Document Title: Flange Management Procedure

COPI Doc No.: ID-G-BU-XXXXX-XXXXX-XXXXX

Originator: PT. Wijaya Karya (Persero). Tbk

COPI Group Owner: Engineering-Onshore Sumatra
Area: Suban
Location: Suban Station
System: General
Document Type: Flange Management Procedure
Discipline / Subdiscipline: Piping / Piping
Old COPI Document No.:

18 June
0A IFC Issued for Comment AR FAD AGN MER / HS
2012

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.
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Revision Sheet
ConocoPhillips Indonesia Inc. Ltd

REVISION DATE DESCRIPTION OF CHANGE

0A 18 June 2012 Issued for Comment

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Contents
1. Purpose
2. Scope
3. Reference
4. Safety Precautition
5. Equipment and man power
5.1. Equipment
5.2. Man power
6. Bolt Tightening
6.1. Tightening Preparation
6.2. Recommended Bolt Tightening Procedure
6.3. Table for Bolt Tightening
7. Appendix
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1 PURPOSE

1.1. This procedure describes the requirement for bolt tightening for piping system perform
by Wika in accordance with Company in the scope of contract of Suban Condensate
Tank.

2 SCOPE

2.1. The procedure defines the method for bolt tightening using manual/hand torque wrench,
hydraulic torque wrench and hydraulic stud bolt tensioner.
2.2. Application of bolts tightening tool shall be done as per the following scope :
Bolt Diameter < 2” : General torque wrench (Manual/hand Torque Wrench or Hydraulic
torque wrench if applicable)

3 REFERENCE

3.1. ASME B16.5 Pipe,Flange, and Fitting

3.2. ASME B16.47 Large Diameter Steel Flange
3.3. ASME B31.3 Proses Piping
3.4. Manufacture Recommended (Hi-Force)

4 SAFETY PRECAUTIONS

Special attention shall be paid to this work as it utilizes high-pressure hydraulic oil (maximum
15,000 psi). Supervisor must be present at location to supervise the worker prior to bolt
tightening activity. Tools and equipment should be inspected before use to ensure good
working condition. The working area shall be roped off and warning notices shall be displayed.
For high elevation or remote area work, adequate scaffolding shall be erected for safety.
Operators shall handle components during placing or removing the bolt tightening equipment
as per manufacturers recommendation. Operators shall also be equipped with safety glasses,
hard hats, gloves and safety shoes.
Additional safety equipment shall be worn as advised by the Project HSE Department.
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5 EQUIPMENT AND MAN POWER

5.1 Equipment
a. Hi-Force Including Accessories.
b. Manual/Hand Torque Wrench
c. Hand Tools

5.2 Manpower
a. Mechanical Supervisor
b. Safety man
c. Mechanic/Helper

6 BOLT TIGHTTENING

6.1 Tightening Preparation

a. Flanged joints shall be properly aligned before torquing and maximum allowable
translation of flange centerline & faces should be specified. Maximum allowable run
out’ between flange faces should also be specified. (To be noted as max
values/tolerances according to the relevant spec’s). see Appendix for dimensional
tolerance.
b. Prior to tightening, all equipment shall be checked for any damage or imperfections.
After cleaning, studs should be lubricated with an approved compound.
c. The operator shall set the correct hydraulic pressure to achieved the required bolt
torque for each stud bolt size according to appendix 1 (recommended tensioning
pressure table).
d. COMPANY reserves the right to witness the applied pressure for the torquing of the
joint during reinstatement

6.2 Recommended Bolt Tightening Procedure

a. Install the gasket on the flange face and bring the flanges together until contacting
the gasket.
b. Install all bolts and studs, making sure they are free from dirt and grit and that the
threads and under nut faces are well lubricated.
c. Run up nuts finger tight
d. Mark the proper tightening sequence on the studs with chalk as per diagram on Para
5.3 or as per recommended by the equipment manufacturer
e. Determine the torque value for the studs or bolt to be tightened.
1. First tightening stage should be limited to a maximum of 30% of final torque
setting.
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2. Second tightening stage should be limited to a maximum of 60% of final torque

setting.
3. Third tightening stage should be carried out at the 100% torque setting.
Note : 1, 2 & 3 should be tightened using the diagonal bolt sequence shown in the
diagram
f. On the fourth and final tightening sequence change from diagonal tightening to
adjacent bolt-to-bolt tightening using the 100% torque setting value

6.3 Table for Bolt Tightening

a. For 4 set Bolt Flange

BOLT
TORQUE
STAGE SETTING
SEQUENCE REMARKS
TIGHTENING

I 30% 1-2-3-4

II 60% 4-3-2-1

III 100% 1-2-3-4

IV 100% 3-4-1-2

b. For 8 set Bolts Flange

BOLT
TORQUE
STAGE SEQUENCE REMARKS
SETTING
TIGHTENING

I 30% 1-2-3-4;5-6-7-8

II 60% 8-7-6-5;4-3-2-1

III 100% 1-2-3-4;5-6-7-8

IV 100% 2-6;1-5;4-8;3-7
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c. For 12 set Bolt Flange

BOLT
TORQUE
STAGE SEQUENCE REMARKS
SETTING
TIGHTENING
1-2-3-4;5-6-7-
I 30%
8;9-10-11-12
12-11-10-9:8-7-
II 60%
6-5-;4-3-2-1
1-2-3-4;5-6-7-
III 100%
8;9-10-11-12
8-5-12;7-6-11;4-
IV 100%
2-10;3-1-9

d. For 16 set Bolt Flange

TORQUE BOLT SEQUENCE

STAGE REMARKS
SETTING TIGHTENING

1-2-3-4;5-6-7-8;9-10-
I 30%
11-12;13-14-15-16

16-15-14-13;12-11-
II 60%
10-9:8-7-6-5-;4-3-2-1

1-2-3-4;5-6-7-8;9-10-
III 100%
11-12;13-14-15-16

1-12-8-13;2-11-7-
IV 100%
14;3-9-5-15;4-10-6-16

e. For 20 set Bolt Flange

TORQUE BOLT SEQUENCE

STAGE REMARKS
SETTING TIGHTENING

1-2-3-4;5-6-7-8;9-
I 30% 10-11-12;13-14-15-
16;17-18-19-20
20-19-18-17;16-15-
II 60% 14-13;12-11-10-
9;8-7-6-5;4-3-2-1
1-2-3-4;5-6-7-8;9-
III 100% 10-11-12;13-14-15-
16;17-18-19-20
8-1-20-12;7-2-19-
IV 100% 11;6-4-18-10;5-3-
17-9;16-15-14-13
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f. For 24 set Bolt Flange

BOLT
TORQUE
STAGE SEQUENCE REMARKS
SETTING
TIGHTENING
1-2-3-4;5-6-7-
8;9-10-11-
12;13-14-15-
I 30%
16;17-18-19-
20;21-22-23-
24
24-23-22-
21;20-19-18-
17;16-15-14-
II 60%
13;12-11-10-
9;8-7-6-5;4-3-
2-1
1-2-3-4;5-6-7-
8;9-10-11-
12;13-14-15-
III 100%
16;17-18-19-
20;21-22-23-
24
3-5-21-13;4-
6-22-14;17-
16-1-9;18-15-
IV 100%
2-10;24-12-
20-8;23-11-
19-7
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g. For 28 set Bolt Flange

BOLT
TORQUE
STAGE SEQUENCE REMARKS
SETTING
TIGHTENING
1-2-3-4;5-6-
7-8;9-10-11-
12;13-14-15-
I 30% 16;17-18-19-
20;21-22-23-
24;25-26-27-
28
28-27-26-
25;24-23-22-
21;20-19-18-
II 60% 17;16-15-14-
13;12-11-10-
9;8-7-6-5;4-3-
2-1
1-2-3-4;5-6-
7-8;9-10-11-
12;13-14-15-
III 100% 16;17-18-19-
20;21-22-23-
24;25-26-27-
28
17-13-3-5-9-
25;18-14-4-6-
10-26;16-20-
IV 100% 8-1-28-11;15-
19-7-2-27-
19;21-22-23-
24
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h. For 32 set Bolt Flange

BOLT
TORQUE
STAGE SEQUENCE REMARKS
SETTING
TIGHTENING
1-2-3-4;5-6-
7-8;9-10-11-
12;13-14-15-
16;17-18-19-
I 30%
20;21-22-23-
24;25-26-27-
28,29-30-31-
32
32-31-30-
29;28-27-26-
25;24-23-22-
21;20-19-18-
II 60%
17;16-15-14-
13;12-11-10-
9;8-7-6-5;4-3-
2-1
1-2-3-4;5-6-
7-8;9-10-11-
12;13-14-15-
16;17-18-19-
III 100%
20;21-22-23-
24;25-26-27-
28,29-30-31-
32
32-6-24-
14;31-5-23-
13;30-7-22-
15;29-8-21-
IV 100% 16;28-4-18-
10;27-3-20-
9;26-1-17-
12;25-2-18-
11
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7 APPENDIX

7.1 Recommended flange bolt torque.

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Appendix 7.1.

7.1 Recommended flange bolt torque for ANSI 150 RF

Bolting Torque (Kg.m)
Size Bolt Size Min Torque Max Adopted Step 1 Step 2
Torque Torque
½” U-1/2 0.16 3.61 2.0 1.0 2.0
¾” U-1/2 0.24 3.61 2.0 1.0 2.0
1” U-1/2 0.33 3.61 2.0 1.0 2.0
1 ½” U-1/2 0.65 3.61 2.0 1.0 2.0
2” U-5/8 0.64 7.2 5.0 1.0 5.0
3” U-5/8 1.10 7.2 5.0 2.0 5.0
4” U-5/8 1.57 7.2 5.0 3.0 5.0
6” U-3/4 2.14 12.84 8.0 3.0 8.0
8” U-3/4 3.09 12.84 8.0 4.0 8.0
10” U-7/8 3.6 20.72 11.0 5.0 11.0
12” U-7/8 4.91 20.72 12.0 6.0 12.0
14” U-1 5.15 31.09 17.0 6.0 17.0
16” U-1 6.5 31.09 18.0 8.0 18.0
18” U-1 1/8 7.63 45.83 26.0 9.0 26.0
20” U-1 1/8 9.11 45.83 27.0 10.0 27.0
24” U-1 1/4 13.84 64.61 39.0 15.0 39.0

7.2 Recommended flange bolt torque for ANSI 300 RF

Bolting Torque (Kg.m)

Size Bolt Size Min Torque Max Adopted Step 1 Step 2
Torque Torque
½” U-1/2 0.38 3.61 2.0 1.0 2.0
¾” U-1/2 0.70 7.2 4.0 1.0 4.0
1” U-1/2 0.97 7.2 4.0 2.0
1 ½” U-1/2 2.30 12.84 8.0 3.0 8.0
2” U-5/8 1.50 7.2 5.0 3.0 5.0
3” U-5/8 3.08 12.84 8.0 4.0 8.0
4” U-5/8 4.41 12.84 9.0 5.0 9.0
6” U-3/4 5.00 12.84 10.0 6.0 10.0
8” U-3/4 8.48 20.84 15.0 10.0 15.0
10” U-7/8 9.79 31.09 22.0 11.0 22.0
12” U-7/8 14.79 45.83 30.0 16.0 30.0
14” U-1 13.58 45.83 30.0 15.0 30.0
16” U-1 19.04 64.61 32.0 20.0 32.0
18” U-1 1/8 19.85 64.61 32.0 21.0 32.0
20” U-1 1/8 23.72 64.61 33.0 25.0 33.0
24” U-1 1/4 38.86 116.25 76.0 40.0 76.0
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7.3 Recommended Flange bolt torque for ANSI 600 RF

Bolting Torque (Kg.m)

Size Bolt Size Min Torque Max Adopted Step 1 Step 2
Torque Torque
½” U-1/2 1.26 3.61 3.0 2.0 3.0
¾” U-1/2 2.31 7.2 6.0 3.0 6.0
1” U-1/2 3.17 7.2 6.0 4.0 6.0
1 ½” U-1/2 7.55 12.84 12.0 8.0 12.0
2” U-5/8 4.92 7.2 6.0 6.0 6.0
3” U-5/8 10.12 12.84 12.0 11.0 12.0
4” U-5/8 16.91 20.72 19.0 17.0 19.0
6” U-3/4 21.92 31.09 30.0 23.0 30.0
8” U-3/4 35.63 45.83 44.0 36.0 44.0
10” U-7/8 40.21 64.61 60.0 41.0 60.0
12” U-7/8 53.98 64.61 80.0 55.0 60.0
14” U-1 54.50 87.92 100.0 56.0 80.0
16” U-1 75.04 116.25 120.0 76.0 100.0
18” U-1 1/8 84.76 150.08 120.0 86.0 120.0
20” U-1 1/8 101.28 236.21 200.0 102.0 120.0
24” U-1 1/4 159.55 289.49 250.0 160.0 200.0