RUMAILA OPERATING ORGANISATION

FLANGE MANAGEMENT PROCEDURE

NOTES

1. Molykote 1000 shall be used on all bolts. If a different lubricant is proposed then a formal
deviation to this procedure is required for approval.

2. Friction factor used in calculations, µ = 0.11 (advised by Dow Corning as appropriate for
galvanised carbon steel bolts lubricated by Molykote 1000).

3. Nut factor used in calculations, K = 0.15 (per ASME PCC-1 Appendix K, nut factor taken as
friction factor, µ, plus 0.04).

4. Torques are calculated in accordance with ASME PCC-1 Appendix K.

5. Stud bolt stress = 30 ksi as advised by GPT / Pikotek.

6. Bolt material is assumed to be A193 B7 with minimum yield strength 725 MPa (105 ksi) for
bolt sizes up to and including 2½” for all flanges, including flanges in stainless steel
S01N1B piping specification.

7. Bolt torques and tensions shown are suitable for all flanges, including flanges in stainless
steel S01N1B piping specification.

8. Hydraulic tensioning equipment shall be used for all bolts larger than 1¼“.

9. Hydraulic tensioning equipment is preferred for all bolts of size 1” and larger. Bolt
tensioning equipment has 2 advantages - it pulls flange faces together squarely and it is
considered accurate to approximately ±10% compared with manual torque wrench
accuracy of ±30%.

10. The upper zigzag lines shown in the torque and tension tables on the next page show the
limits for the manual torque wrench. Above and to the left of this line the bolt sizes are
smaller than 1” and it is mandatory to use the manual torque wrench for these bolt sizes.
Between the two zigzag lines, hydraulic tensioning equipment is preferred but not
mandatory. Below and to the right of the lower zigzag line bolts larger than 1¼” where
hydraulic tensioning is mandatory.

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FLANGE MANAGEMENT PROCEDURE

These tables are only to be used for Pikotek VCS Flange Isolation Kits, with galvanised steel stud
bolts which have been coated with Molykote 1000.

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8.3 MC ROO-P02 A – PIPING JOINT INTEGRITY CERTIFICATES

All pressurised flanged joints SHALL be certified by completing the following Mechanical Completions
Joint Integrity Certificate - MC ROO-P02A / P03B Piping. Where flanges do not undergo leak testing
then a P03B form must also be applied. These certificates shall be submitted as part of the “GOC”
handover documentation and is a required deliverable for formal close-out of completed systems.

Sheet 1 of 2 ROO 002A – Piping.

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Sheet 2 of 2 ROO 002A – Piping continued.

NOTES:-

• Item 2 – dirt, paint and rust shall be removed from the raised face using a soft cloth.

• Item 2 – in accordance with ASME PCC-1, a defect on the raised face of the flange or the ring
groove shall not extend over more than half the width of the raised face or ring groove,
regardless of depth of defect.

For raised face flanges, the maximum depth of defect permitted is 0.25mm for a defect extending over
more than one quarter of the width of the raised face, and 0.75mm for a defect extending over less
than one quarter of width of the raised face (see below).

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For ring type joint flanges, the maximum depth of defect permitted is 0.25mm for a defect extending
over more than one quarter of the width of the seating surface of the groove, and 0.75mm for a defect
extending over less than one quarter of width of the seating surface of the groove (see below).

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[from ASME PCC-1, Appendix D]

• Item 5 – only Molykote 1000 shall be used for lubrication – no other lubricant is permitted.

• Item 6 – flange faces shall be aligned horizontally, vertically, rotationally and angularly, prior
to tightening, within the following limits:-

a) Maximum horizontal and/or vertical difference between flanges, i.e. maximum centreline
mismatch, shall not exceed 1.6mm.

b) A small mismatch of holes in rotational direction is permitted provided that bolts shall be able
to pass freely through the bolt holes parallel with the pipe and without touching the edges of
the bolt holes.

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c) Maximum difference in gap between opposite sides of the flanges shall not exceed 1mm, i.e.
maximum angular misalignment shall not exceed 1mm.

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8.4 MC ROO-P03B – COMMISSIONING PREP JOINT CHECKLIST

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8.5 FLANGE JOINT ASSEMBLY TAG

This example assembly TAG can be used to document completion for all joints.

FLANGE JOINT ASSEMBLY TAG

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