more stringent control of joint stresses is required, flange bolting should, whenever
practical, be tightened using hydraulic jack tensioning equipment. This technique is strongly
recommended for the following services and pressure ratings, (also see Appendices H)
(1) Bolt diameters of 2 inches and above in all services with pressure ratings up to and including
Class 900.
(2) Bolt diameters of 1½ inches and above in all services with pressure ratings Class 1500 and
above.
(3) Bolt diameters of 1 inch and above in critical applications. Critical applications are
considered to be joints exposed to cyclic stress i.e. frequent changes of pressure and/or
temperature.
The bolt tensioning operation must be carried out in accordance with the tension equipment
manufacturer’s specified procedure and the load loss factors should be recorded. Ideally
tensioning should be applied simultaneously to all studs in one operation. Where this is not
possible, tensioning should be applied in phases using differing pressures as per suppliers
guidelines.
Note: if tensioning equipment cannot be applied due to access restrictions then the
Operation/Maintenance Supervisor/Lead shall be advised and a Risk Assessment
completed detailing the additional controls required to ensure joint integrity, this may
include using conventional spanners and joint make up verification by a second
Worker/Technician.
3.4 Hot Bolting and Preventative Bolting

3.4.1 Hot Bolting Requirement
The practice of hot bolting (see definitions) is a potentially hazardous operation and must not be
undertaken unless all other options have been considered and there remains an outstanding, and
fully justified, operational reason to carry out hot bolting in a safe manner. A risk assessment shall
be carried out, and a plan developed to achieve isolation of the joint in the event of a problem
during the hot bolting operation. Changing bolts by hot bolting simply to save time during a
forthcoming shutdown is not an adequate reason for hot bolting. However, partially backing off
and re-tightening one nut at a time is permitted to identify bolts that may be difficult to remove in a
later shutdown, but shall be subject to the same safety review, and risk assessment and controls
as for hot bolting.
Holt bolting work should be approved by site manager and site specific procedure should be
developed.
Hot bolting may only be considered on systems in the following duties:
(1) Seawater and Service water

(2) Fire water ring mains
(3) Cooling medium
(4) Crude Oil systems provided the system pressure does not exceed 5.0 barg.
(5) Diesel fuel
(6) Drains systems
(7) Low-pressure mud conveying systems associated with drilling.
(8) The operating pressure must be less than 75% of the MAWP (Maximum
Allowance with Pressure) of the piping or process system to be hot
bolted).
Hot Bolting is NOT permitted on the following systems:
(1) Hydrocarbon gas

(2) High pressure Water Injection >25 barg
(3) Toxic fluids
(4) Fluid temperature > 90 degrees C
(5) Intermittent flow or surging flow
(6) Flange with bolt less than eight (8).
3.4.2 Hot bolting procedure
Before any work commences ensure that hot bolting has been fully justified; that a risk
assessment has been performed and approved; that a permit to work states that hot bolting on
the joint is permitted; and that a contingency plan exists to isolate the joint in the event of a
problem during the hot bolting operation.
The hot bolting procedure given below shall be followed:
(1) Latest past history records of the joints in question shall be consulted to identify any
anomalies or previous problems with the joint.
(2) To anticipate any fastener or flange or gasket relaxation an attempt shall first be made to
evenly re-tension each fastener before attempting to loosen any single fastener. Both the
tightening and slackening activities shall be carried out by controlled means (if extra length
studs have been fitted, bolt tensioning is strongly recommended over torquing during hot
bolting as it maintains a more accurate gasket seating stress, and is less likely to result in an
overloaded bolt). Bolt tension and bolt torques shall be in accordance with Appendix F.
(3) The break out torque shall be recorded for every fastener. If the break out torque is
significantly less than the torque specified in Appendix F it may indicate a loose or
overstressed joint. In such cases the system shall be isolated, depressurized, purged and
vented prior to any further fastener being removed. In this instance please notify the COP
onshore maintenance responsible engineer.
(4) Proceed to slacken the first fastener (on the side furthest away from personnel), monitoring
for leakage continuously. Under no circumstances shall two bolts be slackened
simultaneously. In the event of the gasket leaking the joint shall be immediately re-tightened.
(5) The removed stud and nut should be cleaned, examined for damage or strain, lubricated with
Copperslip only, reinstalled and re-tightened. If in doubt the stud and nut should be replaced.
(6) Only one fastener shall be removed and replaced at a time working in the diametrically
opposite sequence as shown in Table 1 of this procedure. Each fastener shall be replaced
immediately and shall be tightened to the torque or tension as specified in Appendix F.
(7) Continue with this procedure (6) until all the fasteners have been changed out.
(8) When all fasteners have been replaced their exposed nuts and threads shall be given a
liberal coating of grease in order to prevent corrosion.
(9) Any jacking bolts that have been removed to improve access should be greased and refitted.
(10) Verify that the joint is totally leak-free.
3.4.3 Preventative Maintenance Bolting
The practice of checking for looseness and where necessary re-tightening fasteners in flanged
joints on a live (on-line) system is a potentially hazardous operation. It must not be undertaken on
a joint in a hydrocarbon, hazardous or toxic fluid system, unless all other options have been
considered and there remains an outstanding, and fully justified, operational reason to perform
preventative maintenance bolting in a safe manner. A risk assessment shall be carried out, and a
plan developed to achieve isolation of the joint in the event of a problem during the operation. The
joint must have a minimum of 8 bolts. This preventive works shall get approval from site
management representative.
3.4.4 Preventative Maintenance Bolting Procedure
(1) Bolt tightening shall be carefully performed by controlled means. Bolt tensioning shall be
used if possible (if extra length studs have been fitted), otherwise bolt torquing shall be used.
Controlled tightening shall be used even if the bolt is equipped with a load-monitoring device
(e.g. Rotabolt).
(2) Re-tensioning and re-torquing of the flange bolting shall be performed in accordance with
Appendix F, and bolt torquing shall be in the bolt sequence shown in Table 1 of this
procedure. It should be noted that although the thread lubricant may have dried out which will
increase friction losses, the bolt torque applied must not exceed the values stated in
Appendix F.
(3) Monitor the joint during the operation for leakage, and at the end of the work verifies that the
joint is totally leak-free.
4 Flange System Records

The certainty of a successful joint being made up increases if data is controlled and historical data exists
on the activities carried out in the past. Recording traceable data encourages best practice at the time of
the activity, and will provide useful planning data for the next time the joint is disturbed.
Learning from incident is important. A gathering relevant data, which should be collected by everyone
involved in flanged joints and periodically reviewed to establish trends, performance and improvement.
This can be achieved if records and data are kept as part of a management control process.
It is recommended that as a minimum keeps records for all joints those on other services which have a
history of leakage, or potential to leak, and that this is kept with any relevant procedures for monitoring
specific joint. To minimize the possibility of the problem resurfacing, methods for countering the leak
should be included within the individual joint records.
Any changes from original specification should be maintained through MOC process.
5 Responsibilities
InspectorsAsset Integrity
IN-SERVICE ROUTINE INSPECTION Maintenance/Operation
Asset Integrity/Pipeline
Offshore Installation
Asset Integrity Mgr.

Mechanical Lead /
Supervisor/Lead
Technician
RACI
Engineer
Manager
R Responsible
A Accountable
C Consult
I Inform
No Activity
1 Perform Visual Inspection I I I C R A
2 Perform Fugitive Emission I I I C R A
3 Perform Snoop Leak Detector R C A I I

Operation Supervisor/Lead
Maintenance Spt./ Pipeline
FLANGE MANAGEMENT
Specialist Flange Vendor
Manager/ Operation Spt./
Asset Engineering Team

Work/Technician Leader
REQUIREMENT & PROCEDURE

Worker / Technician

Supervisor/Lead
Superintendent
Field Manager
Maintenance
Engineer
RACI
R Responsible
A Accountable
C Consult
I Inform
No Activity
Overall accountability for compliance with this

1 R A C C I C
guideline
Site Accountability for compliance with this

2 R A C I I I C
procedure
3 Determine Flanges to be disturbed during each task C R A I I C
4 Completion of Side A of Flange disturbance Tag R R C C A I I I
5 Confirm Method of tightening to be used R R C C A I I I

Operation Supervisor/Lead
Maintenance Spt./ Pipeline

FLANGE MANAGEMENT
Specialist Flange Vendor
Manager/ Operation Spt./
Asset Engineering Team

Work/Technician Leader
REQUIREMENT & PROCEDURE
Worker / Technician

Supervisor/Lead
Superintendent
Field Manager
Maintenance
Engineer
RACI
R Responsible
A Accountable
C Consult
I Inform
6 Torque/Tension to correct Value R R C C A I I I
7 Complete disturbed flange tightening report R R C C A I I I
8 Complete Side B of flange disturbance Tag R R C C A I I I
9 Leak Test As Required R R C C A I I I
Close out entry within flange management database

10 R R C C A I I I
and complete flange disturbance register
11 Close Work Order within SAP C C C R A I
Original of P&ID’s/Isometric, Flange Tag, and

12 C C C R A I I I I
controlled tightening reports to be kept.
Procedure/Work Instruction/Job Note ID-G-BU-00000-00000-01548 Rev. 2
In- Service Flange Integrity Guideline
APPENDIX A
FLANGE MANAGEMENT PROCEDURE FLOWCHART
L:\2.0 Project\16
Material & Corrosion\160079.01 COPI A&OI SIP 2010\11.0 ENGINEERING\SIP\SIP #3\WOR
APPENDIX-B
FLANGE DISTURBACE TAG
L:\2.0 Project\16
Material & Corrosion\160079.01 COPI A&OI SIP 2010\11.0 ENGINEERING\SIP\SIP #3\Flang
APPENDIX-C
CONTROLLED TIGHTENING REPORT
L:\2.0 Project\16
Material & Corrosion\160079.01 COPI A&OI SIP 2010\11.0 ENGINEERING\SIP\SIP #3\CONT
Procedure/Work Instruction/Job Note: ID-G-BU-00000-00000-01548 Rev. 2
APPENDIX-D
LUBRICANT
No. Lubricant's Product Producer Coefficient Of Friction

1 API Bull 5A2 - 0.13
2 Anti Seize Acheson Colloids 0.09
3 Anti Seize (paste) Chesteron 0.14
International
4 Beldamite ASC Beldonite 0.13
5 Berutex FH-34 R.S. Clare 0.16
6 Berutex FH-35 R.S. Clare 0.16
7 Biral BASC Sieben Technical 0.11
8 Castrol Nucleol S202 Castrol 0.08
9 Copaslip National Chemical Co 0.12
10 Coppercrest Illex Lubricant 0.14
11 Copper Ease Comma Oil & 0.14
Chemical
12 Coppergrease Chemodex 0.15
13 **Coppergrease Chemofina 0.11
14 Copperslip Belzona Molecular Ltd 0.09
15 **DAG156 Acheson Colloids 0.15
16 DAG580 (Dry Lubricant) Acheson Colloids 0.16
17 Easyrun100 K.S Paul 0.08
18 Fel-ProC-102 Fel-Pro Inc 0.16
19 Fordec Copper Anti Seize Fordec 0.15
20 Gleitmo165 Gleitmo 0.1
21 HP anti seize Belzona Molecular Ltd 0.15
22 LFCP 5006 Maxol (Irish) 0.2
23 Molykote Cu-7439 Dow Corning 0.15
24 Molykote1000 Dow Corning 0.11
25 Molykote Q5-7405 Dow Corning 0.04
26 Molykote G-Rapid Dow Corning 0.08
27 Molykote G-Rapid Plus Dow Corning 0.09
28 Molykote HSC Dow Corning 0.11
29 Molykote Ti 1200 Dow Corning 0.12
30 Molykote 7443 Dow Corning 0.13
31 Molykote P37 paste Dow Corning 0.12
32 Molyslip AS60 Molyslip 0.07
33 Never seez Std grade Bostik Ltd 0.18
(NS160)
34 Never seez Spl grade Bostik Ltd 0.18
(NS165)
35 Nickel-Eez Swan Chemical 0.12
No. Lubricant's Product Producer Coefficient Of Friction

36 OKS 235 OKS 0.11
37 OKS 240 OKS 0.12
38 OKS 250 OKS 0.08
39 OKS 503 OKS 0.06
40 OKS 504 OKS 0.09
41 OKS 505 OKS 0.1
42 OKS 506 OKS 0.11
43 OKS 507 OKS 0.1
44 Omega 99 Sovereign Lubricants 0.13
45 Omega 99N Sovereign Lubricants 0.09
46 Omega 95 Sovereign Lubricants 0.12
APPENDIX-E
FLANGE BOLTING CHARTS

Series 150 Flange *For standard flanges only, Add

length when washers or Double Nuts are used
Pipe Wrench Flange Bolts
Size Size
Number Diameter Raised Face Ring Joint
Length Length Ring#
1 ⅞ 4 ½ 2½ 3 R15
1½ ⅞ 4 ½ 2¾ 3¼ R19
2 1 1/16 4 ⅝ 3¼ 3¾ R22
3 1 1/16 4 ⅝ 3½ 4¼ R29
4 1 1/16 8 ⅝ 3½ 4¼ R36
6 1¼ 8 ¾ 4 4½ R43
8 1¼ 8 ¾ 4¼ 4¾ R46
12 1 7/16 12 ⅞ 4¾ 5½ R56
14 1⅝ 12 1 5¼ 6 R59
16 1⅝ 16 1 5¼ 6 R64
18 1 13/16 16 1⅛ 6 6½ R68
20 1 13/16 20 1⅛ 6¼ 7 R72
24 2 20 1¼ 7 7¾ R76

Size Size
Length Length Ring#
1 1 1/16 4 ⅝ 3 3¼ R16
1½ 1¼ 4 ¾ 3½ 4 R20
2 1 1/16 8 ⅝ 3½ 4¼ R23
3 1¼ 8 ¾ 4¼ 5 R31
4 1¼ 8 ¾ 4½ 5¼ R37
6 1¼ 12 ¾ 4¾ 5¾ R45
8 1 7/16 12 ⅞ 5½ 6¼ R49
10 1⅝ 16 1 6¼ 7¼ R53
12 1 13/16 16 1⅛ 6¾ 7½ R57
14 1 13/16 20 1⅛ 7 7¾ R61
16 2 20 1¼ 7½ 8¼ R65
18 2 24 1¼ 7¾ 8½ R69
20 2 24 1¼ 8 9¼ R73

Size Size Number Diameter Raised Face Ring Joint
Length Length Ring#
1 1 1/16 4 ⅝ 3½ 3½ R16
1½ 1 ¼ 4 ¾ 4¼ 4¼ R20
2 1 1/16 8 ⅝ 4¼ 4½ R23
3 1 ¼ 8 ¾ 5 5¼ R31
4 1 7/16 8 ⅞ 5¾ 6 R37
6 1⅝ 12 1 6¾ 7 R45
8 1 13/16 12 1⅛ 7¾ 8 R49
10 2 16 1¼ 8½ 8¾ R53
12 2 20 1¼ 8¾ 9 R57
14 2 3/16 20 1⅜ 9¼ 9½ R61
16 2⅜ 20 1½ 10 10 ¼ R65
18 2 7/16 20 1⅝ 10 ¾ 11 R69
20 2 7/16 24 1⅝ 11 ½ 11 ¾ R73

Size Size
Length Length Ring#
1 1 7/16 4 ⅞ 5 5 R16
1 ½ 1⅝ 4 1 5½ 5½ R20
2 1 7/16 8 ⅞ 5¾ 6 R24
3 1 7/16 8 ⅞ 5¾ 6 R31
4 1 13/16 8 1⅛ 6¾ 7 R37
6 1 13/16 12 1⅛ 7¾ 8 R45
8 2 3/16 12 1⅜ 7¾ 9 R49
10 2 3/16 16 1⅜ 9¼ 9½ R53
12 2 3/16 20 1⅜ 10 10 ¼ R57
14 2⅜ 20 1½ 10 ¾ 11 ¼ R62
16 2 9/16 20 1⅝ 11 ¼ 11 ¾ R66
18 2 15/16 20 1⅞ 13 13 ½ R70
20 3⅛ 20 2 13 ¾ 14 ½ R74

Size Size
Length Length Ring#
1 1 7/16 4 ⅞ 4¾ 4¾ R16
1 ½ 1⅝ 4 1 5¼ 5¼ R20
2 1 7/16 8 ⅞ 5½ 5¾ R24
3 1 13/16 8 1⅛ 6¾ 7 R35
4 2 8 1¼ 7½ 7¾ R39
6 2 3/16 12 1⅜ 10 10 ¼ R46
8 2 9/16 12 1⅝ 11 ¼ 11 ¾ R50
10 2 15/16 12 1⅞ 13 ¼ 13 ½ R54
12 3⅛ 16 2 14 ¾ 15 ¼ R58
14 3½ 16 2¼ 16 16 ¾ R63
16 3⅞ 16 2½ 17 ½ 18 ½ R67
18 4¼ 16 2¾ 18 ¼ 20 ¼ R71
20 4⅝ 16 3 21 22 ¼ R75

Size Size
Length Length Ring#
1 1 7/16 4 ⅞ 5¾ 5¾ R18
1 ½ 1 13/16 4 1⅛ 7 7¼ R23
2 1⅝ 8 1 7¼ 7½ R26
3 2 8 1¼ 9 9¼ R32
4 2⅜ 8 1½ 10 ¼ 10 ¾ R38
6 3⅛ 8 2 13 ¾ 14 ½ R47
8 3⅛ 12 2 15 ¼ 16 R51
10 3⅞ 12 2½ 19 ½ 20 ½ R55
12 4¼ 16 2¾ 21 ½ 22 ½ R60
APPENDIX-F
BOLT TORQUE/TENSIONING VALUES

The following table covers the Torquing / Tensioning Details for the following Bolting Materials:
Carbon Steel, Duplex Stainless Steel, Super Austenitic Stainless Steel, B7 & Equivalent (Bolt Stress is
approx 310 Mpa (45000 psi)) using a Coefficient of Friction (COF) 0.10
Stud Bolt Details Required Bolt Required Torque Recommended Tool

Tension (lbf) Details
Bolt Size Thread Ft.lbs N.m
¼ UNC 1672 6 8 Manual Wrench
5/16 UNC 2700 12 16 Manual Wrench
⅜ UNC 3952 20 27 Manual Wrench
½ UNC 7157 46 62 Manual Wrench
⅝ UNC 11322 90 120 Manual Wrench
¾ UNC 16584 150 205 Hydraulic Wrench
⅞ UNC 22778 240 325 Hydraulic Wrench
1 UNC 27681 330 450 Hydraulic Wrench
1⅛ UN8 36537 480 650 Hydraulic Wrench
1¼ UN8 45529 660 890 Hydraulic Wrench
1⅜ UN8 56110 880 1200 Hydraulic Tensioner
1½ UN8 67796 1150 1550 Hydraulic Tensioner
1⅝ UN8 81307 1500 2000 Consult
1¾ UN8 94480 1850 2500 Consult
1⅞ UN8 109478 2300 3100 Hydraulic Tensioner
2 UN8 125581 2700 3700 Hydraulic Tensioner
2¼ UN8 161101 4000 5400 Hydraulic Tensioner
2¾ UN8 245394 7200 9800 Hydraulic Tensioner
3 UN8 294167 9400 12700 Hydraulic Tensioner
3½ UN8 404967 15000 20200 Consult
3¾ UN8 466994 18400 25000 Hydraulic Tensioner
4 UN8 533439 22400 30300 Consult
B8M Class 2 (Bolt Stress is approximately 65% of yield load) using a Coefficient of Friction (COF) 0.10
Stud Bolt Details Required Bolt Required Torque Recommended Tool

Tension (lbf) Details
Bolt Size Thread Ft.lbs N.m
¼ UNC 2295 8 11 Manual Wrench
⅜ UNC 5423 27 37 Manual Wrench
½ UNC 9821 62 85 Manual Wrench
⅝ UNC 15537 120 165 Manual Wrench
¾ UNC 22756 210 280 Hydraulic Wrench
⅞ UNC 26321 275 375 Hydraulic Wrench
1 UNC 31987 380 520 Hydraulic Tensioner
1⅛ UN8 34304 450 610 Hydraulic Tensioner
1⅜ UN8 40524 640 860 Hydraulic Tensioner
B8M Class 2 Yield Strength:
ASTM Material - Size Yield Strength 65% Yield Strength

(psi) (psi)
ASTM A193 – B8M Class 2 – For ¾” and under 95000 61750
ASTM A193 – B8M Class 2 – For ¾” to 1” 80000 52000
ASTM A193 – B8M Class 2 – For 1” and to 1 ¼” 65000 42250
ASTM A193 – B8M Class 2 – For 1 ¼” to 1 ½ “ 50000 32500
In-Service Flange Integrity Guideline
APPENDIX-G
GUIDELINE FOR EVALUATING FAILURE IN FLANGED JOINTS

GUIDELINE FOR EVALUATING FAILURE IN FLANGED JOINTS
Failure Mode Cause Corrective Actions
FLANGE
Flange surface scarred  Installation error in the  Renew sealing surface
tools used to insert or remove
the gasket
 Damaged flange was not
inspected during make up
Flanged bowed  Over torque  Revise assembly
 Flange pressure rating is procedure
too low for service conditions
 Flange material is not
adequate for service conditions
Flange rotation  Over torque  Revise assembly
 Flange pressure rating is procedure
too low for service condition  New Flange
GASKET
Gasket crush all around  Over torque  Install a proper new
 Gasket is too soft: low gasket
modulus of elasticity
 Gasket is too thick
Gasket crush on one end  Excessive pipe moments  Additional passes
only  Pipe misalignment  In tightened correctly
 Incorrect bolt up refer to Asset Integrity
procedure Engineer
Gasket crush on outer edge  Flange rotation  Crush control
 Over torque  Stretch control
 Gasket is too hard: high  Low stress gasket
 Flange pressure rating is
too low
Gasket cut  Installation error in the  Provide gasket
tools used to insert the gasket; handling instruction and
mishandling the gasket during fixtures
installation
 Damaged gasket was not
inspected at installation
Gasket disintegration  Incorrect gasket Material  Change gasket
 Contamination of the material
flange and/or gasket
Gasket blowout  Flange surface is too  Machine
smooth
 Incorrect gasket material
Gasket extrusion  Gasket is too soft; low  Stretch control
modulus of elasticity  Gasket control
 Over torque
Failure Mode Cause Corrective Actions

Localized corrosion  Localized contamination of  Renew sealing surface
the flange and/or gasket
 Damaged surface
Generalized corrosion  Generalized contamination  Change gasket
of the flange and/or gasket material
No gasket compression (not  Under torque  Increase torque
seated for full  Gasket is too hard: high  Measure fastener
circumference) modulus of elasticity strength
 Gasket is too thin  Softer gasket
BOLT
Loose bolts on one end only  Pipe misalignment  Align the pipe
 Excessive pipe moments  Additional passes
 Incorrect bolt up
procedure
All bolt loose  Bolt relaxation; bolt creep  Reestablish the load
 Gasket relaxation; gasket  Install spacers or
creep Belleville springs
 Under torque  Metal-to-metal contact
with controlled gasket
deflection
Random bolts loose  Incorrect bolt up  Additional passes
procedure  Vary the stretch
 Bolt relaxation; if some low patterns
yield bolts have been mixed
with the correct bolting
Bolts elongated  Over torque  Revise assembly

 Incorrect bolting material procedure
 Gasket is too hard; high  New gasket
More detail about trouble shooting of flanged joint could be found in Appendix P of ASME PCC-1 (2010).
A series of diagnostic tables is provided with each dedicated to a specific type of leak event includes:
 Leak during Hydro Test (LHT)
 Leak during heat-up or initial operation (LIO)
 Leak corresponding to thermal or pressure upset (LCU)
 Leak after several months operation (LTO)
 Leak during shutdown (LDS)

Flange Management Procedure IFU

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Flange Management Procedure IFU

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Document Title: Flange Management Procedure

COPI Doc No.: ID-N-SB-LL0-PRO-ST-00-0001

Originator: PT. Wijaya Karya (Persero). Tbk

0B IFA 12 Okt 2012 Issued for Approval GP ZR AGN MER / HS AIB

Prepar Check OEE / Project Unit Owner

REVISION DATE DESCRIPTION OF CHANGE

0A 18 June 2012 Issued for Comment

This document doesn’t cover the following:

Tensioning- The loading of flange bolts usually using hydraulic equipment.

3 Flange Management Requirement and Procedure

3.1 Flange Joints Disturbance Procedure

3.1.2 Breaking Flange Joints

4. The tagging system is used starting from breaking flange joint.

3.1.3 Making Joints

5. It does not allow to use cut from sheet gasket.

9. Ensure the flanges are parallel after tightening.

3.1.4 Tagging Procedure

Flange disturbance tagging is given in Appendix B.

Section 4 Section 3 Section 2 Section 1

 Section 1 (Flange Not Disturbed)

Section 2 is removed and returned to the Maintenance Supervisor/Work Leader to provide a

Section 3 is removed and returned to the Maintenance Supervisor/Work Leader to provide a

a) Flange face cleanliness

3.2 Flange General Requirements

Bolt Length – Bolts should extend completely through their nuts.

 They are free from obvious defects (corrosion, cracks, etc.).

Table-3 Stud and Nut Compatible

Stud Compatible Nut

3.2.2 Thread Lubricants and Preservatives

1. The torque/tensioning values given in Appendices F as a general guidance. If required the

3. Friction coefficient (COF) of some preservative lubricant can be referred at Appendix D.

3.2.3 Flange Faces

Any deviation of tolerances shall be put in IAAN process.

If in doubt contact the COPI Asset Engineering for guidance.

3.2.5 Insulation Gasket Sets and Specialty Gasket

The following table is general rule for selection of tightening method:

Table-4 Torque/Tension Guidance based on bolt size and flange class

Bolt Size Flange Class Tension Torque Comments

Bolt Size Flange Class Tension Torque Comments

The equipment must have a valid calibration certificate.

Note: the flogging of bolts in hydrocarbon systems is not permitted.

3.3.1.2 Torque Wrenches

3.3.1.3 Torquing Procedure

Figure 1 Tightening Sequence

3.3.1.4 Hydraulic Jack Bolt Tensioning Equipment

3.4 Hot Bolting and Preventative Bolting

Hot bolting may only be considered on systems in the following duties:

(1) Seawater and Service water

Hot Bolting is NOT permitted on the following systems:

(1) Hydrocarbon gas

3.4.2 Hot bolting procedure

(10) Verify that the joint is totally leak-free.

3.4.3 Preventative Maintenance Bolting

3.4.4 Preventative Maintenance Bolting Procedure

4 Flange System Records

Asset Integrity Mgr.

1 Perform Visual Inspection I I I C R A

2 Perform Fugitive Emission I I I C R A

3 Perform Snoop Leak Detector R C A I I

Maintenance Spt./ Pipeline

Manager/ Operation Spt./

Asset Engineering Team

REQUIREMENT & PROCEDURE

Asset Integrity Mgr.