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Document Title: Flange Management Procedure: Revision Sheet
Document Title: Flange Management Procedure: Revision Sheet
Document Title: Flange Management Procedure: Revision Sheet
ID-G-BU-XXXXX-XXXXX-XXXXX
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Old COPI Document No.:
0A
IFC
18 June
2012
Rev
Status
Issue Date
AR
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AGN
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The originals are held within Document Management.
Revision Sheet
ConocoPhillips Indonesia Inc. Ltd
Unit Owner
REVISION
DATE
0A
18 June 2012
DESCRIPTION OF CHANGE
Issued for Comment
Contents
1.
2.
3.
4.
5.
Purpose
Scope
Reference
Safety Precautition
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
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
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.
Equipment
5.2
a.
b.
c.
Hand Tools
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 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
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.
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.
6.3
STAG
E
TORQU
E
SETTIN
G
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
REMARK
S
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
c.
STAG
E
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;7-611;4-2-10;3-1-9
REMARK
S
STAG
E
TORQU
E
SETTIN
G
BOLT SEQUENCE
TIGHTENING
REMARK
S
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;4-10-616
STAG
E
TORQU
E
SETTIN
G
30%
II
60%
III
100%
IV
100%
BOLT
SEQUENCE
TIGHTENING
REMARK
S
1-2-3-4;5-6-7-8;910-11-12;13-1415-16;17-18-1920
20-19-18-17;1615-14-13;12-1110-9;8-7-6-5;4-32-1
1-2-3-4;5-6-7-8;910-11-12;13-1415-16;17-18-1920
8-1-20-12;7-2-1911;6-4-18-10;5-317-9;16-15-14-13
f.
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
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
STAGE
TORQUE
SETTING
30%
II
60%
III
100%
IV
100%
7.1
BOLT
SEQUENCE
TIGHTENING
REMARKS
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
A
P
P
E
N
DI
X
Appendix 7.1.
7.1
Size
1
1
2
3
4
6
8
Min Torque
0.16
0.24
0.33
0.65
0.64
1.10
1.57
2.14
3.09
Max
Torque
3.61
3.61
3.61
3.61
7.2
7.2
7.2
12.84
12.84
Step 2
2.0
2.0
2.0
2.0
5.0
5.0
5.0
8.0
8.0
10
12
14
16
18
20
24
7.2
Size
1
1
2
3
4
6
8
10
12
14
16
18
20
24
U-7/8
U-7/8
U-1
U-1
U-1 1/8
U-1 1/8
U-1 1/4
3.6
4.91
5.15
6.5
7.63
9.11
13.84
20.72
20.72
31.09
31.09
45.83
45.83
64.61
11.0
12.0
17.0
18.0
26.0
27.0
39.0
5.0
6.0
6.0
8.0
9.0
10.0
15.0
11.0
12.0
17.0
18.0
26.0
27.0
39.0
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
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
Size
1
1
2
3
4
6
8
10
12
14
16
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
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
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
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
18
20
24
U-1 1/8
U-1 1/8
U-1 1/4
84.76
101.28
159.55
150.08
236.21
289.49
120.0
200.0
250.0
86.0
102.0
160.0
120.0
120.0
200.0