MD-04-MT-MSSTA-PD-025 Rev.03 Maintenance Procedure For Bolted Flange Joint Management (2023)

[ NSRP INTERNAL ]
Amendment Table
Rev. Prepared Reviewed

Date Description Approved by
No. by by
N.V Trang/
00 28.5.21 Initial release N.B.Huy Jan Kusche
N.D Thang
N.V Trang/
N.D
01 15.7.21 Revised N.B.Huy Jan Kusche
Thang/ H.
Dijkstra
N.V Trang/
N.D
02 16.9.21 Revised N.B.Huy Thang/ Jan Kusche
Nicolas
Dowling
N.V
N.V Trang/
Canh/T.Q. Jan Kusche/
03 20.10.22 Revised N.D
Khai/NB TZ
Thang/
Huy
(*) With reference to MD-04-MT-RSSTA-PD-025 Revision 8 Maintenance Procedure for bolted

flange joint management and because of the change in document code which is mentioned in
MD-04-MT-DMS-PD-003 Maintenance Document Management Procedure. Detail of revision to
be updated in Amendment Report (Page 4)
Document No.: MD-04-MT-MSSTA-PD-025

Document title: Maintenance procedure for bolted flange joint management
Effective date: 01st-Apr-2023 Rev. No.: 03 Page 3 of 87
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AMENDMENT REPORT FORM
Rev Item Original Revised Reason

00 6.5.1 Non- rated Remove non-rated blind, using Ensure the safety
blinds temporary rated blinds instead factor for blinding
of non-rated blinds works.
00 6.5.3 - Add blind storage To ensure blind has
been stored
properly and
identify the blind
information
01 6.5.1 Rated blinds Permanent rated blind will be More definition of
Instead of rated blinds permanent rated
blinds and
temporary rated
blinds
01 6.2.6 - Add definition of critical flange To avoid repeat
joints and special requirement works and control
for inspection critical flange joint flange joint
properly.
02 6.2.6 Critical flanges Add new definition of critical To match with new
flanges concept of critical
flanges.
02 6.3.5 Tightening All previous torque is replaced To match with
method by new calculation of torque as ASME PCC 1-2019
attachment 5 standard.
02 Attachment 1 Attachment 6 Removed To match with
Attachment 2 Attachment 8 ASME PCC 1-2019
Attachment 6 Attachment 9 standard.
Attachment 8 Attachment 10
Attachment 12
Attachment 14
02 Attachment 1 To match with new
revised
revised
revised
revised
revised
revised
02 Attachment 16 Attachment 16 Attachment 10 To match with new

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revised
revised
revised
02 - - Attachment 5 Add new torque
value for bolt
tightening
02 Attachment 3 Attachment 3 Attachment 3 Tightening Add new for
Flange Bad sequence which direct refer to Control Bac Actor
Actor List ASME PCC-1 Item
03 Attachment 1 NA NA Newly add
03 6.3.8.3 Manual Legacy Cross Speedy Alternative Assembly Update follow
Torque Wrench Pattern Parttern #1 ASME PCC-1
or Control
Torque Method
03 6.3.8.4 Manual Not clearly Add requirement for Bolt Newly add
Torque Wrench specify Tensioning and Alternative
or Control method
Torque Method
03 6.4 Flange NA NA Newly add
Management
Tracker and
Tagging
03 6.5 Quality NA NA Newly add
Assurance and
Quality Control
Provision.
03 6.6 TA Flange NA NA Newly add

Management
Provision

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CONTENTS
1. PURPOSE ........................................................................................................... 9
2. SCOPE ................................................................................................................ 9
3. RESPONSIBILITY ............................................................................................. 10
4. DEFINITION & ABBREVIATION ........................................................................ 10
5. REFERENCE .................................................................................................... 11
6. FLANGE MANAGEMENT PROCEDURE .......................................................... 13
6.1 General ............................................................................................................. 13
6.2 Preparation of work......................................................................................... 13
6.2.1 Confirmation of Work Order and safety requirements .................................... 13
6.2.2 Personal protective equipment....................................................................... 14
6.2.3 Environmental precautions............................................................................. 15
6.2.4 Materials and tools ......................................................................................... 15
6.2.5 Critical flanges/ Bad Actor .............................................................................. 16
6.3 Execution of work ........................................................................................... 18
6.3.1 Training .......................................................................................................... 18
6.3.2 Cleaning and Examination of flange and Fastener Contact surface .............. 18
6.3.3 Alignment of bolted flanged joints .................................................................. 20
6.3.4 Installation of gasket ...................................................................................... 22
6.3.5 Lubrication of Working Surface ...................................................................... 22
6.3.6 Installation of Bolts: ........................................................................................ 23
6.3.7 Numbering of Bolts: ....................................................................................... 23
6.3.8 Tightening of bolts .......................................................................................... 24
6.3.8.1 Target Bolt Assembly Stress .......................................................................... 24
6.3.8.2 Tightening methods........................................................................................ 24
6.3.8.3 Manual Torque Wrench or Control Torque Method......................................... 25
6.3.8.4 Bolt Tensioning or Control Torque with Bolt Stress Measurement .................. 26
6.3.9 Start-up Re-torque ......................................................................................... 28
6.3.10 Live Tightening for Flange Leak Rectification................................................. 29

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6.3.11 Hot Bolting ..................................................................................................... 29
6.3.12 Half Bolting..................................................................................................... 31
6.3.13 Guidelines for leakage test by hydrogen ........................................................ 31
6.3.14 Guidelines for Joint Pressure and Tightness Test .......................................... 31
6.3.15 Joint Disassembly: ......................................................................................... 32
6.4. Flange Management Tracker and Tagging ..................................................... 32
6.4.1 Flange Management Tracker ......................................................................... 32
6.4.2 Flange Joint Mapping ..................................................................................... 32
6.4.3 Flange Tagging .............................................................................................. 33
6.5. Blinding and Tagging ...................................................................................... 34
6.4.4 Blinding .......................................................................................................... 34
6.4.5 Blind Tagging ................................................................................................. 35
6.4.6 Blind storage .................................................................................................. 36
6.5 Quality Assurance and Quality Control Provision. .......................................... 36
6.5.1 Flange Quality control .................................................................................... 37
6.5.1.2 Non-critical Flange ......................................................................................... 37
6.5.1.2 Critical Flange ................................................................................................ 37

6.5.1.3 Bad Actor Flange ........................................................................................... 38
6.5.2 Key Performance Areas/ Indicators ................................................................ 38
6.5.3 Bolting Service Contractor minimum Requirement ........................................ 39
6.5.4 Punching: ....................................................................................................... 39
6.6 Work order closure ......................................................................................... 40
6.7 TA Flange Management Provision ................................................................. 41
6.7.1 Temporary Gasket .............................................................................................. 41
6.7.2 Temporary Blind during TA ................................................................................. 41
6.7.3 Flange Protection during TA ............................................................................... 41
ATTACHMENT – 01 .................................................................................................... 42

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ATTACHMENT – 02 Bolts Numbering ....................................................................... 42

ATTACHMENT - 03: Bad Actor Flange List ................................................................. 43
ATTACHMENT - 04 ..................................................................................................... 44
ATTACHMENT – 05 Flange Target Stress Tightening Value ....................................... 45
ATTACHMENT – 06 .................................................................................................... 47
ATTACHMENT - 07 ..................................................................................................... 48
ATTACHMENT - 08 ..................................................................................................... 49
ATTACHMENT – 09 TEMPORARY RATED BLIND TABLE ........................................ 67
ATTACHMENT - 10 ..................................................................................................... 68
ATTACHMENT - 11 ..................................................................................................... 69
ATTACHMENT - 12 ..................................................................................................... 70
ATTACHMENT – 13 Flange Management Tracker ..................................................... 71
ATTACHMENT – 14 – TA/ Pitstop Flange Management Detail guideline. ................... 72

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1. PURPOSE
This procedure is to identify and describe fundamental requirements for the management of
all bolted flange joints in Nghi Son Refinery& Petrochemical LLC (NSRP) to ensure that all
joints are disassembly/ assembly/tightening follow the ASME PCC-1 guideline to achieve
target bolt tress assembly defined by this procedure for Free Leak Goal for Flange Bolted
Flange Management work. Depending on individual situations, Vendor documents are
required to refer.
This procedure shall be considered a supplement to ASME PCC-1 and should be used in
conjunction with the ASME PCC-1 guidelines.
2. SCOPE
The practices in this document apply to all standard ASME B16.5 and ASME B16.47 piping
flanges using ASME B16.20 or similar ring-type gaskets where the gaskets are enclosed
entirely within the bolt hole circle. It includes flange preparation, assembly, and bolt tightening
recommendations. The non-metallic Flange can be referred to with tightening value refer to
Attachement-4. For non-circular Flange, the Assembly/Disassembly procedure can be
referred to in Principal.
The general concepts in this document can also be adapted for use with engineered
equipment flanges (such as heat exchanger shell and channel flanges) and other similar
made-to-order bolted flanged connections where the flanges are designed using the rules in
ASME Section VIII, Division 1, Appendix 2, or another similar standard. However, the target
bolt assembly stress for engineered equipment flanges is normally evaluated for each specific
equipment item, with consideration of the target gasket seating stress required for each
individual flanged connection.
The objectives of this RP are:
a) Ensure sustained mechanical joint integrity, to prevent loss of containment and fugitive
emissions from bolted flanged connections.
b) Provide guidance on the preferred bolt tightening method.
c) Provide guidance on the target gasket assembly stress,
d) Prevent excessive levels of stress on the joint components (flanges, bolting, and gaskets)
and.
e) Provide guidance on training and QA / QC recommendations for flange assembly.

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This procedure is intended for use in facilities related to oil and gas production, gas handling,
oil refining, chemical processing, gasification, distribution, and supply/marketing. Application
in other facilities may also apply. This document can be used as a reference for bolt tightening
scenarios with existing or new flanges. New construction standards may differ, so the
appropriate project requirements should be referenced when making up new piping systems.
Installations associated with mechanical equipment and instrumentation may require special
attention and are considered outside the scope of this document. Consult with Maintenance
Supervision, the Mechanical Equipment Inspector, or the Pressure Equipment Inspector for
additional guidance associated with those special items.
This procedure will not be applied to the flanges which tightening was completed before
shipping from factory.
3. RESPONSIBILITY
This procedure is approved by Division Manager (DM) of Maintenance Division. DM is

responsibility for issuing and distributing this procedure. The procedure will be reviewed
periodically, revised, and updated as needed. The DM reserves the right to make any
amendment and modification this procedure subject to requirements of proper management.
4. DEFINITION & ABBREVIATION
LOTO Lock out and tag out

HSE Health, Safety, Environment Division.
CMMS Computerized Maintenance Management System
DM Division Manager
MSDS Material Safety Data Sheet
MRO Maintain, Repair and Operate material
NSRP Nghi Son Refinery & Petrochemical LLC.
PM Preventive Maintenance
P& ID Piping& Instrument Drawing
PTW Permit To Work
SWMS Safe Work Method Statement
WO Work Order
WR Work Request
WP Work Pack
ASME The people have the experience of working on ASME Bolted Flange Joint

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Bolting and Qualified as Bolting Specialist Qualification by ASME PCC-1 or

Specialist Equivalent Certification by 3rd Party (Accepted for ASME PCC-1, ECITB or
EN1591)
Flange QC The people are competence and designated for Inspect the Bolted Flange
Inspector Joint element with Bolt, Nut, Flange, Gasket, Tightening Method, Sequence
which required Hold ASME PCC-1 Bolting Specialist qualification or Eq
Hot Bolting the sequential removal and replacement of bolts on flanged joints while the
unit is under reduced operating pressure
Half Bolting the removal of every other bolt (so the flange is left with half the number of
bolts) during plant depressurization, usually when the system is close to
atmospheric pressure.
Live tightening all bolts on a joint while the unit is operational or has been in
Tightening operation for a period of time
Start-up tightening all bolts on a joint while the unit is coming up to operating
retorque temperature in a circular pass until the nuts no longer turn
Bad Actor Problematic joints that have a history of leakage
Critical Joint Joints that are typically more difficult to seal, or joints where leaks could result
in high consequence incidents due to their size or service conditions
Flange The competence and experience on Flange Management job person who
Coordinator designate for Manage, Control and coordinate for Flange Joint Management
work which required Hold ASME PCC-1 Bolting Specialist qualification or Eq
Bolting The Specialized Service to provide the High-Quality Bolting Work on Critical/
Service Bad Actor Joint which included Flange Assembly, Flange Inspection and
Contractor Rectification, Bolt Tensioning, Control Torque with Bolt Stress Measurement
which meeting minimum requirement for Bolting Service Contractor.
5. REFERENCE
Document Number Title
Chapter 10.
ISRS V8.1 Book of Knowledge
Asset Management
MD-02-MT-PR-001 Principle for Maintenance Division
MD-03-MT-WF-005 Breakdown Maintenance Workflow for Production Facilities
MD-03-MT-WF-006 Predictive Maintenance Workflow for Production Facilities
MD-03-MT-WF-001 Preventive Maintenance Workflow for Production Facilities
MD-03-MT-WF-012 Workshop management Workflow

MD-04-HSE-HS-PD-
Permit to Work Procedure
003

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MD-04-HSE-HS-PD-
Personal Protective Equipment Management Procedure
001
MD-04-HSE-HS-PD- Job Safety Analysis (JSA)& Safe Work Method Statement (SWMS)
004 Procedure
ASME B16.5 Pipe flanges and flanged fittings (NPS ½ through NPS 24)
ASME B16.1 Gray iron pipe flanges and flanged fittings
ASME B16.20 Metallic gasket for pipe flanges
ASME B16.21 Nonmetallic gasket for pipe flanges
ISO 9001:2008 Quality Management System-requirements
ASME-PCC1-2019 Guidelines for Pressure boundary bolted flange joint assembly

Method statement for flange tightening for GRP pipes and Piping
VV2110-002-A-804
components for Non-pressurized line
VV3130-007-A-645 Flange Management Procedure

Procedure for bolt tightening and hydraulic bolt tensioning of
VM2153-202-A-637
flanged joint
VV3160-001-A-146 Method Statement and JSA for Flange Management Work
VV3160-001-B-016 Bolt tightening/ Tensioning Procedure
VV3160-001-C-676 Bolt tightening Procedure, include flange management
VV3160-006-B-629 Flange Bolt Tightening Procedure
VV3160-008-B-623 Flange Management Procedure
VV3160-001-A-103 Method statement and JSA for Piping Installation
VV3163-101-A-109 Method statement for U/G pipe coating & wrapping work

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S-000-1360-0002V Piping Material Specification
S-000-1360-0004V Specification for Identification of Piping Materials
6. FLANGE MANAGEMENT PROCEDURE
6.1 General
The leakage on bolted flanged joint has always been a problem. This procedure will instruct
to eliminate that issue. This section gives a brief outline of how joints work and provides
guidance on the safe and efficient assembly and disassembly of flanged joints, it also gives
instruction for Hot Torque/ Hot Bolting/Half Bolting application.
The principle of a bolted joint is based on the bolting delivering sufficient joint compression
and gasket seating stress to withstand maximum service pressure end force. A bolted flange
joint shall provide leak-free service for the process system.
6.2 Preparation of work
6.2.1 Confirmation of Work Order and safety requirements
Any preventive maintenance activity shall be performed in accordance with approved PM

schedule. Through CMMS, WO will be generated and approved before execution.
Maintenance team leader and his team members who are assigned the work shall carefully
check the requirements on WO and carry-out following activities:
- Check and confirm location, access way condition to the bolted flange joint. Scaffolding and
insulation will be prepared if necessary.
- Identify any escape route in case of emergency.
- Prepare P&ID drawings, ISO metric drawings, datasheet, MSDS.
- Make sure to understand the process condition and type of fluids/chemicals inside flange.
- Checking LOTO, drains, vents have been done by Operation Division.
- Check and confirm flange information such as size, type, rating of flange and gaskets.
- Verify the gaskets are available to be used in Warehouse.
- All Stud bolts information will be prepared.
- Confirm calibration certificate of air/hydraulic bolt tensioners.
- Confirm and obtain necessary advices from Operation.
- If the maintenance work is high risk, conduct SWMS session with representative from

[ NSRP INTERNAL ]
operation and HSE. All risk assessments will be identified and added. The contingency and
mitigation plan also will be discussed.
- Obtain approval of hot work permit where the work could create a sparking (fire) hazard
including use of electric testing equipment (with or without battery cells).
- Obtain all Permits to Work required within the scope of work as per PTW Procedure.
- Conduct a Safety Toolbox Meeting with dedicated craftsmen and workers to discuss the
following:
▪ Work purpose, scope, expected duration, risk assessment, MSDS, Vendor documents,
drawings, etc.
▪ Do not operate or do any maintenance activity, even opening equipment cover of other
equipment that are not in PTW’s scope.
▪ Un-controlled PTW’s scope or incorrect isolation will become hazardous e.g.: equipment
damage, human injury, explosion, or Refinery shutdown.
▪ Required isolation, check and ensure all isolations have been completed in accordance
with approved LOTO.
▪ Consider any possible interference in the work area, and any possible action to be taken.
▪ Before operating any air/hydraulic bolt tensioners, verify the maximum operating
pressure for each equipment item and do not exceed the specified maximum levels in
operation.
▪ Do not handle air/hydraulic tools by their hoses or air/hydraulic connections.
▪ Always alert to the position and avoid standing on the line or other equipment or line of
fire.
▪ Verify that all quick coupling is well connected and fully engaged before pressurizing.
6.2.2 Personal protective equipment
The personnel who involve into the activity are required to wear the standard personal
protective equipment (PPE) such as Eye protection, Helmet, clothing…. Additional PPE must
be worn for this procedure due to the nature of the work or the location.
- Personal protective hydrogen sulfide (H2S) detector must be worn in designated areas.
- Suitable gloves must be worn when handling hazardous materials or contacting a cold or hot
surface.
- Double ear protection (Ear plug & earmuff) must be attached before entering the area with
noise level above 85 db.

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6.2.3 Environmental precautions
Maintenance is conducted in accordance with governmental requirements for the protection

of the environment.
- Make sure good housekeeping is carried out during and after each work.
- Do not drain or vent any liquid or gas to an open space, on the ground, or into the sea. Use
only the approved method to drain or vent the systems.
- Gather all waste maintenance materials produced during work. After work, move and store
them at the reserved place.
6.2.4 Materials and tools
Before starting work, specification of minimum requirement for identification of piping material
by color coding and/or marking (stamping, stenciling, pressing, cast molding, etc) have to be
identified properly, it is very important to prepare maintenance work, details of color coding
and marking is described in S-000-1360-0004V (Specification for Identification of Piping
Materials).
Details of material selection, design pressure, temperature design, thickness and identification
code must be verified by Piping class index, it is described in S-000-1360-0002V (Piping
Material Specification).
And the following preparation materials and tools shall be done:
- Gaskets.
- Clouts.
- Solvent.
- Air/hydraulic bolt tensioners (include calibration certificates which required annually
calibration.)
- Torque wrench (include calibration certificates which required annually calibration.)
- Hydraulic Torque Machine
- Spanners (non-sparking type).
- Hammers (non-sparking type).
- Flange splitter tool (if required).
- Feeler gauges.
- Flange Surface Finish comparator/ Caliper/measurement tape/ RTJ grooved Gauge Set.
- Bolts and nuts. (Used to replace if necessary)

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- Lubricant – Molykote 1000, etc.

- Temporary Gasket for TA Insolation: Refer 6.7.1
- Plastic Cap/Rubber Sheet for Flange Protection during TA: Refer 6.7.2
6.2.5 Critical flanges/ Bad Actor
The Flange Management work shall identify and classify the Flange to Normal Flange, Critical and
Bad Actor Flange to apply the adequate Flange Quality Control based on the Leak History (Bad
Actor); Medium, Flange Rating, Flange Size. The Quality control and requirement for Non-
critical/Critical Flange/ Bad Actor shall be defined in 6.6 Quality Assurance and Quality Control
6.2.5.1 Bad actor Flange:
The Bad Actor Flange shall be defined based on the Critical Flange with Leak History which is
recorded in CMMS system and Incident Notification. The Bad Actor Flange list is referred to
Attachment 3. The Bad Actor shall be Asset Registered in CMMS with PM set-up such as per
Recommended by AI/CES and tracking the history.
The Bad Actor can be considered for all Heat Exchangers/Equipment with current utilize Metal
Double Jacketed Gasket as this gasket with less durable/ Reliability/ Easy to creep in cyclic service
as not recommended by Code/Standard.
The Bad Actor List shall be reviewed and refreshed yearly to add new location or withdraw the item
out of the list with tracking Flange have no Leak in 04 years since Flange Leak Rectification.
6.2.5.2 Critical Flange
Critical flange Joints are defined as:

A. All Flange Joints belong to Unit 014-GOHDS, 042-CCR, 043-CCRR, 020-RHDS, 070- HMU
and satisfy Class1 will be defined “Critical Flange”.
B. All Flange Joints belong to Unit 014-GOHDS, 042-CCR, 043-CCRR, 020-RHDS, 070- HMU
and satisfy Class2 with Score is 12 and above will be Defined “Critical Flange”.
C. All flanges belong to HHPS and HHPBFW and Hydrogen Pipeline with score in table 2 is from
12 and above shall be Critical Flange.

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Service fluid Critical flanges
1) Flammable services that can auto-refrigerate and

lead to brittle fracture
2) Pressurized services that can rapidly vaporize during
release, creating vapors that can collect and form an
explosive mixture, such as C2, C3, and C4 streams.
Fluids that can rapidly vaporize are those with
atmospheric boiling temperatures below 50 °F (10 °C)
or where the atmospheric boiling point is below the
operating temperature (typically a concern with high- All flanges handed
temperature services) service fluid in class 1
CLASS 1 3) Hydrogen sulfide (greater than 3 % weight) in a shall be critical Flange
gaseous stream Joint
4) Anhydrous hydrogen chloride
5) Flammable services operating above their auto-
ignition temperature
6) on-site strong acids and caustics.
7) HHPS and HHP BFW Pipeline
8) Hydrogen with score is from 12
1) On-site hydrocarbons that will slowly vaporize during All flanges handled
release such as those operating below the boiling point service in class 2 and
but above the flash point with score in table 2 is
CLASS 2
12 scores above shall
2) on-site hydrogen, fuel gas, and natural gas be Critical flange joint.
Table 2
FLANGE RATING
300 600 900 1500&2500

150
RATING RATING RATING RATING
RATING
SCORE 1 2 3 4 5
1/2-4 1 1 2 3 4 5
(included 4 ")
6-8 2 2 4 6 8 10
(included 8 ")
10-12 3 3 6 9 12 15
FLANGE
(included 12 ")
SIZING
14-20 4 4 8 12 16 20
>= 24 INCHES 5 5 10 15 20 25

[ NSRP INTERNAL ]
6.3 Execution of work
Tightening, tensioning of the bolted flange connections shall be done by trained technician or
trained engineer with adequate Supervision, Quality Control to ensure the Flange have
assembly compliance to ASME PCC-1 Requirement, tightening to achieve Target Bolt Stress
and prevent Flange Damaged by Overtightening.
6.3.1 Training
All Contractor who involves the flange joint work shall be trained and qualified follow ASME
PCC-1 Appendix A with Theory, Practical and Examination with witness by NSRP.
NSRP Flange Management Inspector, Contractor Flange Management Inspector, NSRP/
Contractor Flange Management Coordinator shall be qualified by Bolting Specialist
Qualification as per ASME PCC-1 or Eq with Certificated issue by 3rd Party.
Training programs should follow ASME PCC-1 Appendix A and include the following elements:
1. Classroom and hands on training for all crafts that addresses the relationship between
applied torque, bolt loading, gasket stress including theoretical and practical examination. See
A-2.3 and A-2.4 of ASME PCC-1 for more specifics.
2. General Health and Safety Precautions and recognition of hazards, finger pinch points,
injury from tightening tools, line of fire, falling objects, PPE requirements, etc.
3. Guidance within this RP and site recommendations regarding flange alignment and
assembly.
4. Tracking of all bolted joint technicians, experience, and competency (e.g. test certificates
and training records).
5. Bolted joint technicians maintain and use unique identifiers (e.g. Initials or three digit #).
6. Training on “Speedy” Alternate assembly pattern #1 and Legacy assembly Cross pattern of
ASME PCC-1.
7. Refresher practical test every 3 years.
6.3.2 Cleaning and Examination of flange and Fastener Contact surface
6.3.2.1 Flange Surface Examination

Dismantling the flange and removing the gasket, all indications of previous gasket
installation from the gasket contact surfaces shall be removed by using approved solvents
and/or soft-wire brushes. Using carbon steel brushes on stainless steel flange is prohibited.

[ NSRP INTERNAL ]
Flanges which have leakage in history, or any damages of gasket contact surface such as
scratches, nicks, gouges, and burrs shall consider to be assessed. The results of the
assessment shall fully satisfy the requirement of ASME PCC-1 appendix C and D. All flanges
with damage which are outside of ASME PCC-1 requisition shall be repaired or replaced.
Flange Finish surface shall be examined and complied with ASME PCC-1 appendix C using
Flange Surface Finish Comparator with roughness check and profile. For RTJ Flange, groove
to be check and RTJ Grooved Gauge.
Flange Flatness check shall be applied for Bad actor flange which measure by Flange Facer
or Flatness Laser Measurement to compliance to ASME PCC-1 Appendix D for Piping and For
Shell and Tube Heat Exchanger to refer Article 9.8 of API 660 9th Edition 2015.
6.3.2.2 Fastener Contact surface examination
To improve the accuracy in the actual bolt assembly stress, it is important that all studs be free
of rust, scale, grit, or other contaminants prior to lubrication. The studs should be straight and
the threads free from nicks, burrs, and chips. As a qualitative test, the nuts will turn easily on
the stud by hand when both the nut and stud are in good condition. If the nut and stud
combination will not turn easily by hand, the stud and nut should be replaced with new
components.
Bolt re-used
Stud bolts should be reused only if the bolts and nuts are free of any galling or thread
deformation.
This is generally true if the nut runs freely up and down the stud beyond the location where
the nut was seated during the previous assembly.
If bolts have been abused, or installed without lubrication during previous assemblies, or if the
bolts were difficult to remove during disassembly, the bolts should be replaced.
For critical joints and joints with a history of leakage, the stud bolts and nuts should be replaced
after every use for Bolt with any sign of Damaged/Jammed or Flange have tightened reach
90% of Bolt Yield Strength., the re-used bolt shall be evaluated with Bolting Specialist Qualified
Personnel. The guidelines relating to the reuse of bolts/nuts are offered for consideration as
per ASME PCC-1 and Appendix N The reused Bolt Guideline.
Where threaded holes exist (e.g. heavy wall reactor manways, heavy wall “pillbox” style heat
exchanger channels, etc.), the stud bolts should thread in by hand without use of additional
tools. If the studs don’t thread in easily by hand, new studs should be used, or re-tapping of
the female threads is recommended.
For the Bolts are damaged which shall be marked/painted and clearly identified by Task

[ NSRP INTERNAL ]
Supervisor for disposal to prevent reuse damaged Bolt.
6.3.3 Alignment of bolted flanged joints
Pulling the flanges into position could cause unacceptable loads and deflections in other parts
of the system and mean that bolt load is being used to pull the flanges together instead of
compressing the gasket.
To mate flanges with a minor gap or parallelism issue, flanges should be brought into contact
with the uncompressed gasket using less than 10% of the total target bolt assembly stress.
No individual bolt should be tightened above 20% of the target bolt assembly stress to achieve
the tolerance on excessive gap or parallelism (i.e. half the bolts can be tightened up to 20% of
target bolt assembly stress). Note that when evaluating the actual parallelism as compared to
the parallelism limit, the gap should be checked at four locations around the flange (90 degree
apart) after application of the bolt loads allowed in this paragraph. If the flange alignment meets
the parallelism limit, there will be minimal (if any) daylight between the flange faces after the
allowed loads have been applied. Taking an actual gap measurement is not necessarily
required
During alignment of bolted flange joints, the following requirements of 04 parameter must be
met:
- Centerline high/low: the tolerance is measured at 04 points around the flange and it should
not exceed 1.5 mm. Refer to figure 1 below
Figure 1
- Parallelism: The tolerance is usually determined by measuring the closest and farthest
distance between the flanges and comparing. An acceptable practice is a difference no
greater than 0.8 mm (1⁄32 in.) at the O.D. of the sealing surface, achieved using a force of
no greater than 10% of the maximum torque or bolt load for any bolt. Refer to figure 2
below.
Or, alternatively, the mating gasket contact surfaces shall be aligned to each other (before
bolting) within 1 mm in 200 mm (1⁄16 in./ft), measured across any diameter.

[ NSRP INTERNAL ]
However, for flange connection to rotating equipment or machinery as defined by PCC-1

App. E-1 (e) and E-2.1/API 686 the out of parallelism shall be max 0.8mm.
Figure 2
- Rotational - two hole: The tolerance is measured by observing a 90-deg angle where the
fastener passes through the flanges or the holes are within 3 mm. Refer to figure 3 below
Figure 3.
- Excessive spacing or gap: This parameter is not greater than twice the thickness of the
gasket. Refer to figure 4 below
Figure 4.
- If any the parameter above is not achieve, the execution Team shall notify NSRP QC and
Supervisor for further rectification.

[ NSRP INTERNAL ]
6.3.4 Installation of gasket
All gaskets will not be re-used after opening the flanges, all ring joint type gasket must be
replaced by new one also. Re-using gasket will be decided by Management in detail situation
and condition.
During installation of gaskets, the following steps shall be taken:
- Verify that the gasket complies with the dimensional and material specifications, rating.
Information of gaskets including color coding must be filled into check sheet as attachment
- 06.
- Position the gasket to be concentric with the flange I.D, talking suitable measures to ensure
that it is adequately supported during the positioning process. No portion of the gasket
should project into the flow path.
- Ensure that the gasket is adequately supported during placement to avoid twist or bends
that will crease the surface or break the gasket structure.
- Particular care is taken to ensure flanges and gasket are compatible with process fluid to
avoid creating resulting in stress corrosion cracking or pitting of flange surface
- Do not tape the gasket in place across the sealing surface, which may result in potential leak
paths across the gasket face.
- Do not use glue or grease to keep the gasket in place, which will contaminate the sealing
surface once the gasket is put into operation.
- The very light dusty adhesive spray can be used to secure the gasket in place ( Spray to
Gasket, not spray to Flange). Example 3M-Super Adhesive 77 follow ASME PCC-1
- Do not assume that the gasket inserted ahead flange positioning will automatically stay in
position.
6.3.5 Lubrication of Working Surface
Lubrication reduces the coefficient of friction and results in less required torque to achieve a
given tension, improves the consistency of achieved load from bolt to bolt within the joint, and
aids in the subsequent disassembly of the fasteners. Hence, the Nut Bearing Face/ Bolt
Thread Part., Washer Face must be lubricated properly by Approved Lubricant such as
Molykote 1000.
Before lubricant is applied to the bolt and nut threads, nuts must run freely by hand past
where they will come to rest after tightening. If nuts will not turn freely by hand, check for
cause and make necessary corrections/replacements

[ NSRP INTERNAL ]
6.3.6 Installation of Bolts:
Install bolts and nuts so they are hand-tight with the marked ends of the bolts and nuts located
on the same side of the joint and facing outward to facilitate inspection; then snug up to 15
Nm. (10 ft-lb) to 30 Nm. (20 ft-lb), but not to exceed 20% of the Target Torque. If nuts do not
hand tighten, check for cause and make necessary corrections.
6.3.6.1 Bolt/Nut Specification:

Verify compliance with bolt and nut specification with Material, Diameter, Bolt Length, Thread
Pitch, Nut Thickness with Specification follow S-000-1360-0002V Piping Material
Specification.
6.3.6.2 Bolt Length:
As a minimum, bolts should have full engagement through the length of the nut
For Temporary Blind Installation, the Thread Length shall be fully engaged or less than 1
thread is acceptable as per ASME B31.3 or ASME PCC-1
6.3.6.3 Washer:
The use of through hardened washers can improve the translation of torque into bolt
assembly stress by providing a smooth, low friction bearing surface for the nut. Washers can
also protect the contact surface of the flange from damage caused by a turning nut. The use
of hardened washers should be considered on critical joints or joints that have a history of
leakage, when controlled torque is the selected assembly method.
Through-hardened washers can also be used to provide a smooth bearing surface for the nut
when minor damage is noted on the nut bearing surface of the flange face. Flange
Management Inspector or Central Engineering should be consulted to determine if hardened
washers can be used or if the flange should be repaired or replaced.
Through-hardened washers used for bolting applications should be SAE (AISI) 4140 or ASTM
F436 materials. The 2nd Edition of ASME PCC-1 includes specifications for washers, and
washers manufactured to these specifications should be purchased, if available.
6.3.7 Numbering of Bolts:
The Bolts numbering shall be for applied for Torque and Tensioning Technique prior
Tightening with Single Tool or Multi Tool utilization.
For single Tool application, the Bolts Numbering shall be Legacy or Alternative Legacy follow
guideline by ASME PCC-1 refer Attachment 2.

[ NSRP INTERNAL ]
For Multi Tool applications such as Bolt Tensioning, the Bolts Numbering shall follow Appendix
Alternative Pattern #4 or #5.
For Bolt Tensioner, the Bolts Numbering shall do base on the Coverage with refer the
Appendix Q with Example of 50% Coverage.
6.3.8 Tightening of bolts
6.3.8.1 Target Bolt Assembly Stress
Follow ASME PCC-1 and Appendix S of ASME BPVS, Section VIII, Division1, the co
mmon range of Target Bolt Prestress from 40-70% Minimum Bolt Yield. NSRP calcula
ted follow the 50% minimum Bolt yield Strength which tightening value selected high
enough to cover the Gasket Relaxation, Bolt Relaxation to eliminate Start-up Hot Torq
ue. The Tightening table for NSRP shall be selected with combine Bolt Material refer
Appendix 4 - NSRP Bolt Tightening Value follow ASME PCC-1 for Torque Control Me
thod and Bolt Tensioning
In case the Live Tightening for Leak Rectification, If require the tightening over 70%
Min Bolt Yield, the Bolt Applied Stress shall be advice by CES for execution with risk
assessment.
6.3.8.2 Tightening methods
The Tightening shall be following the Flange Design configuration as per Attachment 1 –
Summary, Table of Tightening. The selected Tightening Method shall base on the table with
Highest Precision of Tightening Technique applied. However, depending on actual situation,
the available of Tool, the Tightening method can be tightening be lower method such as Bolt
Control Torque can be tightening for Bolt Tensioner with approved and Instructed by NSRP
Bolting Specialist,
Tightening Method can be considered for applied with Bolt Stress precision increasing:
- Manual tightening by Spanner or Striking wrench with Hammer – only applied for
Snug Tight when Assembly.
- Manual Torque wrench
- Hydraulic or Pneumatic Torque Wrench
- Bolt Tensioner
To avoid damage and misalignment between the mating flanges, suitable tools must be used
correctly.

[ NSRP INTERNAL ]
Flogging of bolts is prohibited for common use. It can be used in special cases only. Before
using flogging, approved by Maintenance Division Manager.
6.3.8.3 Manual Torque Wrench or Control Torque Method
6.3.6.3.1 For Non-Critical Flange: When controlled torque is recommended for assembly of
flanges using Spiral wound or Kammprofile gaskets, the Speedy Alternate assembly pattern
#1 based on ASME PCC-1 should be followed:
a) Install the gasket, ensure proper alignment per the pre-assembly inspection, and bring all
bolts to hand tight per flange make-up. Re-check flange alignment at each flange
quadrant
b) Pass 1a – Tighten 4 bolts in a cross pattern to 20% - 30% of the final torque value. Use
cross patterns per ASME PCC-1 and Appendix 5. Re-check flange alignment.
c) Pass 1b – Tighten the next 4 bolts in a cross pattern to 50% - 70% of the final torque
value. Re-check flange alignment.
d) Pass 1c – Tighten the remaining bolts in a cross pattern to 100% of the final torque value.
Recheck flange alignment.
e) Pass 2, Pass 3, and Pass 4 – Tighten bolts in a circular pattern at 100% of the target
torque value. Continue in a circular pattern until no nut turn is observed for one complete
rotational pass around the bolt circle. A minimum of three circular passes should be
performed. Note that in some cases, five to seven complete circular passes may be
necessary for this step to reach the point where nut movement has stopped
6.3.6.3.2 For Critical Flange/ Bad Actor Flange and Hex Exchanger Girth Flange: When
controlled torque is recommended for assembly of critical joints/ Bad Actor or HEX Girth
Flange or Equipment flanges using soft gaskets (e.g. double jacked or sheet gaskets), the
Legacy assembly pattern based on ASME PCC-1 should be followed:
a) Install the gasket, ensure proper alignment per the pre-assembly inspection, and bring all
bolts to hand tight per flange make-up. Re-check flange alignment at each flange
quadrant.
b) Pass 1 – Tighten all bolts in a Legacy Cross pattern to 20% - 30% of the final torque value.
Use Legacy Star patterns per ASME PCC-1. Re-check flange alignment.
c) Pass 2 – Tighten all bolts in a Legacy Cross pattern to 50% - 70% of the final torque value.
Re-check flange alignment.

[ NSRP INTERNAL ]
d) Pass 3 – Tighten all bolts in a Legacy Cross pattern to 100% of the final torque value. Re-
check flange alignment.
e) Pass 4, Pass 5, and Pass 6 – Tighten bolts in a circular pattern at 100% of the target
torque value. Continue in a circular pattern until no nut turn is observed for one complete
rotational pass around the flange. A minimum of three circular passes should be
performed.
Note that in some cases, five to seven complete clockwise circular patterns may be necessary
for this step to reach the point where nut movement has stopped. Note 1: Other joint assembly
patterns, such as those listed in ASME PCC-1, may be used, but should be approved by the
asset pressure equipment or mechanical engineering discipline.
The choice of Manual Torque Wrench, or hydraulic torque wrenches should be determined
by the guidelines in Attachment 1.
Manual torque wrenches are only practical for bolts with an assembly torque less than
approximately 1200 N-m
For Multi Hydraulic Torque shall be tightening follow Alternative Assembly Pattern #4
for 04/08 Multi Tools and Alternative Assembly Pattern #5 for 02 Multi Tools refer to ASME
PCC-1 Appendix F.
6.3.8.4 Bolt Tensioning or Control Torque with Bolt Stress Measurement
Hydraulic bolt tensioning should be used on all critical flanges/ Bad Actor follows Attachment
3 and follow the Project Flange Design Configuration as attachment 1. Controlled torquing
with bolt-stretch measurement may be used as an alternative to bolt tensioning, e.g., when
tensioning is not possible due to access restrictions where the tensioning tool will not fit on
the nuts.
The bolt tensioning contractor is responsible for providing procedures and quality control to
ensure a properly tightened joint. The number of bolts tightened per cycle, the total number
of passes, and the percentage of target load achieved per pass should be reviewed and
approved by NSRP Bolting Specialist. When tensioning the bolts in a flange, typically a
minimum of 50% of the bolts are tensioned at one time (i.e. 50% coverage which would
require two passes), but as many as 100% of the bolts can be tensioned simultaneously (i.e.
100% coverage or one pass) if the tooling is available and the nuts on the flange are
accessible. The Flange Tensioning Sheet shall be submitted with based on the Professional
Sheet providing by Tensioner Equipment Software with well-trained and competence Bolting

[ NSRP INTERNAL ]
Engineer with Consideration of Load Loss, Coverage, Applied Bolt Stress, Residual Bolt
Stress, Bolt yield, etc.
The Sequence of Bolt Tensioning refers to ASME PCC-1 Appendix Q with example of 50%
Coverage.
The contractors tensioning procedure should include the following steps:
1. A minimum of 3 pressure cycles should be performed during each pass prior to removal of
the tensioners to ensure the nut is properly embedded. Failure to cycle the tensioner will
result in loss of accuracy.
2. Check-passes should be performed until no further nut turn is obtained at the final pass
pressure. This provides some assurance that the target bolt stress has actually been
achieved.
3, The Leaked Tensioner/Hose shall be rejected and immediately brough to outside for repair
to prevent under tightening.
Notice:
➢ All Manual Tools using at site must be non-sparking tools, except for:
✓ Sparking Tool (normal Tool) can be used for flange with inside fluid:
Steam, Water, Boiler Feed Water, Plant Air, Nitrogen, Catalyst….
➢ For Non-critical Flanges: for location which one will be obstructed and cannot
or very difficult or high risk to apply Torque Wrench/Hydraulic
Machine/Tensioning. Manual Tool will be referred to use which obtained
approved by NSRP Bolting Specialist.
➢ For Critical Flanges:
✓ Torque or Tensioning method is mandatory
✓ For Location which one will be obstructed and cannot or high risk to
apply Torque Wrench/Hydraulic Machine/Tensioning. Deviation Form will
be issued and got approval before execution.
Toque value for non-metallic flange shall follow attachment - 04 torque values for non- metallic
flanges
Torque value for metallic flanges shall follow Target torque at 50% Min Bolt Yield Strength
N.m table in attachment - 05

[ NSRP INTERNAL ]
6.3.9 Start-up Re-torque
Start-up Re-torque is the torquing applied to bolts for restoring bolt loads that have
relaxed in service at elevated temperature (>500°F or (>260°C). This relaxation
normally occurs during the first heat-up cycle of the flanged joint, after initial assembly,
and is caused by relaxation of the gasket at elevated operating temperatures. For this
reason, hot torquing (start-up retorque) is normally applied to newly assembled joints
during the heat-up cycle, to restore gasket stress lost to relaxation. The Start-up Re-
torque should be performed when the process temperature is between 250°F to 400°F
(121°C to 204°C). All the nuts should be turned a minimum of ¼ flat to ensure uniform
application of bolt load and gasket stress. All critical joints with an operating
temperature greater than 500°F (260°C) should be hot torqued during the first start-
up after initial assembly. Note that as an alternative to Start-up Retorque, the gasket
assembly stress can be specified such that the residual gasket stress after gasket
relaxation is still sufficient to maintain a reliable seal. For example, the gasket
assembly stress for ASME B16.5 flanges in class 900, 1500, and 2500 is typically high
enough to preclude the need for startup retorque. Additional guidance regarding hot
torquing (start-up retorque) can be found in Appendix O of ASME PCC-1.
Start-up Re-torque shall be applied only for Bad Actor Flange Which Tightening
by Bolt Torquing Method and defined in Bad Actor list. – Appendix 3
The information for Start-up re-torque must be recorded in attachment - 06. However,
for the below conditions, Start-up re-torque method are not allowed or no need to apply.
1. Flanges that are being controlled toque value by tensioner.
2. The first flange at Pump side
3. Flanges that using PTFE based gasket, sheet gaskets are not allowed. (Basically,
hot bolting method is applied for flanges that using spiral wound gasket, ring joint
gasket).
Timing Start-up re-torque implementation:
For Start-up (Increasing Temperature sequence):
1. Operation temperature is from 150 to 230 degrees; all bolts shall be re-tightened
only 1 time at operating temperature with target toque value as attachment 5 by
Circular Pass. And the tightening will do within 24hrs since the system/flange
reach to this temperature range.
For Shutdown (Decreasing Temperature sequence):

[ NSRP INTERNAL ]
Depend on the leaking historical of critical Flanges during shutdown. Start-up re-
torque also can be considered during Temperature reducing. All bolts shall be re-
tightened only 1 time when Temperature reduce to around 230 degrees Celsius.
For BLC Heat Exchanger (12 items in RHDS), the Retorque shall be applied in any
time of Unit Shutdown, retorque to be completed before the temperature at start-up
increase to 200oC.
6.3.10 Live Tightening for Flange Leak Rectification
This is to guideline to rectify leak for bolted flange in NSRP plan. The Risk assessment and
countermeasure shall be evaluated throughout for Live Tightening for leak Rectification.
When leak occurs on bolted flange, the following steps shall be followed in sequence for the
rectification:
- 1st step: Re-tighten the bolted flange with torque value in Target torque at 50%
Min Bolt Yield Strength table in attachment - 05 and sequence for tighten in
clause 6.3.4. If leakage does not stop, go to 2nd step.
- 2nd step: Apply the torque value Maximum Target Bolt Torque at 70% Min Bolt
Yield Strength Nm in attachment - 05.
In case system cannot be shutdown/isolated, check with operation for plan of
nearest possible window to do shutdown or isolate the flange, if cannot be isolated
at all in near future, then transfer to 3rd step.
- For Live tightening over 70% min Bolt Yield Strength, the AI/Central Engineering
calculation shall be followed with Risk Assessment Evaluation of Joint Integrity
Elements.
- 3rd step: Apply clamp on leak location by online sealing service. Clamp and
compound will be calculated and selected by Online Sealing Contractor and
approved by NSRP.
During tightening, the jobs shall be supervised by NSRP Supervisor
6.3.11 Hot Bolting
Hot bolting and half bolting are techniques that can be utilized to expedite bolt removal at the
beginning of a turnaround. These subjects are covered in detail in Article 3.11, Hot and Half
Bolting Removal Procedures, of ASME PCC-2.
ASME PCC-2, Article 3.11 should be consulted in detail before developing a hot bolting or half

[ NSRP INTERNAL ]
bolting plan. In general, here are a few important considerations from Article 3.11:
• Hot bolting is also the sequential removal and replacement of bolts on flanged joints while
under reduced operating pressure. It is carried out one bolt at a time in a predetermined
cross pattern sequence. Each replaced bolt is fully tensioned before the next one is
removed.
• Hot bolting can be used to clean, lubricate, and reinstall existing bolts for pre-shutdown
activities, replace corroded or damaged bolts, or upgrade the material specification or
grade of bolts.
• Unless the results of the engineering and risk analysis establish that the consequences of
either joint leakage or gasket blowout are acceptable, flanges should have a minimum of
eight bolts.
• Unless otherwise justified by an engineering and risk analysis, hot bolting should not be
performed when the operating pressure is greater than 50% of maximum pressure rating
of the flanged joint.
Following flanges will not be applied “hot bolting” for removal and replacement of bolts for
any purpose:
Normal Flange Flange Normal Remark
pipe size class type bolt count
2” 150 RF 4 Insufficient gasket-seat force without
use of hot bolt clamp.

[ NSRP INTERNAL ]

Noted: When conducting hot bolting removal procedures, the risks of fluid leakage are
increased due to increased bolting stresses and relaxation of gasket compression, both
potentially resulting in joint leakage or gasket segment blow-out.
6.3.12 Half Bolting
With refer to Article 3.11 Hot and Half Bolting Removal Procedures
• Half bolting can be used for the removal of every other bolt (so the flange is left with half
the number of bolts) during plant depressurization, usually when the system is close to
atmospheric pressure. This half bolting shall not only start when system is depressurized
to equal or less than 25% Flange Maximum Pressure Rating or 3.4 Barg whichever is lower,
and when low pressure steam, air, or nitrogen is the purging media
Noted: When conducting half bolting removal procedures, the risks of fluid leakage are
increased due to reduced gasket compression and the possibility that the system may
inadvertently be re-pressurized. For this reason, the system pressure at which half bolting
is conducted should be well below design pressure and preferably at or near atmospheric
pressure with local management controls in place to prevent re-pressurization. Flange
clamps can be used to add clamp force if necessary. The half bolting shall only conduct
with an validated PTW issue by Operation.
6.3.13 Guidelines for leakage test by hydrogen
This guideline is to provide the acceptance criteria for leakage test system by hydrogen. The
detail of requirement should be followed attachment 7 in this procedure. The leak test will be
handled by Operation Division.
6.3.14 Guidelines for Joint Pressure and Tightness Test
Bolted joint assemblies should be tested to ensure leak tightness. Subject to code/regulatory
requirements, the user should establish
(a) the type of leak test (e.g., visual, bubble-forming solution, sniffer)
(b) test fluid (e.g., air, inert gas, water, service fluid)
(c) test pressure (e.g., low pressure or up to a code mandated visual inspection pressure)
(d) acceptance criteria (often simply “no detectable leaks”)

[ NSRP INTERNAL ]
The Gasket for Pressure Test or Tightness test shall be original Gasket as design.
For TA period. The Temporary SPW gasket with no Inner Ring Can be use for Pressure Test.
Other than that, the Original Gasket shall be used.
6.3.15 Joint Disassembly:
In parallel with ASME PCC-1 for Joint Disassembly Procedure, addition note to be follow-up:
Impact methods (e.g. impact wrenches or hammer wrenches) should not be used for joint
disassembly with materials that are susceptible to embrittlement to avoid brittle fracture during
the unbolting process. Examples of services susceptible to embrittlement include temper
embrittlement of Cr-Mo flanges and piping in high temperature service, or hydrogen
embrittlement of Cr-Mo reactors and exchangers in a hydro processing unit
6.4. Flange Management Tracker and Tagging
6.4.1 Flange Management Tracker
The Flange Execution Team shall create a Flange Management Tracker. During the Preparation
and Execution Phase of the work, this shall be managed by the Flange execution Team, and
provided upon request to the NSRP Team. The completed Flange Management Tracker shall be
added to the QA Handover document requirement, on completion of the Flange Execution Team
scope of Works.
Refer: Attachment 13 for Flange Management Tracker.
6.4.2 Flange Joint Mapping
WE shall provide a detailed Flange Map that defines the location of each flange within a
Work scope, that shall be opened / cracked / broken during the Execution of the Work.
The Flange Map shall be legible and marked on a detail drawing or Isometric, that ensures
the noted flange is easily identifiable.
Flange numbering shall commence at the upstream farthest point and continue downstream,
vertical / horizontal legs shall be numbered consecutively

[ NSRP INTERNAL ]
All flanges shall be numbered that fall within the scope starting with F1.
6.4.3 Flange Tagging
All flanges within the work scope that shall be cracked / broken within the scope, for either
isolation, hydro test or replacement of equipment, shall be numbered on a flange map; section
6.4.2 and shall have a Flange Management Report form as Attachment 5 provided by the Flange
Execution Team. Said report must be signed off by all required Parties during the Flange
Management Process.
All flanges shall have, before Work starts, a Flange Tag as below tag, the Tag number and all
Flange related details added to the Flange Tracker (Refer: Attachment 13).
Flange Tag Sections shall be removed as the various process stages are completed. The
Flange Tag Sections shall be taken by the relevant actioning Party to the controlling entity.
All records and reports related to flange Management shall be provided at any time and be
available for review verification by the NSRP Team.

[ NSRP INTERNAL ]
6.5. Blinding and Tagging
6.4.4 Blinding
Basically, all blinds used for maintenance work shall be rated with specification in
ASME 16.48- 2005.
The rated Blinds will be defined as two type: Permanent rated Blind and Temporary
rated Blind.
Permanent rated Blinds: Blinds are designed for permanent using at site as original
design on our piping system (Spectacle Blind, Paddle & Ring spacer…). The thickness
will be calculated based Design Pressure plus CA (Corrosion Allowance), refer to
attachment - 08 for detail thickness.
Temporary rated Blinds: Blinds will be inserted for all flanges was not designed the
space for Spectacle Blind, Paddle & Ring spacer, and existing isolating valve at
upstream. These Blinds just install for short time during maintenance duration. The
thickness will be calculated based on operating pressure without CA (Corrosion
Allowance).
The thickness of temporary rated blinds shall be selected as table in attachment - 09

[ NSRP INTERNAL ]
Note:
- Blinding required for hydro-test or pressure-test need to be with rated
blinds for the specific test.
- The opening flanges will be covered by plastic/wood plate to protect flange
surface if available blind at upstream.
- Any blinds needed to be placed within an already isolated system with
rated binds, such as for CSE or specific hot work, do NOT require rated
blinds.
- If the System is within the envelope of already rated, Battery limit isolation
blinds, then they do NOT need to be rated blinds
Bleeder blinds are to be used in piping and equipment that require hydro testing where no
bleeders are available.
Example: Bleeder blind
6.4.5 Blind Tagging
All blinds location shall be numbering and hang the tag as attachment - 10 at blind location.
Tagging shall be managed and control by Task Supervisor. The tagging shall be removed only
by authorized person after all temporary blind for maintenance work remove completely.
Blind Tags Tagging Sequences:
Blinding
- Step 1: Verify blind flange with operation and maintenance.
- Step 2: Mark up/numbering blind locations following blind list and marked up P&IDs.
- Step 3: Insert blinds and hanging the blind tags at blind flange and tagging shall expose to

[ NSRP INTERNAL ]
walkway side.
- Step 3: Sign on Control sheet as attachment - 11, Operator and Contractor.
De-Blinding
- Step 4: Remove the blind and yellow blind tag
6.4.6 Blind storage
All blinds must be safety stored in suitable location to avoid corrosion and damage. Good
housekeeping essential to avoid any hazard.
All blind must be tagged with basic information below:
Type Permanent rated blind/ Temporary rated blind
Size
Rating
Thickness Must be filled for temporary rated blind
6.5 Quality Assurance and Quality Control Provision.
The asset should have a bolted flange joint quality control and quality assurance program that tracks
flange assemblies and reject rates similar to welding. This program should be the same for routine
maintenance activities, turnarounds, and capital projects executed at the asset. In general, the bolting
technician should be responsible for supplying a properly tightened joint per the method identified in
the assembly procedure. The bolting technician’s company should have a quality control plan and
NSRP should have a quality assurance plan in place for management of bolted flanged connections.
These plans should be reviewed, approved, and communicated so that all parties know and
understand their role in providing leak-free flanged connections. All contractors considered for flange
bolt tightening should have a training program for their bolting technicians and should maintain
documentation of training as per requirement in Training. All bolting technicians should have a unique
identifier to allow QA / QC tracking of the flanges they have assembled. Contractors being considered
for bolt tensioning services should meet the recommendations of 6.5.3 Bolting Service Contractor
Minimum Requirement
Quality Control plans should include the following elements:

1. Technicians should apply a Flange tag with their unique identifier on assembled flanges for tracking.
2. QC personnel with hands on training and a minimum of 3 years of experience in flange assembly.
3. QC checks should include a mix of visiting pre, during, and post flange assembly.
4. QC evaluation should include a minimum of10% of random flange assemblies by each technician.
5. Maintained reject rate below 1% for each technician. Failure of any of the following elements

[ NSRP INTERNAL ]
equates to a reject:
a. Flange surface clean and free of defects
b. Correct gasket material and type
c. Correct stud material and length
d. Correct nut material and orientation
e. Correct application lubrication
f. Correct tools for assembly
g. Up-to-date calibration of applicable tools
h. Flange alignment within tolerances
i. Correct tightening pattern applied
j. Correct torque value applied
A method of tagging disturbed flanges is recommended refer to 6.4.2. The tag should identify the
flange uniquely, tie it to a work package, have information like flange and bolt size, critical joint or not,
type of assembly method – controlled or not, and torque values if required, with traceability to the
bolting technician via their unique identifier, QC inspector, and NSRP QA if required. NSRP QA should
sample a percentage of completed flanges in the field, compare those flanges to the QC tracking
results, and track the reject rate.
6.5.1 Flange Quality control
The Flange Management work quality control shall be set-up based on the Flange Criticality with
Normal Flange, Critical flange and Bad Actor Flange.
6.5.1.2 Non-critical Flange
Personnel: Well-trained and Qualified Personnel follow ASME PCC-1 Appendix A

Scoping: WO issued Basic
Tightening Method: Manual Torque Wrench/ Torque Control/ Bolt Tensioning
QC requirement: 100% witness by Contractor QC with Recording.
10% witness by NSRP and Punching with following refer 6.5.3 Punching guideline.
6.5.1.2 Critical Flange
Personnel: Well-trained, 02 years Experienced, and Qualified Personnel follow ASME PCC-1
Appendix A.
Scoping: WO issued Basic
Tightening Method: Torque Control/ Bolt Tensioning

[ NSRP INTERNAL ]

50% witness by NSRP and Punching with following refer 6.5.2 Punching guideline
Flange Tagging shall be applied
6.5.1.3 Bad Actor Flange
Personnel: Well-trained, 03 years Experienced, and Qualified Personnel follow ASME PCC-1
Appendix A and under instructed by ASME PCC-1 Bolting Specialist.
Scoping: Work Pack issued with detail requirement for Flange Management Tracker with Location,
Flange Rating, Flange Size, Tightening Method, Tightening Value, QA/QC, Tagging and Tracking for
Applicator.
Tightening Method: Torque Control with Bolt Stress Monitoring/ Bolt Tensioning which is conducted
by Bolting Service Contractor.
100% witness by NSRP and Punching with following refer 6.5.3 Punching guideline
Beside the required Flange Joint Examinator as per this procedure, the Flange shall
be inspecting the Flatness by Flange Facer or Flatness Laser Measurement.
Flange Tagging shall be applied
Start-up re-torque to be updated as per Bad Actor recommended action.
6.5.2 Key Performance Areas/ Indicators
The following Key Performance Areas / Indicators (KPAs / KPIs) shall be measured,
analyzed, and reported by the Process Owner at the frequency documented as part of the
QMS measurement, analysis and improvement initiative.
Table 1: KPAs/KPIs
KPI Category KPI Description Leading/ Reference to Industry Best Reason for
Lagging Standard in Class Metric
LOPCs Leaks of Lagging N/A Zero Evaluate the
assembled effectiveness
flanges within 4 of the bolted
weeks of initial joint assembly
assembly and technician
return to training and
operation assembly
work practices
QC/QA Number of bolted Lagging N/A Zero Evaluate the
flanged joint effectiveness
assemblies of the bolted
identified with joint assembly

[ NSRP INTERNAL ]
deficiencies technician
during QC/QA training and
activities assembly
work practices
6.5.3 Bolting Service Contractor minimum Requirement
The qualifications of a contractor specializing in bolt tensioning should be addressed in the

contract bidding phase. The following deliverables should be reviewed and subsequently
agreed upon prior to award of a contract.
1. Qualifications of personnel assigned (e.g. training program, experience level, safety training
for petrochemical industry).
2. Number of craftsman and supervision per field crew and roles.
3. Quality Control / Quality Assurance plan.
4. Utilities and / or equipment required of purchaser.
5. Tensioning contractor approved joint assembly and disassembly procedures.
6. Proposal for bolt loading when there is not enough clearance for a tensioning device.
7. The written procedure for hydraulic tensioning should include:
a. Documentation of acceptance criteria versus actual readings. This may be in the form of a
checklist.
b. Expected level of joint assembly (e.g. joint aligned with stud bolts inserted, flanged drawn
such that gasket and flanges are in contact).
c. Required increase in bolt length for the tensioning device.
d. Number of bolts loaded per cycle.
e. Number of stepwise bolt loading passes and percent load at each step. f. Bolt loading
pattern. g. Load factor applied to account for loss of assembly stress when tensioning device
is removed
6.5.4 Punching:
For Critical Flanges/ Bad Actor and which ones already control strictly by NSRP supervisor
during execution, these ones do not need to do Punching.
For remaining Flanges are requested to do Punching to be well control and make sure for
good quality before starting up:

[ NSRP INTERNAL ]
a) Confirming the Stud, Nut, Washer compliance with Spec of project
b) Confirming the stud, Nut, Washer are suitably lubricated with an approved lubricant
c) Confirming for bolts Size
d) Any missing of tightening for bolt by using small hammer to checking-based sound from
e) Confirming for flange alignment
f) Confirming the gasket type/material
g) Confirming gasket installed in correct position.
Punching check will be recorded in QCR Form as attachment 12
6.6 Work order closure
Before hand over to Operation, checking tighten of bolts by using hammer shall be done by
Task Supervisor, and Walk Down check sheet as attachment – 12 shall be filled and attached
into closure WO document. After that, the following steps shall be taken:
- Return unused spare parts and reusable parts.
- Clean all tools before returning to warehouse.
- Handover to Operation Division for leak test.
- Record all information of the maintenance work such as actual manpower, actual MRO and
actual tools.
- Update the information below into CMMS:
+ Attachment - 06 with full information.
+ Man-hours for jobs.
+ Starting and finish timing for jobs.
- Close WO on CMMS.

[ NSRP INTERNAL ]
6.7 TA Flange Management Provision
Flange Management in Turn Around Period which the Huge Number of disturbed in short period,
hence the proper process for Management, huge Resources need to put in Place to ensure the Zero
Gold leak with the mentioned detail in Process with Appendix 14 – TA Flange Management Process.
Noted: 100% Flange breaking in TA shall be Punching by NSRP Supervisor
6.7.1 Temporary Gasket
Temporary Gasket for TA Isolation only applicable for Spiral Wound Gasket without Inner
Ring which subject Color Code with Full Red at Outer Edge for identification. Other than that,
the Gasket for TA Isolation shall be Original Gasket such as RTJ, Rubber, Metal Grooved,
Double Jacketed, Sheet Gasket.
6.7.2 Temporary Blind during TA
Temporary Blind during TA with Process Unit where the Unit have HC Free and Blind
Installation at Battery Limit, the Temporary Blind with the thickness under size can be used
which required approval and TA Manager and Operation Manager.
6.7.3 Flange Protection during TA
All opened flanges shall be protected. Protection shall be Molded plastic (low-density
polyethylene) press-in flange protectors/ Rubber Plate with Secured Wire or similar,
sufficient to protect the flange face against damage. Tape is insufficient
Example of Temporary Cover for Flange Protection

[ NSRP INTERNAL ]
ATTACHMENT – 01
ATTACHMENT – 02 Bolts Numbering – Legacy and Alternative Legacy and tightening

[ NSRP INTERNAL ]
ATTACHMENT - 03: Bad Actor Flange List

[ NSRP INTERNAL ]
ATTACHMENT - 04
Referential torque values for non-metallic flanges.
Pipe ID (mm) Max. Torque value (Nm)

25 10
40-50 15
80-100 25
150-200 35
250-300 50
350-500 75
600-700 100
750-800 200
900-1400 300
1500-4000 100 (O-ring seal)
In case the flange is not sealed, it is allowed to increase the bolt torque value 1.5 times
of recommended torque value mentioned in above table.

[ NSRP INTERNAL ]
ATTACHMENT – 05 Flange Target Stress Tightening Value

[ NSRP INTERNAL ]

[ NSRP INTERNAL ]
ATTACHMENT – 6
Flange Management Report
Report No#: Date:

Work Pack No#: Flange No#:
Line/Isometric No#: Rating:
Vessel Equipment No#: No.of Bolts:
Flange No#: Material:
Contractor: Flange Management Team:
Flange Location: Flange Face Condition:
Vessel/Ta Spec
Piping Valve/PSV Spool
nk Break Acc Rej Repair Detail:
Gasket (Contractor Inspector shall sign for acceptance )

Requirement Acc Rej Requirement Acc Rej
Verify gasket material (color code) Gasket Position Central
Confirm winding material color Spiral wound gasket
Confirm filler material color Confirm rating/outer ring color
Kamprofile/Meta Grooved Gasket Metal Double Jacketed

Detail or Other type of gasket define
Ring joint gasket: R……; Material:….................
Bolting
Bolt Length Manual Bolt Torque Bolting Pattern Used
Bolt Grade Hydraulic Bolt Torque Single Tool Legacy Alternative #1
Nut Grade Bolt Tensioning Multi Tools Coverage

Flange Inspection Prior to Torque
A B C D
Flange alignment detail prior to torque

Note 1: 'A' tolerance = Gasket Thickness X 2 (add to column 1) Contr. QAQC Sign
Tolerance 0 90ᶿ 180ᶿ 270ᶿ Acc Rej Name & Surname:
A See Note 1
B 1.5 mm Signature
C 0.8 mm
D 3.0 mm Date:
If tolerances found rejected, Contractor must define actions and records to define remedial actions taken and attach to this form
Calibrated Torque Wrench/ Tensioning Torque/Tensioning Value

Unique Number: 1st Pass 30% PA
Calibration Date: 2nd Pass 60% PB
Certificate Number: 3rd Pass 100% Check
Torque/Tensioner Model: Circular Pass 100%
Bolt show (no# threads showing): Binding surfaces of thread greased:
Contractor Resp. Super. Contractor QC/ Inspector NSRP Supervisor NSRP QC/ Inspector
Date: Date: Date: Date:

Name: Name: Name: Name:
Signature Signature Signature Signature

[ NSRP INTERNAL ]
ATTACHMENT - 07
(Flange leak test criteria for hydrogen pressure test)

1. Purpose
The purpose of this appendix is to provide the criteria for flange leak test by hydrogen.
2. The criteria in NSRP
The following criteria to be applied for hydrogen pressure test in NSRP.
Condition Criteria Note 2)

Note 1)
1) Static To satisfy both of a) & b):

a) System pressure drop is “lower than 1% of test
pressure/2hr” or “21kPag/2hr” whichever lower is applied.
b) No bubble with soapy water test in 15 seconds after putting
soapy water.
2) Dynamic To be tested with the following steps:

a) To check leak status by gas detector without sealing tape on
flanges.
b) If no gas is detected, it is judged as no leakage.
c) If gas is detected, quantitative leakage measurement to be
applied with sealing tape on flanges. The acceptance criteria
for proceeding next step are as follows:
➢ Leak quantity is less than 100 scf/year per flange in
open area.
➢ Leak quantity is less than 20 scf/year per flange in
enclosed area. Note 3)
Note 1) Static condition means that the system to be kept at a certain pressure without any
commissioning of rotating equipment. Dynamic condition mean the unit to be
maintained at a set pressure with commissioning of rotating equipment.
Note 2) If Licensor/Vendor criteria exist, the more stringent criteria shall be applied
Note 3) Enclosed area: Area where Confined Space Entry procedure is to be applied

[ NSRP INTERNAL ]
ATTACHMENT - 08

[ NSRP INTERNAL ]
ATTACHMENT - 08 (con’t)

[ NSRP INTERNAL ]

[ NSRP INTERNAL ]

[ NSRP INTERNAL ]

[ NSRP INTERNAL ]

[ NSRP INTERNAL ]

[ NSRP INTERNAL ]

[ NSRP INTERNAL ]

[ NSRP INTERNAL ]

[ NSRP INTERNAL ]

[ NSRP INTERNAL ]

[ NSRP INTERNAL ]

[ NSRP INTERNAL ]

[ NSRP INTERNAL ]

[ NSRP INTERNAL ]

[ NSRP INTERNAL ]

[ NSRP INTERNAL ]

[ NSRP INTERNAL ]
ATTACHMENT – 09 TEMPORARY RATED BLIND TABLE

[ NSRP INTERNAL ]
ATTACHMENT - 10
TAGGING FOR TEMPORARY BLIND

[ NSRP INTERNAL ]
ATTACHMENT - 11
BLIND TAGGING CHECKLIST
Unit
Equipment No.
PTW No.
Blind No. Temporary blind type Attached date Detached date
Name Signature Date
Task Supervisor
Maintenance Supervisor
Operation

[ NSRP INTERNAL ]
ATTACHMENT - 12
FLANGE WALKDOWN REPORT
WO No.: ______________________ Flange No.: ________________
Task Result Acceptance (Y/N) Date Noted

Flange sizing (NPS)
Flange rating
Flange aligned
• Centerline high/low - D1
(mm)
• Parallelism - D2 (mm)
• Rotational - two hole - D3
(mm)
• Excessive spacing or gap -
D4 (mm)
Type of gasket
Gasket in correct position
Bolt size (in)
Type of bolts
Type of nuts
Has Bolts applied lubricant?
Has Bolts tighten properly?
Final applied Torque Just optional for special
case requirement
Notes:
1. Flange misalignment (D1<1.5mm; D2 ≤ 0.8mm; D3 ≤ 3mm; D4 < 02 twice the thickness of gasket)
2. Legend for Gasket, bolt & Nuts as table below:
GASKET BOTLS NUTS

SW Spiral wound gasket B7M ASTM A193-Gr B7M 2HM A194 Grade 2HM
CNAF Compressed Non- Asbestos fiber
B7 ASTM SA193-Gr B7 4H SA194 Grade 2H
gasket
KP Kamprofile gasket L7 ASTM A320-Gr L7 4 A194 Grade 4
R Rubber Gasket B16 ASTM A193-Gr B16 7M A194 Grade 7M
RJ Ring Joint Gasket L7M ASTM A320-Gr L7M A A563 Grade A
DJ Double Jacketed Gaskets B ASTM A307-Gr B 8MA A194 Grade 8MA
B8MC2 ASTM A193-Gr B8M 8MA A194 Grade 8MA
Class 2
B8MC1 ASTM A193-Gr B8M 660C A453 Grade 660 Class
Class 1 C
660C ASTM A453-Gr 660
Class C
D1 D2 D3 D4
Punched by
NSRP- Supervisor

[ NSRP INTERNAL ]
ATTACHMENT – 13 Flange Management Tracker

[ NSRP INTERNAL ]
ATTACHMENT – 14 – TA/ Pitstop Flange Management Detail guideline.
1.0 Objective
This Appendix to the NSRP MD-04-MT-RSSTA-PD-025 Maintenance Procedure for Bolted

Flange Joint Management, defines the processes and requirements for Flange
Management within a TA or Pitstop at the Nghi Son Refinery & Petrochemical LLC (NSRP).
It shall ensure that all flanges actioned in the TA within the Refinery are managed, recorded,
and documented with evidence of conformity (Tightness), which shall be available and
verifiable.
2.0 Process Definition
2.1 Process Map/Flowchart
The process defined herein is documented pictorially via a “Process Map” below:
TA Flange Management Appendix 1 Process Flow Diagram
TA Preparation Pre Turnaround

Flange Coordinator
Identify Flanges
Preperation
required to be Upload Flange

Prepare all Flange Attach all Flange
actioned per Work Information to End
Tags Tags
Start Pack Flange Database
Identify Isolation
Flanges
NSRP Operations
Release Flange for Check Isolation

Start
Breaking (HOW) Point
GMC Flange Team
Accepted
Spading/Blinding/ Remove BLUE
Spading/Blinding/Opening
Flange and Bolt Flange Face

Breaks Flange Removal of Section of Flange Isolation Point
Inspection Accepted
Equipment Tag
Rejected
Rejected
Damaged
Inspection
Flange and Bolt

Rejected
Verification Repair Tag
Damaged
Inspection
Coordinator
Random
Update Flange Update Flange
Flange
Surveillance Check Flange and

Repair Log Repair Log End
verification of work BLUE Label
methods
Operations
NSRP
Release Flange for Sign and remove GREEN

Start Service/Leak Test
Breaking (HOW) section from Flange Tag
GMC Flange
Team
Sign and remove

De-Spading/De-blinding and Closing
Breaks Flange Flange Assembly RED section from

Flange Tag
Inspection
Sign and remove

NO Leak/Service Sign and remove GREEN
Flange Tightening YELLOW section Leak/Service Test
Test section from Flange Tag
from Flange Tag
Coordinator
Random
Flange
Surveillance Update Flange

verification of work Repair Log End
methods
Coordinator
Flange
Update and Close Flange Data

Post TA
Remove the remaining

Start WHITE section of the Flange base End
Tag

[ NSRP INTERNAL ]
3.0 Process Definition
3.1 Flange Management During Turnarounds (TA) and Pitstops
During a Turnaround, many flanges will be opened and closed to:
• Remove equipment
• Remove lines
• Spading of equipment
• Turn SB’s (Spectacle Blinds)
• Open drains & vents
• Make temporary connections
To ensure this process is executed in a controlled and verifiable manner, a Flange

Management Process must be implemented to ensure a leak free commissioning and start
up. By the implementation of this Appendix, the risk of a leak can be greatly reduced and
negate the impact on said commissioning and start-up.
3.2 Flange Team
A Flange Team shall be provided by each GMC. The Team shall be comprised of suitably
experienced and qualified individuals. The TA Team shall review personnel details and
confirm acceptance of the team members prior to Work starts. The Flange Team shall
complete and pass the Flange Management Training Module as per ASME PCC-1 Appendix
A. The noted Flange Teams shall be in Areas and Units defined by the TA Team for:
• Flange Alignment/ Flange Gasket Contract Surface inspection.
• Gasket Type
• Torque/ Tensioning Value of bolting
• Verification of thread showing past the nut (minimum 3 threads)
• Verify bolt/Nut spec/ Gasket Spec
• Verification of nuts and bolts used for re-use
• Grease application to bolts, using Molykote 1000

[ NSRP INTERNAL ]
The TA Team Inspection resources shall action random verification of the Contractor Flange
Teams Work. A Tap test shall be actioned within the punching process by the Punching Team.
3.3 Process and Appendix Implementation Process
To ensure the Flange Management Process is executed competently the following shall be
implemented:
• Dedicated Flange Coordinator during preparation and execution
• Flange Management database
• Flange identification system (label)
• A Flange management process
• Effective torque and tensioning value table
3.4 Flange Coordinator
The TA Flange Coordinator shall be identified by the TA Team, who shall be the focal point
for the Flange Coordination. The GMC shall provide sufficient and agreed by the TA Team to
oversee the requirements of this Appendix.
The Flange Coordinator shall in the Preparation Phase, be responsible to identify all flanges
that shall be actioned within the TA. Flanges shall be referenced to.
• Area
• Block
• Unit
• Work Pack
The logging of the information and verification of both the size type and torque values etc.,
shall be the responsibility of the Flange Coordinator.
The Flange Coordinator shall be responsible for identifying damaged flanges after
confirmation inspection has been actioned by Inspection and confirmed. Flange details and

[ NSRP INTERNAL ]
the damage noted along with the remedial works required shall be completed on the Flange
Repair Tag. Coordinator shall update the repair flange details into the Flange Repair Register
and ensure all relevant sections as the remedial works are completed including the final
approval inspection shall also be updated timeously.
Coordinator Flange Organogram
TA Team Flange
Coordinator
TA Flange Coordination
Area 5 Catalyst
Change out & Unit
Area 1 Area 2 Area 3 Area 4
20
GMC Area Flange GMC Area Flange GMC Area Flange GMC Area Flange GMC Area Flange
Coordinator Coordinator Coordinator Coordinator Coordinator
Baseline Flange Coordinator Organogram shall be updated with names and designations of TA /
GMC Flange Coordinators, by TA QAQC.
3.5 Flange Management Database
The information required to be uploaded into the Flange Management Database shall be
provided by TA Planners and NSRP Operations. All flanges related to the TA shall be
identified within the Flange Management Database, inclusive of;
• Spade list
• Removing lines, equipment (NRV’s, PSV’s, RV’s, etc.)
• Temporary connections

[ NSRP INTERNAL ]
• SB’s for flushing and/or purging
• Drains & vents
• Manways
• Special flanges
• HE-covers, cover plates, heads,
• Valve bonnets
The flange management database shall be based on a software system that allows the
following to be managed measured and allow identification of a single flange status within
the TA phases.
It shall track, but not be limited to the following.
• Flange Tag Number
• Flange Number (as per Tag Number)
• Area
• Unit Number
• System Number
• Equipment Number
• Work Pack Number
• P&ID Number
• ISO Number
• Isolation Point (Y/N)
• Flange
o Type
o Rating
o Size
• Gasket
o Quantity

[ NSRP INTERNAL ]
o Gasket type/material
• Torquing Requirement
• Flange Broken
o Isolation (Y/N)
o Equipment Isolation (Y/N)
o Blind Flange (Y/N)
o Pressure Test (Y/N)
o Temporary Gasket (Y/N)
o Flange Protection(Y/N)
• Flange Assembly Protocol (Y/N)
• Flange Tightness
o Torque Value 30%
o Torque Value 70%
o Torque Value 100%
o Or Tensioning Sequence
• Flange Tested
o Leakage Test (Y/N)
o Service Test (Y/N)
3.6 Flange Tags
All flanges that shall be actioned within the TA, shall be Tagged to ensure that identification and
traceability of the Flange opening and closing, and subsequent torquing and tensioning can be
managed and verified.
3.7 Flange Tag Format
4.0 Below is the format of the Flange Tag to be utilized.

[ NSRP INTERNAL ]
4.1 Flange Tag Preparation
Flange Tags shall be prepared within the preparation phase of the works.
Flange tag preparation is the responsibility of the Flange Coordinator, Flange Tag information
on the WHITE section of the Flange tag shall be completed in alignment and verification with
the details of the Flange Management Database.
The following sections shall be completed;
• Flange Tag Number (As identified in Flange Management Database)
• Unit Number
• System Number
• Equipment Number
• MC Package Number
• Work Pack Number
• P&ID Number
• ISO Number
• Flange Number
• Rating #
• Size”

[ NSRP INTERNAL ]
• Isolation Point (Y/N)
• Bolt Material
• Bolt Size
• Torque type
• Gasket Type
• Type of Flange (Mark)
• Dismantle (Mark)
• Assemble (mark)
Front side of the Tag is used for is sign-off, the back-side provides the relevant flange
information.
4.2 Flange Tag Action and Responsibility
Noted below in sketch the actions within each color section of the Flange Tag defines who and when

[ NSRP INTERNAL ]
each section of the Flange Tag is actioned / signed.
Who Completes and

Section represents when
Flange Information Flange Coordinator in

1st
Preparation Phase
Flange Tag Removal on

6th
Completion of TA
Leak or Service GMC Flange Team and 5th

Testing of the Flange NSRP Operations
GMC Flange Team

Tightening the Supervisor Non Critical
Flange, Torque/ Flanges 4th
tensioning
Flange Contractor for
Critical Flanges
Assembling the GMC Flange Team

Flange 3rd
Supervisor
Breaking the Flange GMC Flange Team

2nd
Supervisor
Flange Tag Action breakdown
4.3 Flange Tag Requirements
4.3.1 Combi Flange
Combi blinds shall have two flange tags attached.
This blind will be installed for 2 jobs (e.g., equipment blind and line repair job)
The blind can only be removed after both jobs are completed
4.3.2 Pressure Test
If pressure test is required: new gaskets / rated blinds / spades are required
4.3.3 Flange Tag Blue Section (Break/Open Flange)
The first step is the operational release. Once NSRP operations have checked the system
to ensure its gas-free & de-pressurized, the operator releases the flange for opening by

[ NSRP INTERNAL ]
signing on the BLUE Section of the Flange Tag.
GMC Flange Team will break the flange and immediately inspect the flange faces, the
alignment of the flange and the status of the bolts.
If the initial inspection is Accepted the installation of a blind or temporary cover can be
actioned.
If the initial inspection is Unacceptable, a verification inspection shall be executed by TA

Inspection/NSRP Inspection, spading or temporary cover can be done prior to the repair.
Execution then signs of the middle part of the blue label, tears of the blue part of the label
and submits it to the Flange Coordinator.
If a verification by Ops needs to be done, this will be reported by the flange coordinator who
will hand-over the blue labels to Ops.
Once Ops. verification has been done and the blind-list is updated, the label will be returned
to the flange coordinator. He checks the flange for correct installation (QC) and updates the
flange management database.
During the spading or temporary blinding activities random checks will be performed by the
flange coordinator.
The blue label will be logged onto the Flange Pin Board based in the Area PTW office.
After the spading and removing of the equipment has been done the following activities need
to be done to ensure proper assembly of the flanges once the spades will be removed and
the equipment will be re-instated
4.3.4 Pin Board in PTW Office
As the relevant sections are taken off the flange tag, each of the different color sections
must be taken to the Area PTW office. Within the office shall be a pinboard that reflects each
of the flange numbers to be actioned. As the sections are presented then each tag section
shall be placed on the relevant pin.
The PTW office shall have a letter box where flange tag sections can be placed that are
actioned within the night shift.

[ NSRP INTERNAL ]
4.3.5 Flange Tag Red Section (Final Assembly Close)
The first step of assembling the flange is to check if the flange is an isolation point or not. If
not the assembly of the flange can be done without the release of NSRP operator (the top
box of the red label has a strike-through)
If it is an isolation point, operations have to release the flange prior to the re-assembly of
the flange If all pre-required steps have been done for reinstatement, the operator will
release the flange by signing of the top part of the red label.
GMC execution will then remove the spade or temporary cover and start to re-assemble the
flange.
The following conditions shall be checked:
• Flange face conditions verified
• Flange alignment verified
• Conditions of the bolts & nuts verified
• Bolts & nuts lubricated
• Correct gasket verified
If all the above conditions are ok, he checkmarks the back side of the label and “Hand tighten”
the bolts & nuts.
Verified Complete and Acceptable
FLANGE
ensure that on completion of repair this is noted on the Flange Repair
Flange Coordinator shall update Flange Repair Regiister initially and
REPAIR
20
Stamp No#
20
Issued by Flange Coordinator

/
Stamp No#
Inspector
Flange Repair Tag:

/
Date:
Register
/
Date:
Work Pack Number
Repair Requirement
Flange Repair No#
System Number
Flange Number
Unit Number
Inspector
Damage
Verified
Rating
Size
He then signs the bottom part of the red label, tears off the red label and hand it over to the
Flange coordinator.

[ NSRP INTERNAL ]
4.3.6 Flange Tag Yellow Section (Flange Tightening)
The yellow section of the Flange Tag defines the tightening requirements, and the Flange
Technician (FT) required to carry out the work.
The flange will be tightened according to the attachment 1- Summarized Flange tightening
Table
• Manual Torque Wrench: FT - 1
• Hydraulic Torque Controlled: FT - 2
• Bolt Tensioning: FT - 3
Torque / Tensioning values are on the back side of the yellow label
FT-2 & FT-3 also need to fill-in the flange protocol with required info on the protocol.
The flange technician then checks if the flange requires a leak test or a service test on the
green label.
If Yes (No strikethrough): he will leave the green label in place with the flange. Ops must do
a check on this flange during commissioning.
If No (Strikethrough): He will tear-off the green label together with the yellow label (see
next point below).
Then the Flange Technician sign-off the top part of the yellow label and return the label(s)
to the flange coordinator.
The flange coordinator ensures the flange will be inspected and verified Acceptable by
QA/QC
QA/QC then sign-off the middle part of the yellow label and return the label to the flange
coordinator
Finally, if the flange was an isolation point, Ops need to verify and sign-off the bottom part
of the yellow label and update the blind-list.
4.3.7 Flange Tag Green Section (Leak Service Test)
The final check on the flange is the so-called leak or service test.

[ NSRP INTERNAL ]
This is to verify that the flange is not leaking when the line or equipment is pressurized
Normally this is done during commissioning of the Unit / systems
Some systems will be tested with the medium that normally runs through the line
(e.g., steam, BFW, Air, N2, etc.). This is called a service test
Leak-testing usually will be done with N2 and its normal design pressure (or maximum
allowable pressure if this is lower than the N2-pressure).
Once the service – or leak test is done and accepted, NSRP Operations. sign-off the top
part of the green label.
NSRP Operations tear-off the green label and leaves the grey label in place. The green label
will be handed over to the flange coordinator who then updates the flange database
4.4 Flange Tightening Teams and Resources
4.4.1 Flange Technician 1 ( FT-1) Duties
• FT-A can to bolt up with Manual torque Wrench/ unbolt flanges with normal
spanners/Manual Torque Wrench
• Minimum requirement to touch flanges
• Strike-through (not required) on yellow label:
• Torque values
• Checkmark on red label:
No protocol required
4.4.2 Flange Technician 2 (FT-2) Duties - Hydraulic

Torque Controlled as Appendix 1
• FT-B can bolt / unbolt flanges with machine torquing wrenches (pneumatic or
hydraulic)
• Fill-in the pre-defined Torquing values

[ NSRP INTERNAL ]
• Tensioning Values
• Protocol required
4.4.3 Flange Technician 3 (FT-3) Dutíes - Follow

Appendix 1 for Bolt Tensioning and Bad Actor Flange
Management
• FT-C can use tensioning equipment to Bolt / unbolt flanges. In case Bad Actor
Flange which required Bolt Tensioning however this technique can’t perform, the
Controlled Torque shall be applied with Ultrasonic Measurement.
• Fill-in the pre-defined Tensioning values
• Torque Values
• Protocol required
4.4.4 Execution Do’s and Don’t
Do:
• Use flogging spanners only for holding the back bolt
• Use bolt splitters for cutting stuck bolts
• Use (pneumatic) stroke tolls for unbolting
• Use WD-40 prior to unbolting
• Use Molykote 1000 (only) prior to tightening
Don’t:

[ NSRP INTERNAL ]
• Use flogging spanners with hammers
• Use an expansion rod on spanners or torque wrenches
• Use grinders for cutting stuck bolts
• Use equipment that is NOT designed to use for unbolting and bolting flanges
• Use (pneumatic) stroke tolls for bolting
• Mix-up Molykote & WD-40 !!

[ NSRP INTERNAL ]


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Rev. Prepared Reviewed

(*) With reference to MD-04-MT-RSSTA-PD-025 Revision 8 Maintenance Procedure for bolted

Document No.: MD-04-MT-MSSTA-PD-025

AMENDMENT REPORT FORM

Rev Item Original Revised Reason

Document No.: MD-04-MT-MSSTA-PD-025

03 6.6 TA Flange NA NA Newly add

Document No.: MD-04-MT-MSSTA-PD-025

6.2.1 Confirmation of Work Order and safety requirements .................................... 13

6.2.2 Personal protective equipment....................................................................... 14

6.2.3 Environmental precautions............................................................................. 15

6.2.4 Materials and tools ......................................................................................... 15

6.2.5 Critical flanges/ Bad Actor .............................................................................. 16

6.3 Execution of work ........................................................................................... 18

6.3.1 Training .......................................................................................................... 18

6.3.3 Alignment of bolted flanged joints .................................................................. 20

6.3.4 Installation of gasket ...................................................................................... 22

6.3.5 Lubrication of Working Surface ...................................................................... 22

6.3.6 Installation of Bolts: ........................................................................................ 23

6.3.7 Numbering of Bolts: ....................................................................................... 23

6.3.8 Tightening of bolts .......................................................................................... 24

6.3.8.1 Target Bolt Assembly Stress .......................................................................... 24

6.3.8.2 Tightening methods........................................................................................ 24

6.3.8.3 Manual Torque Wrench or Control Torque Method......................................... 25

6.3.9 Start-up Re-torque ......................................................................................... 28

6.3.10 Live Tightening for Flange Leak Rectification................................................. 29

Document No.: MD-04-MT-MSSTA-PD-025

6.3.11 Hot Bolting ..................................................................................................... 29

6.3.12 Half Bolting..................................................................................................... 31

6.3.13 Guidelines for leakage test by hydrogen ........................................................ 31

6.3.14 Guidelines for Joint Pressure and Tightness Test .......................................... 31

6.3.15 Joint Disassembly: ......................................................................................... 32

6.4. Flange Management Tracker and Tagging ..................................................... 32

6.4.1 Flange Management Tracker ......................................................................... 32

6.4.2 Flange Joint Mapping ..................................................................................... 32

6.4.3 Flange Tagging .............................................................................................. 33

6.5. Blinding and Tagging ...................................................................................... 34

6.4.4 Blinding .......................................................................................................... 34

6.4.5 Blind Tagging ................................................................................................. 35

6.4.6 Blind storage .................................................................................................. 36

6.5 Quality Assurance and Quality Control Provision. .......................................... 36

6.5.1 Flange Quality control .................................................................................... 37

6.5.1.2 Non-critical Flange ......................................................................................... 37

6.5.1.2 Critical Flange ................................................................................................ 37

6.5.2 Key Performance Areas/ Indicators ................................................................ 38

6.5.3 Bolting Service Contractor minimum Requirement ........................................ 39

6.5.4 Punching: ....................................................................................................... 39

6.6 Work order closure ......................................................................................... 40

6.7 TA Flange Management Provision ................................................................. 41

6.7.1 Temporary Gasket .............................................................................................. 41

6.7.2 Temporary Blind during TA ................................................................................. 41

6.7.3 Flange Protection during TA ............................................................................... 41

Document No.: MD-04-MT-MSSTA-PD-025

ATTACHMENT – 02 Bolts Numbering ....................................................................... 42

Document No.: MD-04-MT-MSSTA-PD-025

Document No.: MD-04-MT-MSSTA-PD-025