Document Title:

Flange Management Procedure

COPI Doc No.:

ID-G-BU-XXXXX-XXXXX-XXXXX

Originator:
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Area:
Location:
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Document Type:
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Old COPI Document No.:

0A

IFC

18 June
2012

Rev

Status

Issue Date

PT. Wijaya Karya (Persero). Tbk

Engineering-Onshore Sumatra
Suban
Suban Station
General
Flange Management Procedure
Piping / Piping

Issued for Comment

Reason for Issue

AR

FAD

AGN

Prepar
ed

Check
ed

Approval

MER / HS
OEE / Project
Approvals

Printed initials in the approval boxes confirm that the document has been signed.
The originals are held within Document Management.

Unit Owner

Flange Management Procedure

Piping /piping
ConocoPhillips Indonesia

ID-G-BU-xxxxx-xxxxx-xxxxx
Page 2 of 13

Revision Sheet
ConocoPhillips Indonesia Inc. Ltd

REVISION

DATE

0A

18 June 2012

DESCRIPTION OF CHANGE
Issued for Comment

Flange Management Procedure

Piping /piping
ConocoPhillips Indonesia

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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Flange Management Procedure

Piping /piping
ConocoPhillips Indonesia
1

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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.

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)

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)

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.

Flange Management Procedure

Piping /piping
ConocoPhillips Indonesia

ID-G-BU-xxxxx-xxxxx-xxxxx
Page 5 of 13

EQUIPMENT AND MAN POWER

5.1

Equipment
a. Hi-Force Including Accessories.

5.2

b.

Manual/Hand Torque Wrench

c.

Hand Tools

Manpower
a.

Mechanical Supervisor

b.

Safety man

c.

Mechanic/Helper

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 specs). 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.

Flange Management Procedure

Piping /piping
ConocoPhillips Indonesia

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Page 6 of 13

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
STAGE

TORQUE
SETTING

BOLT
SEQUENCE
TIGHTENING

30%

1-2-3-4

II

60%

4-3-2-1

III

100%

1-2-3-4

IV

100%

3-4-1-2

REMARKS

b. For 8 set Bolts Flange

STAGE

TORQUE
SETTING

BOLT
SEQUENCE
TIGHTENING

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

REMARKS

Flange Management Procedure

Piping /piping
ConocoPhillips Indonesia
c.

ID-G-BU-xxxxx-xxxxx-xxxxx
Page 7 of 13

For 12 set Bolt Flange

STAGE

TORQUE
SETTING

BOLT
SEQUENCE
TIGHTENING

30%

1-2-3-4;5-6-78;9-10-11-12

II

60%

12-11-10-9:8-76-5-;4-3-2-1

III

100%

1-2-3-4;5-6-78;9-10-11-12

IV

100%

8-5-12;7-6-11;42-10;3-1-9

REMARKS

d. For 16 set Bolt Flange

STAGE

TORQUE
SETTING

BOLT SEQUENCE
TIGHTENING

30%

1-2-3-4;5-6-7-8;9-1011-12;13-14-15-16

II

60%

16-15-14-13;12-1110-9:8-7-6-5-;4-3-2-1

III

100%

1-2-3-4;5-6-7-8;9-1011-12;13-14-15-16

IV

100%

1-12-8-13;2-11-714;3-9-5-15;4-10-6-16

REMARKS

e. For 20 set Bolt Flange

STAGE

TORQUE
SETTING

BOLT SEQUENCE
TIGHTENING

30%

1-2-3-4;5-6-7-8;910-11-12;13-14-1516;17-18-19-20

II

60%

20-19-18-17;16-1514-13;12-11-109;8-7-6-5;4-3-2-1

III

100%

1-2-3-4;5-6-7-8;910-11-12;13-14-1516;17-18-19-20

IV

100%

8-1-20-12;7-2-1911;6-4-18-10;5-317-9;16-15-14-13

REMARKS

Flange Management Procedure

Piping /piping
ConocoPhillips Indonesia

f.

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For 24 set Bolt Flange

STAGE

TORQUE
SETTING

30%

II

60%

III

100%

IV

100%

BOLT
SEQUENCE
TIGHTENING
1-2-3-4;5-6-78;9-10-1112;13-14-1516;17-18-1920;21-22-2324
24-23-2221;20-19-1817;16-15-1413;12-11-109;8-7-6-5;4-32-1
1-2-3-4;5-6-78;9-10-1112;13-14-1516;17-18-1920;21-22-2324
3-5-21-13;46-22-14;1716-1-9;18-152-10;24-1220-8;23-1119-7

REMARKS

Flange Management Procedure

Piping /piping
ConocoPhillips Indonesia

ID-G-BU-xxxxx-xxxxx-xxxxx
Page 9 of 13

g. For 28 set Bolt Flange

STAGE

TORQUE
SETTING

30%

II

60%

III

100%

IV

100%

BOLT
SEQUENCE
TIGHTENING
1-2-3-4;5-67-8;9-10-1112;13-14-1516;17-18-1920;21-22-2324;25-26-2728
28-27-2625;24-23-2221;20-19-1817;16-15-1413;12-11-109;8-7-6-5;4-32-1
1-2-3-4;5-67-8;9-10-1112;13-14-1516;17-18-1920;21-22-2324;25-26-2728
17-13-3-5-925;18-14-4-610-26;16-208-1-28-11;1519-7-2-2719;21-22-2324

REMARKS

Flange Management Procedure

Piping /piping
ConocoPhillips Indonesia

ID-G-BU-xxxxx-xxxxx-xxxxx
Page 10 of 13

h. For 32 set Bolt Flange

STAGE

TORQUE
SETTING

30%

II

60%

III

100%

IV

100%

BOLT
SEQUENCE
TIGHTENING
1-2-3-4;5-67-8;9-10-1112;13-14-1516;17-18-1920;21-22-2324;25-26-2728,29-30-3132
32-31-3029;28-27-2625;24-23-2221;20-19-1817;16-15-1413;12-11-109;8-7-6-5;4-32-1
1-2-3-4;5-67-8;9-10-1112;13-14-1516;17-18-1920;21-22-2324;25-26-2728,29-30-3132
32-6-2414;31-5-2313;30-7-2215;29-8-2116;28-4-1810;27-3-209;26-1-1712;25-2-1811

REMARKS

Flange Management Procedure

Piping /piping
ConocoPhillips Indonesia

APPENDIX
7.1

Recommended flange bolt torque.

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Flange Management Procedure

Piping /piping
ConocoPhillips Indonesia

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Appendix 7.1.

7.1
Size

1
1
2
3
4
6
8
10
12
14
16
18
20
24

7.2

Size

1
1
2
3
4
6
8
10
12
14
16
18
20
24

Recommended flange bolt torque for ANSI 150 RF

Bolt Size
U-1/2
U-1/2
U-1/2
U-1/2
U-5/8
U-5/8
U-5/8
U-3/4
U-3/4
U-7/8
U-7/8
U-1
U-1
U-1 1/8
U-1 1/8
U-1 1/4

Min Torque
0.16
0.24
0.33
0.65
0.64
1.10
1.57
2.14
3.09
3.6
4.91
5.15
6.5
7.63
9.11
13.84

Max
Torque
3.61
3.61
3.61
3.61
7.2
7.2
7.2
12.84
12.84
20.72
20.72
31.09
31.09
45.83
45.83
64.61

Bolting Torque (Kg.m)

Adopted
Step 1
Torque
2.0
1.0
2.0
1.0
2.0
1.0
2.0
1.0
5.0
1.0
5.0
2.0
5.0
3.0
8.0
3.0
8.0
4.0
11.0
5.0
12.0
6.0
17.0
6.0
18.0
8.0
26.0
9.0
27.0
10.0
39.0
15.0

Step 2
2.0
2.0
2.0
2.0
5.0
5.0
5.0
8.0
8.0
11.0
12.0
17.0
18.0
26.0
27.0
39.0

Recommended flange bolt torque for ANSI 300 RF

Bolt Size
U-1/2
U-1/2
U-1/2
U-1/2
U-5/8
U-5/8
U-5/8
U-3/4
U-3/4
U-7/8
U-7/8
U-1
U-1
U-1 1/8
U-1 1/8
U-1 1/4

Min Torque
0.38
0.70
0.97
2.30
1.50
3.08
4.41
5.00
8.48
9.79
14.79
13.58
19.04
19.85
23.72
38.86

Max
Torque
3.61
7.2
7.2
12.84
7.2
12.84
12.84
12.84
20.84
31.09
45.83
45.83
64.61
64.61
64.61
116.25

Bolting Torque (Kg.m)

Adopted
Step 1
Torque
2.0
1.0
4.0
1.0
4.0
2.0
8.0
3.0
5.0
3.0
8.0
4.0
9.0
5.0
10.0
6.0
15.0
10.0
22.0
11.0
30.0
16.0
30.0
15.0
32.0
20.0
32.0
21.0
33.0
25.0
76.0
40.0

Step 2
2.0
4.0
8.0
5.0
8.0
9.0
10.0
15.0
22.0
30.0
30.0
32.0
32.0
33.0
76.0

Flange Management Procedure

Piping /piping
ConocoPhillips Indonesia

ID-G-BU-xxxxx-xxxxx-xxxxx
Page 13 of 13

7.3 Recommended Flange bolt torque for ANSI 600 RF

Size

1
1
2
3
4
6
8
10
12
14
16
18
20
24

Bolt Size
U-1/2
U-1/2
U-1/2
U-1/2
U-5/8
U-5/8
U-5/8
U-3/4
U-3/4
U-7/8
U-7/8
U-1
U-1
U-1 1/8
U-1 1/8
U-1 1/4

Min Torque
1.26
2.31
3.17
7.55
4.92
10.12
16.91
21.92
35.63
40.21
53.98
54.50
75.04
84.76
101.28
159.55

Max
Torque
3.61
7.2
7.2
12.84
7.2
12.84
20.72
31.09
45.83
64.61
64.61
87.92
116.25
150.08
236.21
289.49

Bolting Torque (Kg.m)

Adopted
Step 1
Torque
3.0
2.0
6.0
3.0
6.0
4.0
12.0
8.0
6.0
6.0
12.0
11.0
19.0
17.0
30.0
23.0
44.0
36.0
60.0
41.0
80.0
55.0
100.0
56.0
120.0
76.0
120.0
86.0
200.0
102.0
250.0
160.0

Step 2
3.0
6.0
6.0
12.0
6.0
12.0
19.0
30.0
44.0
60.0
60.0
80.0
100.0
120.0
120.0
200.0