Flange Management Procedure For THE Controlled Tightening OF Pressurised Bolted Joints

RUMAILA OPERATING ORGANISATION
FLANGE MANAGEMENT PROCEDURE

FLANGE MANAGEMENT PROCEDURE FOR
THE CONTROLLED TIGHTENING OF
PRESSURISED BOLTED JOINTS
0000BF-C-G0-G000-PE-PRO-0001
Date 10th January 2019
Rev Description Originator Review Approved Date
2nd
B02 Re-Issued for Use A Henderson C Careres D Paisley February
2016
Stephen Keegan David Halliwell Nick Kennington 22nd

B03 Issued for Use February
Steve Wright Jason Wild James Onslow 2018
10th
Stephen Keegan David Halliwell Nick Kennington January
B04 Issued for Use 2019
Steve Wright Derek Smith James Onslow
Digitally signed by
Wright,
Digitally signed by Wright, Stephen (NES)
DN: cn=Wright, Stephen (NES), o=Rumaila
Operating Organisation, ou=DOperations, David J. Digitally signed by
David J. Halliwell Nicholas P. Nicholas P.
Stephen (NES)
email=stephen.wright@roobasra.com,
Halliwell Date: 2019.01.10 Kennington

c=US
Kennington Date: 2019.01.13

Date: 2019.01.10 09:18:17 +03'00'
09:43:29 +03'00'
12:17:59 +03'00'
Document Number
0000BF-C-G0-G000-PE-PRO-0001 Rev B04 - Date 10th January 2019 Page 1 of 31
This document is the property of Rumaila Operating Organisation. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
REVISION DESCRIPTION SHEET
Rev Para Reason for Revision

0 Issued for IDC
B01 Issued for Use
B02 Re-Issued for Use
42” and 48” pipe sizes added
Torque values for 36”, 42”, 48” 150# flanges, 36” 600# and 30” 900# flanges
increased slightly in Appendix 8.1
Pikotek Flange Isolation Kit torque and bolt tension figures added as
Appendix 8.2
B03 Document Removed, Project and replaced with Operating organisation

Title
All Replaced ROO with COMPANY throughout where applicable
1 Added, COMPANY at WORK SITE, second paragraph,
Reworded, third paragraph, CONTRACTOR / SUBCONTRACTOR’s
working out of country i.e. at WORKSITE’s, or performing work on behalf of
COMPANY shall adhere to this procedure. Any deviation by CONTRACTOR
/ SUBCONTRACTOR’s is to be approved in writing by the authorised
COMPANY representative prior to performing this type of work.
1.1 Added, fourth paragraph with relevant bolting certification and training
2.1 Reformatted into table and updated definitions
2.2 Reformatted into table
3.1
Deleted, As a minimum, equipment shall be designed, manufactured, tested
and delivered in accordance with the latest Engineering International Codes
and Standards as referenced in the following document.
Reference ROO Document: 0000RP-C-G0-G000-QA-IDX-0001
3.2 Added, As a minimum, equipment shall be designed, manufactured, tested

and delivered in accordance with the latest revisions of relevant sections of
the international Codes, Standards and Regulations below.
The current edition or revision of the Codes and Standards referenced within
this specification shall be used at the time of activity.
Any conflicts between the requirements of this Specification and other

reference documents shall be referred to COMPANY for resolution.
In case of conflict between documents, order of precedence is shown in

section 3.4
Included table for standards.
3.3 Revised Hierarchy to be consistent with other project documents
Document Number
4 Deleted, Fig 1 and have

Replaced with has
Deleted 4.1.1, 4.1.2 and Appendix 8.8 of the procedure.
Replaced with 3.3
4.0.2 Added, 300 after CLASS 150 to

4.1 Added, first bullet point , as applicable
Added, 11. Confirm Bolted Flanged joints are free of any rust dirt or other
contamination.
12. Joints are brought up flush and square without forcing, bearing uniformly
on the gasket.
13. There shall be sufficient gap between the flanges to allow the installation
and replacement of gaskets.
14. Gasket shall not protrude into the bore of the pipe. Ring type joints (RTJ)
are to be lightly smeared on the mating surface with a proprietary anti friction
lubricant prior to fitting.
15. Bolting shall move freely through accompanying bolt holes at right angles
to the flange.
16. Confirm Molykote 1000 has been applied
4.3 Deleted, 4. Appendix 8.4

Replaced, 4. Appendix 8.5
Added, 6. & section 5
5 Added, fourth paragraph, When Torqueing is completed tag to be added to
the assembly. (ITR table PO2A to be populated). This ITR shall be completed
progressively throughout the bolting activities.
6 Added, when applicable after P03B PIPING 8.3
7 Deleted, Control of the competence of people working on bolted pipe joints is
a critical factor in achieving joint integrity. All persons / contractors deemed
competent to carry out specialist bolt tightening activities must have
completed a ROO-approved training course on the equipment which they will
be using prior to commencement of work.
Replaced, All persons/contractors deemed competent to carry out specialist
bolt tightening activities shall have completed a ROO approved industry
training course and certified after practical demonstrations of proficiency on
the equipment they will be using prior to the commencement of work
B04 8.3 Updated to include the statement that where flanges do not undergo leak
testing then a P03B certificate must be applied.
Hold Para. Description of Hold
Document Number
CONTENTS
1 PURPOSE .......................................................................................................................... 5
1. 1 Br ie f De s cr ipt ion ......................................................................................................... 5
1. 1. 1T or que W re nc he s ( M anu al and P ow er ed) ............................................... 5
1. 1. 2 Bolt T en sio ne r s .............................................................................................. 6
2 DEFINITIONS ABBREVIATIONS AND REFERENCES ................................................... 7
2. 1 Def in it io ns ...................................................................................... 7
2. 2 Ab b rev iat ion s ................................................................................. 8
3 REFERENCE DOCUMENTS ............................................................................................. 9
3. 1 St at ut o r y Re gul at ion s, Co de s an d St and a r ds ................................................ 9
3. 2 Int er nat ion al St and a r ds ........................................................................................... 9
3. 3 P roj e ct Do cum ent s ................................................................................................... 10
4 GENERAL DESIGN INFORMATION ............................................................................... 12
4. 0. 1 Bolt s an d Nut s ............................................................................................... 12
4. 0. 2 G a sk et s ............................................................................................................. 12
4. 0. 3 Lubr i ca nt ......................................................................................................... 12
4. 1 W O RK C H EC K L I ST P RIO R T O F L AN G E AS S EM BLY .................................. 12
4. 2 BO LT T IG HT E NI NG S EQ U EN CE S ........................................................................ 13
4. 3 W O RK C H EC K L I ST P O ST FL AN G E T IG HT E NI NG ........................................ 14
4. 4 T EST F AI L UR E ............................................................................................... 14
4. 5 M ULT IPL E T O O L T IG HT EN ING P AT T ER N S .................................................... 14
5 FLANGE MANAGEMENT DATA SYSTEM (FMDS) ....................................................... 15
6 “GOC” GUIDANCE ON CERTIFICATION ...................................................................... 16
7 TRAINING, QUALIFICATION AND EQUIPMENT CALIBRATION ................................. 17
8 APPENDIX A - SUPPORTING TECHNICAL DATA ........................................................ 18
8. 1 C AL CU L AT E D BO LT T O RQ U E AN D BO LT T EN SIO N S ET T ING S US IN G
S PI R AL W O UN D AN D RI NG T Y P E G AS K ET S ............................................................ 18
8. 2 C AL CU L AT E D BO LT T O RQ U E AN D BO LT T EN SIO N S ET T ING S US IN G
PI KO T E K V C S F L AN G E I SO L AT I O N K IT S .................................................................. 21
8. 3 M C RO O - P0 2 A – P IP I NG JO I NT I NT EG RIT Y C ERT IF IC AT E S ................... 24
8. 4 M C RO O - P0 3B – CO M M ISS IO N ING PR E P J O INT C H EC KL I S T ................. 29
8. 5 FL AN G E JO I NT AS S E M BLY T AG ......................................................................... 31
Document Number
1 PURPOSE
This procedure defines the minimum requirements for the controlled tightening of pressurised bolted
joints and forms part of the overall Flange Management System (FMS) currently being developed
within COMPANY.
COMPANY at SITE shall undertake to implement this flange management procedure to ensure that
leak tight joints can be mechanically accepted by the Mechanical Completions Group in line with
“Guidance on Certification” (GOC) as referenced in section 7 of this document.
CONTRACTOR / SUBCONTRACTOR’s working out of country i.e. at WORKSITE’s, or performing

work on behalf of COMPANY shall adhere to this procedure. Any deviation by CONTRACTOR /
SUBCONTRACTOR’s is to be approved in writing by the authorised COMPANY representative prior
to performing this type of work.
Flange assembly shall only be performed by suitably qualified personnel with relevant bolting
certification and training in accordance with this procedure or by COMPANY approved Contractor
standard operating procedures.
1.1 Brief Description

In order to effectively manage bolt assembly and tightening, manual or powered devices are used to
apply a specific and controlled tension to studs, bolts and cap screws by applying the correct torque
value for a specific bolting material, size and type of lubrication. The tool can also be used to remove
the tension when loosening is necessary.
Tools are normally powered by a console (hydraulic pump). The desired tension is achieved by
precisely controlling the hydraulic fluid pressure produced by the console and controlling the frictional
force exerted between the studs and nuts. The hydraulic fluid pressure produced by the console is
accurate to +/- 1%. The friction force is controlled by applying a lubricant with a known coefficient of
friction to the threads and mating surfaces.
1.1.1Torque Wrenches (Manual and Pow ered)
Torque wrenches provide this tension by controlling the amount of rotational force they apply to the
bolt. As the force is applied the threading draws the nut face and bolt head closer together, stretching
the bolt
and creating the clamping force. This is the most common form of providing load to a bolt. For high
clamping force a large amount of torque is needed; hydraulic wrenches can provide this force. With
hydraulic wrenches, torque is controlled by the hydraulic fluid pressure. The higher the pressure, the
more torque is applied to the bolt. As hydraulic fluid doesn’t compress, this provides very accurate
and consistent torque values.
Torque has been used as a means for controlling bolt loading and clamping force for many years.
Therefore, there are standard torque tables available, which provide guidance for determining the
correct amount of torque to be used for a particular size, grade of bolt and lubricant. For the greatest
possible accuracy when specifying torque for a particular application, it is important to take into
consideration a number of other factors, all of which can affect the amount of clamping force that a
particular amount of torque applies.
➢ The finish used on the bolts, including coating type (if applicable)
➢ The number of times that the bolt has been used
➢ Cleanliness of the bolt
➢ Type of lubricant which has been applied to the threads and nut face
Document Number
1.1.2 Bolt Tensioners
Bolt tensioners work by preloading the bolt, stretching it before the nut is tightened. The tensioner is
clamped to the bolt’s threads and pushes against the flange in the surface being bolted. This provides
a very consistent amount of stretch to the bolt, ensuring consistent bolt stretch and clamping force.
The drawback to bolt tensioners is that they must be selected specific to each application. Much more
data must be compiled and considered in the selection of a tensioner; this includes:
➢ Extended length of stud bolts must be specified

➢ Bolt diameter
➢ Free stud protrusion length
➢ Nut size
➢ Washer thickness and diameter
➢ Bolt grade
➢ Bolt load requirement
The amount of bolt stretch is controlled by the hydraulic pressure applied to the tensioner. Since the
bolt will be pre-stretched by the tensioner, minimal torque is needed to tighten the nut onto the stud.
The necessary clamping pressure or bolt load is accomplished by release of the tensioner, allowing
the natural elasticity of the bolt to provide the clamping pressure.
Document Number
2 DEFINITIONS ABBREVI ATIONS AND REFERENCES
2.1 Definitions
Definitions
ANTISEIZE
Bolt lubricant that reduces the potential for seizure of bolts and nuts that
improves the ability to remove bolts after they have been in service.
BOLT
Used as a generic term that applies to both machine bolts and stud bolts.
COATING
Metallic or non-metallic treatment applied to the surface of bolts
COMPANY The COMPANY is the party, which initiates the project for its design and
construction. The COMPANY will generally specify the technical
requirements. The COMPANY may also include an agent or consultant
authorized to act for, and behalf of, the COMPANY.
CONTRACTOR The party that carries

COMPANY out of
consists allBritish
or partPetroleum
of the design,
Iraq engineering,
NV (BP), Petro procurement,
China
construction, commissioning
(CNPC), Southern Oil Company or management
(SOC) and thetheState
project, or operation or
Oil Marketing
maintenance theIraq
Organization of facility.
(SOMO) The COMPANY
all of whom may
makeundertake all or part
up the Rumaila of the
Operating
duties of the CONTRACTOR.
Organisation
HAND TIGHTENED
Tightened (flange bolts) using unpowered wrenches.
Hydraulic torqueing:
HYDRAULIC BOLT
Using hydraulic tightening equipment to accurately tension bolts.
TENSIONING
HYDRAULIC
Tightening flange bolts using calibrated hydraulic torque wrenches.
TORQUEING
JOINT
The entire connection, including all components (e.g., flanges, gasket, and all
studs/nuts).
LUBRICATION
Application of anti-seize to a bolt
MANUAL TORQUEING
Tightening flange bolts using manual torque wrenches.
MAY One possible course of action
MECHANICALLY
A flanged joint or system that is leak tight and ready to accept process fluids.
COMPLETE
MUST / SHALL A Mandatory requirement
PLANT Shall mean permanent facilities designed, constructed and completed as a

result of execution of the WORK under the Contract.
Document Number
SHOULD A preferred requirement
SITE Shall mean the premises and places on, under, in, over or through which the
WORK is to be executed or carried out COMPANY’s site location in Basra
Province, Iraq
SUB-CONTRACTOR The SUB-CONTRACTOR is the party supplying goods, equipment or material

specified by the CONTRACTOR.
SUB-SUPPLIER Party supplying goods, equipment or material specified by the SUPPLIER
SUPPLIER The SUPPLIER is the party which manufactures or supplies equipment and
services to perform the duties of the CONTRACTOR. Shall be taken to mean
SUBCONTRACTOR
WORK Shall mean all and any of the works and/or services and/or materials required
to be provided by the CONTRACTOR under the Contract with COMPANY.
WORKSITE Any CONTRACTOR or SUBCONTRACTOR fabrication facilities
2.2 Abbreviations
The following abbreviations apply in this specification:
Abbreviations Definition
GOC Guidance on Certification
FMS Flange Management System
FMC Flange Management Contractor
FMDS Flange Management Data Base System
MC Mechanically Complete
BF Brown Field
WNF Weld Neck Flange
UNC Unified National Course Thread
RF Raised Face
FF Flat Face
RTJ Ring Type Joint
SPWD Spiral Wound
Document Number
3 REFERENCE DOCUMENTS
3.1 Statutory Regulations, Codes and Standards

This work shall comply with the applicable Iraqi codes, regulations, ordinances, and rules, where this
is not possible then a deviation request shall be raised for COMPANY review and approval.
It shall be the CONTRACTOR / SUPPLIER’s responsibility to identify and comply with the
requirements of any statutory International and National codes, laws, rules, regulations and standards
for the materials, design, fabrication, import, installation and operation of the equipment within Iraq.
3.2 International Standards

As a minimum, equipment shall be designed, manufactured, tested and delivered in accordance with
the latest revisions of relevant sections of the international Codes, Standards and Regulations below.
The current edition or revision of the Codes and Standards referenced within this specification shall
be used at the time of activity.
Any conflicts between the requirements of this Specification and other reference documents shall be
referred to COMPANY for resolution.
In case of conflict between documents, order of precedence is shown in section 3.4
Document Number Title
ASME (American Society of Mechanical Engineers)

Metallic Gaskets for Pipe Flanges: Ring Joint, Spiral
B16.20
Wound.
PCC-1 Guidelines for Pressure Boundary Bolted Joint Assembly.
B16.5 Pipe Flanges and Flanged Fittings NPS 1/2 - NPS 24
B16.47 Large Diameter Weld Neck Flanges NPS 24 – NPS 60

-
Document Number
3.3 Project Documents
Document Number Title
0000RP-C-G0-G000-ME-BOD-0001 Mechanical Statics, Piping & Rotating

Equipment: Basis of Design
0000BF-C-G0-G000-PL-BOD-0001 Rumaila Brownfield Project Pipelines Basis of
Design
0000RP-C-G0-G000-QA-IDX-0001 Index of Engineering Codes and Standards
0000RP-C-G0-G000-PE-SPC-0001 Specification for Brownfield Piping Class

A01E2B
A03E2B
A06E2B
A09E2B
A15E2B
A30E2B
S01N1B
U03E2B
A03M8B
A01M9B
0000RP-C-G0-G000-PE-SPC-0006 Specification for Brownfield Pipeline Class
Y15E2B
Y09E2B
Y03F3B
Y03F6B
0000RP-C-G0-G000-QA-PRO-0003 Materials Traceability & Certification
0000RP-C-G0-G000-QA-PRO-0004 Deviation Request
0000RP-C-G0-G000-QA-PRO-0001 Technical Query
Document Number
3.4 Order of Precedence
The following hierarchy shall apply to the WORK
1. Statutory Iraqi Laws and Regulations

2. CONTRACT terms and conditions
3. The Material Requisition
4. This PROJECT Specification
5. Other Industry codes and standards
6. Recognised Contractor, Manufactures and Technology specifications
In the event of ambiguity or contradiction between the above, precedence shall be given in the order
listed above. In the event of ambiguity or contradiction within the SPECIFICATION, CONTRACTOR
shall apply the most onerous requirement. In all cases, CONTRACTOR shall seek APPROVAL via an
Engineering or Technical Query before proceeding.
For the avoidance of doubt, hierarchy stipulations in any other document within the SPECIFICATION
are superseded by the above hierarchy.
International codes and standards shall be the latest edition and latest addenda at the time of
CONTRACT award.
Document Number
4 GENERAL DESIGN INFOR MATION

The following technical information has been specified to support the development of this procedure.
The required values for bolt torqueing, tensioning by lubricant type are referenced in appendix 8.1,
has been based upon bolt, nut and gasket types as specified within the new BF pipe classes which
are summarised in section 4.1.1, 4.1.2 and Appendix 8.8 of the procedure.
4.0.1 Bolts and Nuts

CONTINUOUS THREAD STUD BOLT, CHROME-MOLYBDENUM PER ASTM A193 GRADE B7,
WITH 2 HEAVY HEX NUTS, PER ASTM A194 GRADE 2H, PER ASME B1.1 WITH DIMENSIONAL
RECOMMENDATIONS PER ASME B16.5, HOT DIP GALVANISED PER ASTM F2329. (MINIMUM
YIELD STRENGTH = 105000 PSI)
Bolt lengths are to be rounded up to the next 5mm increment for purchase. If the bolts are to be
torqued the bolts are to be set with an even thread protrusion on either side of the flange. There
should be at least one and a maximum three threads extending beyond each nut.
Bolts that are to be hydraulically tensioned require a minimum one diameter of thread at the end
where the tension tool will be applied and a minimum of one thread protruding at the other end.
4.0.2 Gaskets
• GASKET, 316L STAINLESS STEEL WINDING, FLEXIBLE GRAPHITE FILLED, SPIRAL
WOUND TYPE, 1/8" (3.2MM) THICK, 316L STAINLESS STEEL INNER RING, 316L
STAINLESS STEEL OUTER CENTERING RING, CLASS 150 to 300, PER ASME B16.5,
PER ASME B16.20
• GASKET , SOFT IRON (MAX HARDNESS 90 BRINELL) , RING JOINT, OVAL RING ,
CLASS 900 / 1500 , PER ASME B16.5 , PER ASME B16.20
• GASKET , SOFT IRON (MAX HARDNESS 90 BRINELL) , RING JOINT, OVAL RING ,
5000 PSI , PER API 6A TYPE R , 2-1/16" NOMINAL FLANGE SIZE
4.0.3 Lubricant
For bolt tightening activities, a single lubricant paste SHALL be standardised within ROO as follows:
• MOLYKOTE 1000
Refer to Appendix 8.1 and 8.2 for corresponding torque and tensioning values
4.1 WORK CHECK LIST PRIOR TO FLANGE ASSEMBLY

Flange assembly and tightening shall only be performed by suitably qualified personnel.
Prior to commence of controlled tightening the following checks shall be completed:
1. Raise permits as applicable, carry out tool box talks and make the area safe
2. Confirm correct bolts and gaskets are selected in line with the specified flange size and
rating as referenced in the new BF pipe classes
3. Confirm correct bolt tightening method and values for your application (Appendix 8.1)
4. Confirm equipment is calibrated and certified for use and is functioning correctly
5. Complete initial checks as per MC R00-P02A check sheet (Appendix 8.2)
6. Confirm Bolted Flanged joints are free of any rust dirt or other contamination.
7. Joints are brought up flush and square without forcing, bearing uniformly on the gasket.
Document Number
8. There shall be sufficient gap between the flanges to allow the installation and replacement
of gaskets.
9. Gasket shall not protrude into the bore of the pipe. Ring type joints (RTJ) are to be lightly
smeared on the mating surface with a proprietary anti friction lubricant prior to fitting.
10. Bolting shall move freely through accompanying bolt holes at right angles to the flange.
11. Confirm Molykote 1000 has been applied
4.2 BOLT TIGHTENING SEQUENCE S

Once the correct method of tightening has been agreed, the corresponding torque or tensioning
values have been established and verified then the process of staged tightening may proceed in
accordance with this procedure. Note: When hydraulic bolt tensioners are employed, use the
procedure recommended by experienced personnel who are qualified in controlled bolting services.
Note: When loosening, the tool should be sized for torque values at least 1½ and preferably 2 times
that of the tightening torque.
(Recommended Criss-Cross Tightening Sequence)
MARKED UP 8 BOLT FLANGE 1ST, 2nd & 3rd Stage Criss Cross Sequence 4th & Final Stage Adjacent
Bolt Sequence.
• 4 Bolt Flange 1-3-2-4

• 8 Bolt Flange 1-5-3-7-2-6-4-8
• 12 Bolt Flange 1-5-9-3-7-11-2-6-10-4-8-12
• 16 Bolt Flange 1-9-5-13-3-11-7-15-2-10-6-14-4-12-8-16
• 20 Bolt Flange 1-13-5-17-9-3-15-7-19-11-2-14-6-18-10-4-16-8-20-12
• 28 Bolt Flange 1-13-21-5-17-9-25-3-15-23-7-19-11-27-2-14-22-6-18-10-26-4-16-24-8-20-
12-28
• 32 Bolt Flange 1-29-13-21-5-17-9-25-3-31-15-23-7-19-11-27-2-30-14-22-6-18-10-26-4-32-
16-24-8-20-12-28
• 36 Bolt Flange 1-29-13-21-5-17-33-9-25-3-31-15-23-7-19-35-11-27-2-30-14-22-6-18-34-10-
26-4-32-16-24-8-20-36-12-28
Note: Correct numbering of bolts should result in all odd numbered bolts around one side of the
flange and all even numbered bolts around the other side.
1. Mark the correct tightening sequence on the studs in a clockwise direction with chalk as per
diagram.
2. Determine the Torque Value for the stud or bolt to be tightened: -
3. First tightening stage should be limited to a maximum of 30% of the final Torque setting.
4. Second tightening stage should be limited to a maximum of 60% of the final Torque setting.
5. Third tightening stage should be carried out at the 100% Torque setting.
6. On the Fourth and Final tightening stage, change from diagonal tightening to adjacent bolt-to-
bolt tightening clock-wise using the 100% Torque setting and chase around flange until nuts
finally stop rotating.
Document Number
Circular patterns shall be repeated until the nuts do not turn.
Note: First, second and third stages should be tightened using the criss cross tightening sequence
and the fourth stage should be tightened using the adjacent clockwise bolt to bolt sequence as
shown in the diagrams above.
4.3 WORK CHECK LIST POST FLANGE TIGHTENING

Once the flange has been tightened correctly then the following close out activities shall be
completed:
1. Remove tensioning equipment from the flange and power down
2. Complete and sign off MC ROO-P02A – Piping joint Integrity certificate (Appendix 8.2)
3. Complete and sign off MC ROO-P03B – Commissioning prep witnessed joint check
(Appendix 8.3)
4. Once the flange is fully leak tested and energised, complete Joint Assembly Tag
(Appendix 8.5)
5. Once all work is complete, clean up the work area, return permits and return equipment
to workshop
6. Update the Flange Management Data System (Appendix 8.5 & Section 5)
7. Complete handover test packs and issue to QA/QC dept
4.4 TEST FAILURE

If the test fails, an attempt may be made to retighten the joint with the following procedure:
a) The system shall be depressured

b) The same assembly bolt load shall be used in an additional circular pattern
After retightening, the joint shall be subject to a retest.
A joint that still does not seal shall be dismantled and reassembled with a new gasket.
Original gasket and flange surfaces should be inspected to determine possible reasons for the failure
prior to reassembly.
If the joint is taped for leak testing, the tape shall be removed after the test is complete.
Reverse integrity gaskets shall not be used for joint integrity testing.
4.5 MULTIPLE TOOL TIGHTENING P ATTERNS

For multiple tool hydraulic torque and hydraulic tensioning patterns, refer to ASME PCC-1, Appendix
F. Approval shall be provided by the Mechanical TA or EA prior to the commencement of multiple tool
tightening activities.
Document Number
5 FLANGE MAN AGEMENT DAT A SYSTEM (FMDS)

A Flange Management Data System (FMDS) as referenced in Appendix - 8.5 will be used to control
and monitor the implementation of integrity of all bolted joints encompassed by the FM process. The
FMDS will supply point data, torque / tensioning figures from project approved tool manufacturers, tool
fit analysis as well as recording results of inspections, assembly, controlled tightening and testing of
joints as appropriate.
The Flange Management Contractor (FMC) will be responsible for updating the system and ensuring
all data is kept live as the project progresses. Additional features of the FMDS will include generation
of workpacks, work instructions and joint completion certificates.
The FMC will be responsible to liaise with the construction/fabrication contractor and client to prioritise
work and agree the joints to be checked, disassembled, assembled or tightened on a daily basis. The
FMC will issue workpacks, temporary flange tags, drawings confirming location of the joints and
individual joint work instructions to the construction/fabrication contractor. The construction /
fabrication contractor is responsible for carrying out the work and where required obtaining QC
inspection/release from the FMC at key stages of the joint make up as detailed in the project FM
Procedures.
When Torqueing is completed, tag to be added to the assembly. (ITR table PO2A to be populated).
This ITR shall be completed progressively throughout the bolting activities.
On completion of each activity the FM Contractor will update the FMDS of the joint status by using the
tear off tabs from the temporary flange tags and the completed / signed off work instruction. When
work packs / joints have been completed then Joint Completion Certificates (JCC) will be issued and
scanned into the FMDS.
Document Number
6 “GOC” GUIDANCE ON CE RTIFICATION

Certification of pressurised flanges and joints SHALL be completed in accordance with the COMPANY
Guidance on Certification Completions Procedure - 00096R-C-G0-G000-CO-PRO-0001.
All pressurised flanged joints SHALL be certified by completing the following Mechanical Completions
Joint Integrity Certificate - MC ROO-P02A and P03B Piping when applicable, as referenced in
Appendix 8.2 and 8.3. These certificates shall be submitted as part of the “GOC” handover
documentation and is a required deliverable for formal close-out of completed systems.
For further details on “GOC” competency and training please contact the ROO Operations Start-Up
Co-ordinator: ROOOPSC@roobasra.com
Document Number
7 TRAINING, QUALIFICAT ION AND EQUIPMENT CALIBRATION

Everyone with an influence on joint integrity within ROO should be aware of the management systems
used with the ROO, their objectives, expectations and effects on project planning and day to day
working.
For further details on flange management / bolt tightening training and competency please contact the
ROO Operations Start-Up Co-ordinator: ROOOPSC@roobasra.com
Notes:
1. Joint assemblers shall be required to provide a copy of their training course prior to starting
work (subject to approval by COMPANY responsible engineer)..
2. Joint assemblers shall be required to provide a copy of their QC procedures pertaining to

bolted joint assembly prior to starting work. QC procedures shall include at least the
following: Assembly procedure, calibration records, and qualification records.
3. Assembly equipment shall be calibrated in accordance with manufacturer

recommendations, but the maximum period of calibration shall not, in any case, exceed:
a. 1 year for manual and hydraulic equipment
b. 6 months for pneumatic and electric equipment
4. Tools shall be uniquely identified and traceable to the certification documentation
5. Manual torque wrenches should be verified weekly or at checkout and check-in whichever
is shorter. A bench mounted torque wrench calibrator may be used.
Document Number
8 APPENDIX A - SUPPORTING TECHNIC AL DAT A
8.1 CALCULATED BOLT TORQUE AND BOLT TENSION

SETTINGS USING SPIRAL WOUND AND RING TYPE
G ASKETS
Bolt Torque
Bolt Size (in)
(Nm) (ft-lb)
1/2” (150# ½”, ¾”, 1” flange sizes only) 31 23
1/2” (all other flange sizes) 51 37
5/8” 111 82
3/4" (150# 8” flange size only) 249 184
3/4" (all other flange sizes) 203 150
7/8” 326 241
1” (Note 9) 491 362
1 1/8” (Note 9) 734 541
1 1/4 “ (150# 30” flange size only) (Note 9) 621 458
1 1/4 “ (all other flange sizes) (Note 9) 1038 766
Bolt Tension
Bolt Size (in)
(kN) (lbf)
1” 129 29,000
1 1/8” 171 38,500
1 1/4“ (150# 30” flange size only) 130 29,300
1 1/4“ (all other flange sizes) 218 49,000
1 3/8” 271 61,000
1 1/2" (150# 36”, 42”, 48” flange sizes only) 199 44,800
1 1/2" (all other flange sizes) 329 74,000
1 5/8” (300# 42” flange size only) 238 53,400
1 5/8” (all other flange sizes) 391 88,000
1 3/4" 369 83,000
1 7/8” (300# 48” flange size only) 323 72,550
1 7/8” (all other flange sizes) 534 120,000
2” (300# 36” flange size) 421 94,700
2” (600# 30” flange size) 402 90,300
2” (all other flange sizes) 578 130,000
2 1/4" 641 144,000
2 1/2" (600# 36” flange size only) 593 133,280
2 1/2" (all other flange sizes) 801 180,000
2 3/4” 979 220,000
3” 868 195,220
3 1/2 “ 1167 262,400
Document Number
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 = 50% of yield strength for bolts except ½“ bolts and bolts 1¼” and larger
where stresses are reduced to protect these flanges. Stud bolt stress in the 150# 8” flange
size has been increased in order to improve sealing on this flange.
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.
Document Number
Document Number
8.2 CALCULATED BOLT TORQUE AND BOLT TENSION

SETTINGS USING PIKOTEK VCS FLANGE ISOLATION KITS
Bolt Torque
Bolt Size (in)
(Nm) (ft-lb)
1/2” 41 30
5/8” 75 55
3/4" 129 95
7/8” 210 155
1” (Note 9) 312 230
1 1/8” (Note 9) 454 335
1 1/4 “ (Note 9) 637 470
Bolt Tension
Bolt Size (in)
(kN) (lbf)
1” 82 18,400
1 1/8” 106 23,800
1 1/4“ 134 30,050
1 3/8” 166 37,250
1 1/2" 199 44,800
1 5/8” 238 53,400
1 3/4" 279 62,620
1 7/8” 323 72,550
2” 370 83,200
2 1/4" 475 106,850
2 1/2" 593 133,280
2 3/4” 724 162,770
3” 868 195,220
3 1/2 “ 1196 268,920
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.
Document Number
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.
Document Number
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.
Document Number
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.
Document Number
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).
Document Number
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).
Document Number
[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.
Document Number
c) Maximum difference in gap between opposite sides of the flanges shall not exceed 1mm, i.e.
maximum angular misalignment shall not exceed 1mm.
Document Number
8.4 MC ROO-P03B – COMMISSIONING PREP JOINT CHECKLIST
Document Number
Document Number
8.5 FLANGE JOINT ASSEMBLY TAG
This example assembly TAG can be used to document completion for all joints.
FLANGE JOINT ASSEMBLY TAG
Document Number

Flange Management Procedure For THE Controlled Tightening OF Pressurised Bolted Joints

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Flange Management Procedure For THE Controlled Tightening OF Pressurised Bolted Joints

Uploaded by

Copyright:

Available Formats

RUMAILA OPERATING ORGANISATION

FLANGE MANAGEMENT PROCEDURE

RUMAILA OPERATING ORGANISATION

Rev Description Originator Review Approved Date

Stephen Keegan David Halliwell Nick Kennington 22nd

Halliwell Date: 2019.01.10 Kennington

Kennington Date: 2019.01.13

REVISION DESCRIPTION SHEET

Rev Para Reason for Revision

B03 Document Removed, Project and replaced with Operating organisation

Reference ROO Document: 0000RP-C-G0-G000-QA-IDX-0001

3.2 Added, As a minimum, equipment shall be designed, manufactured, tested

Any conflicts between the requirements of this Specification and other

In case of conflict between documents, order of precedence is shown in

Included table for standards.

3.3 Revised Hierarchy to be consistent with other project documents

4 Deleted, Fig 1 and have

Deleted 4.1.1, 4.1.2 and Appendix 8.8 of the procedure.

Replaced with 3.3

4.0.2 Added, 300 after CLASS 150 to

4.3 Deleted, 4. Appendix 8.4

1. 1 Br ie f De s cr ipt ion ......................................................................................................... 5

1. 1. 1T or que W re nc he s ( M anu al and P ow er ed) ............................................... 5

1. 1. 2 Bolt T en sio ne r s .............................................................................................. 6

2 DEFINITIONS ABBREVIATIONS AND REFERENCES ................................................... 7

2. 2 Ab b rev iat ion s ................................................................................. 8

3 REFERENCE DOCUMENTS ............................................................................................. 9

3. 1 St at ut o r y Re gul at ion s, Co de s an d St and a r ds ................................................ 9

3. 2 Int er nat ion al St and a r ds ........................................................................................... 9

3. 3 P roj e ct Do cum ent s ................................................................................................... 10

4 GENERAL DESIGN INFORMATION ............................................................................... 12

4. 0. 1 Bolt s an d Nut s ............................................................................................... 12

4. 1 W O RK C H EC K L I ST P RIO R T O F L AN G E AS S EM BLY .................................. 12

4. 5 M ULT IPL E T O O L T IG HT EN ING P AT T ER N S .................................................... 14

5 FLANGE MANAGEMENT DATA SYSTEM (FMDS) ....................................................... 15

6 “GOC” GUIDANCE ON CERTIFICATION ...................................................................... 16

7 TRAINING, QUALIFICATION AND EQUIPMENT CALIBRATION ................................. 17

8 APPENDIX A - SUPPORTING TECHNICAL DATA ........................................................ 18

8. 3 M C RO O - P0 2 A – P IP I NG JO I NT I NT EG RIT Y C ERT IF IC AT E S ................... 24

8. 4 M C RO O - P0 3B – CO M M ISS IO N ING PR E P J O INT C H EC KL I S T ................. 29

CONTRACTOR / SUBCONTRACTOR’s working out of country i.e. at WORKSITE’s, or performing

1.1 Brief Description

1.1.1Torque Wrenches (Manual and Pow ered)

1.1.2 Bolt Tensioners

➢ Extended length of stud bolts must be specified

2 DEFINITIONS ABBREVI ATIONS AND REFERENCES

CONTRACTOR The party that carries

MAY One possible course of action

MUST / SHALL A Mandatory requirement

PLANT Shall mean permanent facilities designed, constructed and completed as a

SHOULD A preferred requirement

SUB-CONTRACTOR The SUB-CONTRACTOR is the party supplying goods, equipment or material

SUB-SUPPLIER Party supplying goods, equipment or material specified by the SUPPLIER

WORKSITE Any CONTRACTOR or SUBCONTRACTOR fabrication facilities

The following abbreviations apply in this specification:

GOC Guidance on Certification

FMS Flange Management System

FMC Flange Management Contractor

FMDS Flange Management Data Base System

WNF Weld Neck Flange

UNC Unified National Course Thread

RTJ Ring Type Joint

SPWD Spiral Wound