Document Title: Flange Management Procedure 0A IFC 18 June 2012 Rev Status Issue Date Issued for Comment Reason for Issue AR FAD AGN Prepar ed Check ed Approval MER / HS OEE / Project Approvals Printed initials in the approval boxes confirm that the document has been signed. The originals are held within Document Management. Revision Sheet REVISION DATE 0A 18 June 2012 DESCRIPTION OF CHANGE Issued for Comment Unit Owner . Recommended Bolt Tightening Procedure 6. Equipment 5. Bolt Tightening 6. Table for Bolt Tightening 7.Contents 1.1. 5. Purpose Scope Reference Safety Precautition Equipment and man power 5. 4.2. 3. Appendix .3.1. Man power 6.2. 2. Tightening Preparation 6. 2 SCOPE 2. This procedure describes the requirement for bolt tightening for piping system perform by Wika in accordance with Company in the scope of contract of Suban Condensate Tank.000 psi). 2. ASME B16. hydraulic torque wrench and hydraulic stud bolt tensioner.1.47 Large Diameter Steel Flange 3. Operators shall also be equipped with safety glasses.2. Additional safety equipment shall be worn as advised by the Project HSE Department.3 Proses Piping 3. adequate scaffolding shall be erected for safety. Supervisor must be present at location to supervise the worker prior to bolt tightening activity. Tools and equipment should be inspected before use to ensure good working condition. ASME B31.3.4. Manufacture Recommended (Hi-Force) 4 SAFETY PRECAUTIONS Special attention shall be paid to this work as it utilizes high-pressure hydraulic oil (maximum 15.Flange.1 PURPOSE 1. ASME B16. Application of bolts tightening tool shall be done as per the following scope : Bolt Diameter < 2” : General torque wrench (Manual/hand Torque Wrench or Hydraulic torque wrench if applicable) 3 REFERENCE 3.2. The working area shall be roped off and warning notices shall be displayed. 5 EQUIPMENT AND MAN POWER 5. and Fitting 3. The procedure defines the method for bolt tightening using manual/hand torque wrench.1. Operators shall handle components during placing or removing the bolt tightening equipment as per manufacturers recommendation.1 Equipment .1. For high elevation or remote area work.5 Pipe. hard hats. gloves and safety shoes. b. Mechanical Supervisor b. Determine the torque value for the studs or bolt to be tightened. Install all bolts and studs.1 Tightening Preparation a. Run up nuts finger tight d. b. Third tightening stage should be carried out at the 100% torque setting. b. 1. Install the gasket on the flange face and bring the flanges together until contacting the gasket. Prior to tightening.2 Recommended Bolt Tightening Procedure a. Flanged joints shall be properly aligned before torquing and maximum allowable translation of flange centerline & faces should be specified. Hand Tools Manpower a. 2. First tightening stage should be limited to a maximum of 30% of final torque setting.5. d. Note : 1. (To be noted as max values/tolerances according to the relevant spec’s). c. Hi-Force Including Accessories. making sure they are free from dirt and grit and that the threads and under nut faces are well lubricated. Mechanic/Helper 6 BOLT TIGHTTENING 6.3 or as per recommended by the equipment manufacturer e. After cleaning. c. studs should be lubricated with an approved compound. see Appendix for dimensional tolerance. Manual/Hand Torque Wrench c. 2 & 3 should be tightened using the diagonal bolt sequence shown in the diagram . Maximum allowable run out’ between flange faces should also be specified. all equipment shall be checked for any damage or imperfections.2 a. Mark the proper tightening sequence on the studs with chalk as per diagram on Para 5. The operator shall set the correct hydraulic pressure to achieved the required bolt torque for each stud bolt size according to appendix 1 (recommended tensioning pressure table). COMPANY reserves the right to witness the applied pressure for the torquing of the joint during reinstatement 6. 3. Second tightening stage should be limited to a maximum of 60% of final torque setting. Safety man c. On the fourth and final tightening sequence change from diagonal tightening to adjacent bolt-to-bolt tightening using the 100% torque setting value 6.4-8.5-6-7-8 IV 100% 2-6.5-6-7-8 II 60% 8-7-6-5. For 8 set Bolts Flange STAGE TORQUE SETTING BOLT SEQUENCE TIGHTENING I 30% 1-2-3-4.4-3-2-1 III 100% 1-2-3-4.3 Table for Bolt Tightening a.1-5. For 4 set Bolt Flange STAG E TORQU E SETTIN G BOLT SEQUENCE TIGHTENING I 30% 1-2-3-4 II 60% 4-3-2-1 III 100% 1-2-3-4 IV 100% 3-4-1-2 REMARK S b.3-7 REMARKS .f. 4-3-2-1 III 100% 1-2-3-4.3-1-9 REMARK S d. For 16 set Bolt Flange STAG E TORQU E SETTIN G BOLT SEQUENCE TIGHTENING REMARK S . For 12 set Bolt Flange STAG E TORQUE SETTING BOLT SEQUENCE TIGHTENING I 30% 1-2-3-4.7-611.c.5-6-78.4-2-10.9-10-11-12 IV 100% 8-5-12.5-6-78.9-10-11-12 II 60% 12-11-10-9:8-76-5-. 9-1011-12.6-4-18-10.13-14-15-16 IV 100% 1-12-8-13.8-7-6-5.I 30% 1-2-3-4.4-3-2-1 III 100% 1-2-3-4.7-2-1911.2-11-714.16-15-14-13 f. For 20 set Bolt Flange STAG E TORQU E SETTIN G I 30% II 60% III 100% IV 100% BOLT SEQUENCE TIGHTENING REMARK S 1-2-3-4.17-18-1920 8-1-20-12.4-32-1 1-2-3-4.5-6-7-8.3-9-5-15.5-6-7-8.12-1110-9:8-7-6-5-.910-11-12.13-1415-16.12-1110-9.5-6-7-8.4-10-616 e.9-1011-12.17-18-1920 20-19-18-17.5-6-7-8.13-14-15-16 II 60% 16-15-14-13.5-317-9. For 24 set Bolt Flange .13-1415-16.910-11-12.1615-14-13. 5-6-78.17-18-1920.21-22-2324 24-23-2221.5-6-78.24-1220-8.1716-1-9.9-10-1112.20-19-1817.16-15-1413.23-1119-7 REMARKS .18-152-10.STAGE TORQUE SETTING I 30% II 60% III 100% IV 100% BOLT SEQUENCE TIGHTENING 1-2-3-4.17-18-1920.13-14-1516.4-32-1 1-2-3-4.9-10-1112.13-14-1516.46-22-14.12-11-109.8-7-6-5.21-22-2324 3-5-21-13. 12-11-109.21-22-2324.13-14-1516.g.17-18-1920.24-23-2221. For 28 set Bolt Flange STAGE TORQUE SETTING I 30% II 60% III 100% IV 100% BOLT SEQUENCE TIGHTENING 1-2-3-4.18-14-4-610-26.21-22-2324 REMARKS .20-19-1817.13-14-1516.25-26-2728 28-27-2625.1519-7-2-2719.17-18-1920.5-67-8.16-208-1-28-11.16-15-1413.8-7-6-5.25-26-2728 17-13-3-5-925.9-10-1112.21-22-2324.9-10-1112.4-32-1 1-2-3-4.5-67-8. For 32 set Bolt Flange .h. 16-15-1413.28-27-2625.21-22-2324.13-14-1516.28-4-1810.30-7-2215.25-26-2728.1 BOLT SEQUENCE TIGHTENING REMARKS 1-2-3-4.9-10-1112. 7 A P P E N DI X .29-8-2116.5-67-8.25-26-2728.17-18-1920.STAGE TORQUE SETTING I 30% II 60% III 100% IV 100% 7.5-67-8.13-14-1516.8-7-6-5.9-10-1112.29-30-3132 32-6-2414.25-2-1811 Recommended flange bolt torque.27-3-209.21-22-2324.20-19-1817.26-1-1712.29-30-3132 32-31-3029.24-23-2221.17-18-1920.12-11-109.31-5-2313.4-32-1 1-2-3-4. 0 5.0 5.0 5.2 12.61 3.2 7.0 5.10 1.0 3.0 2.57 2.65 0.0 1.0 8.0 8.0 2.0 2.14 3.0 4.0 2.0 5.33 0.61 3.84 Bolting Torque (Kg.0 Step 2 2.61 7.0 8.Appendix 7.16 0.0 .0 1.24 0.0 8. 7.0 2.61 3.09 Max Torque 3.0 2.1.0 3.2 7.1 Size ½” ¾” 1” 1 ½” 2” 3” 4” 6” 8” Recommended flange bolt torque for ANSI 150 RF Bolt Size U-1/2 U-1/2 U-1/2 U-1/2 U-5/8 U-5/8 U-5/8 U-3/4 U-3/4 Min Torque 0.m) Adopted Step 1 Torque 2.0 5.0 1.64 1.0 2.84 12.0 1.0 1. 0 8.0 2.0 8.2 Size ½” ¾” 1” 1 ½” 2” 3” 4” 6” 8” 10” 12” 14” 16” 18” 20” 24” U-7/8 U-7/8 U-1 U-1 U-1 1/8 U-1 1/8 U-1 1/4 3.04 19.63 40.0 60.0 3.0 56.0 Step 2 3.04 Max Torque 3.0 Step 2 2.6 4.72 31.0 19.0 32.0 39.0 10.09 31.17 7.0 9.0 44.0 8.0 32.0 6.0 60.31 3.21 53.26 2.0 12.0 18.0 6.0 4.2 12.0 6.61 11.2 12.0 6.0 76.0 120.0 26.0 26.0 55.0 80.0 33.0 76.84 7.0 20.0 21.0 23.0 22.3 Recommended Flange bolt torque for ANSI 600 RF Size ½” ¾” 1” 1 ½” 2” 3” 4” 6” 8” 10” 12” 14” 16” Bolt Size U-1/2 U-1/2 U-1/2 U-1/2 U-5/8 U-5/8 U-5/8 U-3/4 U-3/4 U-7/8 U-7/8 U-1 U-1 Min Torque 1.0 10.79 14.38 0.0 3.0 17.50 75.92 10.84 12.91 21.84 12.84 7.2 7.m) Adopted Step 1 Torque 3.0 9.61 7.0 12.0 12.72 20.0 8.0 44.0 5.0 30.09 45.83 64.92 35.91 5.58 19.61 64.0 15.72 31.25 Bolting Torque (Kg.83 45.72 38.70 0.61 116.0 25.0 4.0 6.2 12.09 45.0 16.0 40.0 30.0 18.0 8.0 4.00 8.83 64.0 22.5 7.0 1.0 6.0 15.0 2.m) Adopted Step 1 Torque 2.0 80.48 9.83 45.0 41.98 54.41 5.61 87.0 11.85 23.61 64.0 15.11 13.0 15.0 100.08 4.0 32.61 64.86 Max Torque 3.09 45.25 Bolting Torque (Kg.30 1.0 8.84 20.0 60.0 12.83 64.12 16.0 19.0 12.0 3.0 27.0 6.61 7.15 6.0 10.0 5.63 9.0 30.0 100.0 12.0 36.0 5.0 17.92 116.0 11.0 .0 33.0 17.0 11.84 31.0 27.55 4.0 30.84 20.0 30.84 20.0 10.50 3.0 6.2 7.97 2.2 12.0 7.0 30.10” 12” 14” 16” 18” 20” 24” 7.0 6.0 6.0 32.0 39.0 1.0 76.0 9.0 4.0 4.0 5.79 13.0 Recommended flange bolt torque for ANSI 300 RF Bolt Size U-1/2 U-1/2 U-1/2 U-1/2 U-5/8 U-5/8 U-5/8 U-3/4 U-3/4 U-7/8 U-7/8 U-1 U-1 U-1 1/8 U-1 1/8 U-1 1/4 Min Torque 0. 0 86.0 200.0 160.28 159.0 120.0 102.55 150.18” 20” 24” U-1 1/8 U-1 1/8 U-1 1/4 84.49 120.0 120.0 .0 200.21 289.08 236.0 250.76 101.