SHELL GRESIK TERMINAL PROJECT

FLANGE MANAGEMENT SYSTEM

PROCEDURE

STATUS SEISO SGT

REV. DATE
Prepared by Review by Reviewed/Approved by
0 10-Mar-2021 Issued for Review GPA NH
1 19-Apr-2021 Issued for Approval GPA NH

Document type : Document Number :

QA/QC SEI/PRO/FMS/002
Project Name Approval Status :
Approved Commented
SHELL GRESIK TERMINAL
Rev. Date
PROJECT SIGN
1
 SHELL GRESIK TERMINAL PROJECT

Document No. SEI/PRO/FMS/002

Title Revision 1
Flange Management System Procedure Issued Date 19-Apr-2021

REVISION HISTORY

Rev. Date Status

0 10-Mar-2021 Issued for Review

1 19-Apr-2021 Issued for Approval

 SHELL GRESIK TERMINAL PROJECT

Document No. SEI/PRO/FMS/002

Title Revision 1
Flange Management System Procedure Issued Date 19-Apr-2021

TABLE OF CONTENT

1.0 SCOPE
2.0 REFERENCE
3.0 MATERIAL
4.0 PERSONEL
5.0 PRE CHECK FOR FLANGE MANAGEMENT SYSTEM
5.1 Flange Condition
5.2 Acceptable of Pipe Flange Raised Face
6.0 FLANGE ALIGNMENT
7.0 BOLT / NUT AND GASKET
7.1 Bolt/Nut Check
7.2 Gasket Check
8.0 FLANGE BOLT TORQUE SQUENCE
9.0 CONTROL AND TIGHTENING INSPECTION
10.0 TAGGING
 SHELL GRESIK TERMINAL PROJECT

Document No. SEI/PRO/FMS/002

Title Revision 1
Flange Management System Procedure Issued Date 19-Apr-2021

1.0 SCOPE
This procedure provides minimum requirements for flange management / bolt tightening process from a
joining flange connection. The material used in this work is Carbon steel. This procedure does not cover
the design and material requirements, which is covered by Client’s specification document. This
procedure supplements the requirements of the applicable Codes and Standards. The purpose of this
document is to clearly describe all Project Quality Plan related activities within PT. Suci Energi Solusi
Indonesia and/or Client’s requirements.
2.0 REFERENCE
This procedure is developed with reference to the current edition of the following codes, standards and
specification.

ASME B16.5 – Pipe Flange and Flange Fitting

ASME B31.3 – Process Piping
ASTM A193-B7 W / A194-2H - Carbon & Alloy-Steel Nuts for Bolts Material
DEP 70.08.10.11 - Equipment and Tools for Maintenance: Mechanical Maintenance Equipment, tools and
bolt tensioning
3.0 MATERIAL
a. Storage
The store keeper responsible to properly manage material as describe in detail procedure
b. Quantitative Check
The Supervisor is fully responsible for the material flow between warehouse and site location.
Non Conformity shall be documented and reported when shortage material discovered during
material check
4.0 PERSONEL
CONTRACTOR’s Personel shall be responsible for the execution and implementation of this procedure
during installation stage. Pre Commisioning Group shall take control of Mechanical Completion. All
Personel shall be qualified to execute the work.
Personel or Team will be execute shall be trained and understand about sequence thorqueing and
tensioning refrence to Procedure Approved.
5.0 PRE CHECK FOR FLANGE MANAGEMENT SYSTEM
5.1 Flange Condition
 Check conditions of flange faces for scratches, dirt and scale
 Check for corrosion pitting and tool marks
 Inspect the gasket seating surfaces
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Document No. SEI/PRO/FMS/002

Title Revision 1
Flange Management System Procedure Issued Date 19-Apr-2021

 Check the areas on the flange where the nuts will seat, it should be flat and free
from pitting and excessive wear
 RTJ Grooves must be kept clean, corrosion free & undamaged
5.2 Acceptable of Pipe Flange Raised Face
Acceptable imperfection of pipe flange raised face are given in ASME 16.5 table 3. Refer the
table for Permissible Imperfections in Flange Facing Finish for Raised Face Flange
Table 1.0 – Flange Facing
NPS Maximum Radial Projection of Imperfections
(inch) No Deeper Than the Bottom Deeper Than the Bottom
(mm) (mm)

½ 3 1.5
¾ 3 1.5
1 3 1.5
1 1/4 3 1.5
1 1/2 3 1.5
2 3 1.5
2 1/2 3 1.5
3 4.5 1.5
3 1/2 6 3
4 6 3
5 6 3
6 6 3
8 8 4.5
10 8 4.5
12 8 4.5
14 8 4.5
16 10 4.5
18 12 6
20 12 6
24 12 6
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Document No. SEI/PRO/FMS/002

Title Revision 1
Flange Management System Procedure Issued Date 19-Apr-2021

6.0 FLANGE ALIGNMENT

Visually examine the flange alignment to ensure that an acceptable fit has been obtained. While aligning
flanges, make sure that there are no residual stresses in the joint. The use of heat correction for the
alignment of flanges is strictly prohibited.
5.3 Flange faces should be parallel and aligned
5.4 The flange bolt holes should be in line so that the bolts will pass freely
5.5 Perpendicularity tolerance of the face with the bore

7.0 BOLT / NUT AND GASKET

7.1 Bolt/Nut Check
 Visually examine nuts & Stud/bolts before installation to assure they are free from defects such
as corrosion, damage threads etc. Nut-bolts with damaged threads should not be used.
 Check the length of the stud or bolt to avoid short bolting and excessive threads. Minimum 3
threads should be free. Flange bolts shall be furnished in sufficient length to allow the use of bolt
tensioning equipment or spades, spacers, drip rings and wafer valves, and the associated extra
gaskets.
 Visually examine studs and nuts after cleaning to ensure free from burrs. Studs and nuts shall be
cleaned using a wire brush to remove any dirt on the threads. No additional Lubricant shall be
applied on threads and nuts to flange contact surfaces. Lubricant shall not be used in the gasket
and the gasket seating area.
 The bolt and nut material grades should be correctly identified before they are used.
 Bolts and nuts can only be reused if:
- 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.
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Document No. SEI/PRO/FMS/002

Title Revision 1
Flange Management System Procedure Issued Date 19-Apr-2021

7.2 Gasket Check

 Do not use sealing compound, grease or other paste or adhesive on gasket or flange faces.
 While gasket insertion, it shall not be forced into the gasket seat between the mating flange
faces. Once the gasket is seated the mating flanges are brought together carefully without
shaking the gasket off the seat, install all studs and run-up all nuts hand tight
 Visually examine gaskets, before installation, to assure they are free from defects.
 Color coding shall be maintained as per the rate and type of gasket provided by the
manufacture.
 Clean gasket seating face using a copper wire brush.
 Make sure the material is as specified, look for any possible defects or damage in the gasket
such as folds or creases.
 All Soft material gaskets should be replaced with new ones whenever an opened joint is to be
closed again
 Spiral wound gasket shall be used only once.
8.0 FLANGE BOLT TORQUE SQUANCE
Torque bolts and nuts in a sequence using a minimum of three torquing passes and the maximum bolt
stress as defined.
Phase 1 : Torque to a maximum of 30% of the final torque value in accordance with the torque
sequence. Check that gasket is getting compressed uniformly.
Phase 2 : Torque to a maximum of 60% of the final torque value.
Phase 3 : Torque to the final torque value (100%).
After the three basic torque passes are completed, repeat torquing the nuts at least once using the final
torque in a “CRISS-CROSS” manner until no further rotation of the nut is observed. When the bolt
loading requires a torque higher than 678 Nm (500 ft-lbs.) to be applied, hydraulic bolt torquing is
recommended.
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Document No. SEI/PRO/FMS/002

Title Revision 1
Flange Management System Procedure Issued Date 19-Apr-2021

For easy handling, bolt numbering shall be done clockwise around the flange with the following (table
2.0) squence:
 SHELL GRESIK TERMINAL PROJECT

Document No. SEI/PRO/FMS/002

Title Revision 1
Flange Management System Procedure Issued Date 19-Apr-2021

Table 2.0 – Torque Squence

Number of
Bolt Tightening Sequences to Follow
Bolt/Stud
4 Bolt Flange 1-3-2-4
8 Bolt Flange 1-5-3-7-2-6-4-8
12 Bolt Flange 1-7-4-10-2-8-5-11-3-9-6-12
16 Bolt Flange 1-9-5-13-3-11-7-15-2-10-6-14-4-12-8-16
20 Bolt Flange 1-11-6-16-3-13-8-18-5-15-10-20-2-12-17-4-14-9-19
24 Bolt Flange 1-13-7-19-4-16-10-22-2-14-8-20-5-17-11-23-6-18-12-24-3-15-9-21
28 Bolt Flange 1-15-8-22-4-18-11-25-6-20-13-27-2-16-9-23-5-19-12-26-3-17-10-24-7-21-14-28
32 Bolt Flange 1-17-9-25-5-21-13-29-3-19-11-27-7-23-15-31-2-18-10-26-6-22-14-30-8-24-16-32-4-20-12-28

Table 3.0 – Torque of Flange Class #150

Size in Thread Bolt Stress Torque Torque
Size in mm No. of Bolt Bolt Dia.
Inch Type lb/in2 lbf.ft. Nm
1/2 15 4 ½” UNC 25,000 22 30
3/4 20 4 ½” UNC 30,000 26 36
1 35 4 ½” UNC 33,000 29 39
1½ 40 4 ½” UNC 50,000 44 60
2 50 4 5/8” UNC 50,000 86 117
3 80 4 5/8” UNC 50,000 86 117
4 100 8 5/8” UNC 40,000 69 93
6 150 8 ¾” UNC 45,000 137 185
8 200 8 ¾” UNC 45,000 137 185
10 250 12 7/8” UNC 40,000 194 263
12 300 12 7/8” UNC 40,000 194 263
14 350 12 1” UN8 41,000 296 401
16 400 16 1” UN8 40,000 289 392
18 450 16 1 1/8” UN8 40,000 421 571
20 500 20 1 1/8” UN8 40,000 421 571
24 600 20 1 ¼” UN8 40,000 588 797

9.0 CONTROL AND TIGHTENING INSPECTION

After the flanged connection has been tightened, all joints shall be 100% inspected for uniform bolt
loading by wrench testing each bolt in the same sequence listed above until all bolts are judge to have
 SHELL GRESIK TERMINAL PROJECT

Document No. SEI/PRO/FMS/002

Title Revision 1
Flange Management System Procedure Issued Date 19-Apr-2021

the same level of tightness. All inspection activities shall witnessed and approved by Company
Representative. And The Tags shall be fitted on each bolt flange, which already tightening was
completed.
10.0 CALIBRATION EQUIPMENT
Calibration of Torque Shall be Calibrated from National 3rd party Company has Capability. Contractor
will be submit for Review the Certificate of Calibration equipment to check Expired date of
Calibration Certificate.
11.0 TAGGING
Flange joint connection installed shall be “tagged” when Inspection and Bolt Teghtening check already
done by the qualified personel has responsibility.

Attachment. 1.0 – Flange Tag.