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

Contents
1.
2.
3.
4.
5.

Purpose
Scope
Reference
Safety Precautition
Equipment and man power
5.1. Equipment
5.2. Man power
6. Bolt Tightening
6.1. Tightening Preparation
6.2. Recommended Bolt Tightening Procedure
6.3. Table for Bolt Tightening
7. Appendix

1 PURPOSE
1.1. 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.
2 SCOPE

2.1.

The procedure defines the method for bolt tightening using manual/hand torque
wrench, hydraulic torque wrench and hydraulic stud bolt tensioner.

2.2.

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
3.1. ASME B16.5 Pipe,Flange, and Fitting
3.2. ASME B16.47 Large Diameter Steel Flange
3.3. ASME B31.3 Proses Piping
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
15,000 psi). 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. The working area shall be roped off and warning notices shall be
displayed. For high elevation or remote area work, adequate scaffolding shall be erected for
safety. Operators shall handle components during placing or removing the bolt tightening
equipment as per manufacturers recommendation. Operators shall also be equipped with
safety glasses, hard hats, gloves and safety shoes.
Additional safety equipment shall be worn as advised by the Project HSE Department.

5 EQUIPMENT AND MAN POWER

5.1

Equipment

5.2

a.

Hi-Force Including Accessories.

b.

Manual/Hand Torque Wrench

c.

Hand Tools

Manpower
a.

Mechanical Supervisor

b.

Safety man

c.

Mechanic/Helper

6 BOLT TIGHTTENING
6.1

Tightening Preparation
a. Flanged joints shall be properly aligned before torquing and maximum
allowable translation of flange centerline & faces should be specified.
Maximum allowable run out between flange faces should also be specified.
(To be noted as max values/tolerances according to the relevant specs). see
Appendix for dimensional tolerance.
b. Prior to tightening, all equipment shall be checked for any damage or
imperfections. After cleaning, studs should be lubricated with an approved
compound.
c.

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).

d. COMPANY reserves the right to witness the applied pressure for the torquing
of the joint during reinstatement
6.2

Recommended Bolt Tightening Procedure

a. Install the gasket on the flange face and bring the flanges together
until contacting the gasket.
b. Install all bolts and studs, making sure they are free from dirt and grit
and that the threads and under nut faces are well lubricated.
c.

Run up nuts finger tight

d. Mark the proper tightening sequence on the studs with chalk as per
diagram on Para 5.3 or as per recommended by the equipment
manufacturer
e. Determine the torque value for the studs or bolt to be tightened.
1. First tightening stage should be limited to a maximum of 30% of final
torque setting.
2. Second tightening stage should be limited to a maximum of 60% of final
torque setting.
3. Third tightening stage should be carried out at the 100% torque setting.
Note : 1, 2 & 3 should be tightened using the diagonal bolt sequence shown in the
diagram

f.

On the fourth and final tightening sequence change from diagonal

tightening to adjacent bolt-to-bolt tightening using the 100% torque
setting value

6.3

Table for Bolt Tightening

a. For 4 set Bolt Flange

STAG
E

TORQU
E
SETTIN
G

BOLT
SEQUENCE
TIGHTENING

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. For 8 set Bolts Flange

STAGE

TORQUE
SETTING

BOLT
SEQUENCE
TIGHTENING

30%

1-2-3-4;5-6-7-8

II

60%

8-7-6-5;4-3-2-1

III

100%

1-2-3-4;5-6-7-8

IV

100%

2-6;1-5;4-8;3-7

REMARKS

c.

For 12 set Bolt Flange

STAG
E

TORQUE
SETTING

BOLT
SEQUENCE
TIGHTENING

30%

1-2-3-4;5-6-78;9-10-11-12

II

60%

12-11-10-9:8-76-5-;4-3-2-1

III

100%

1-2-3-4;5-6-78;9-10-11-12

IV

100%

8-5-12;7-611;4-2-10;3-1-9

REMARK
S

d. For 16 set Bolt Flange

STAG
E

TORQU
E
SETTIN
G

BOLT SEQUENCE
TIGHTENING

REMARK
S

30%

1-2-3-4;5-6-7-8;9-1011-12;13-14-15-16

II

60%

16-15-14-13;12-1110-9:8-7-6-5-;4-3-2-1

III

100%

1-2-3-4;5-6-7-8;9-1011-12;13-14-15-16

IV

100%

1-12-8-13;2-11-714;3-9-5-15;4-10-616

e. For 20 set Bolt Flange

STAG
E

TORQU
E
SETTIN
G

30%

II

60%

III

100%

IV

100%

BOLT
SEQUENCE
TIGHTENING

REMARK
S

1-2-3-4;5-6-7-8;910-11-12;13-1415-16;17-18-1920
20-19-18-17;1615-14-13;12-1110-9;8-7-6-5;4-32-1
1-2-3-4;5-6-7-8;910-11-12;13-1415-16;17-18-1920
8-1-20-12;7-2-1911;6-4-18-10;5-317-9;16-15-14-13

f.

For 24 set Bolt Flange

STAGE

TORQUE
SETTING

30%

II

60%

III

100%

IV

100%

BOLT
SEQUENCE
TIGHTENING

1-2-3-4;5-6-78;9-10-1112;13-14-1516;17-18-1920;21-22-2324
24-23-2221;20-19-1817;16-15-1413;12-11-109;8-7-6-5;4-32-1
1-2-3-4;5-6-78;9-10-1112;13-14-1516;17-18-1920;21-22-2324
3-5-21-13;46-22-14;1716-1-9;18-152-10;24-1220-8;23-1119-7

REMARKS

g. For 28 set Bolt Flange

STAGE

TORQUE
SETTING

30%

II

60%

III

100%

IV

100%

BOLT
SEQUENCE
TIGHTENING

1-2-3-4;5-67-8;9-10-1112;13-14-1516;17-18-1920;21-22-2324;25-26-2728
28-27-2625;24-23-2221;20-19-1817;16-15-1413;12-11-109;8-7-6-5;4-32-1
1-2-3-4;5-67-8;9-10-1112;13-14-1516;17-18-1920;21-22-2324;25-26-2728
17-13-3-5-925;18-14-4-610-26;16-208-1-28-11;1519-7-2-2719;21-22-2324

REMARKS

h. For 32 set Bolt Flange

STAGE

TORQUE
SETTING

30%

II

60%

III

100%

IV

100%

7.1

BOLT
SEQUENCE
TIGHTENING

REMARKS

1-2-3-4;5-67-8;9-10-1112;13-14-1516;17-18-1920;21-22-2324;25-26-2728,29-30-3132
32-31-3029;28-27-2625;24-23-2221;20-19-1817;16-15-1413;12-11-109;8-7-6-5;4-32-1
1-2-3-4;5-67-8;9-10-1112;13-14-1516;17-18-1920;21-22-2324;25-26-2728,29-30-3132
32-6-2414;31-5-2313;30-7-2215;29-8-2116;28-4-1810;27-3-209;26-1-1712;25-2-1811

Recommended flange bolt torque.

A
P
P
E
N
DI
X

Appendix 7.1.
7.1
Size

1
1
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
0.16
0.24
0.33
0.65
0.64
1.10
1.57
2.14
3.09

Max
Torque
3.61
3.61
3.61
3.61
7.2
7.2
7.2
12.84
12.84

Bolting Torque (Kg.m)

Adopted
Step 1
Torque
2.0
1.0
2.0
1.0
2.0
1.0
2.0
1.0
5.0
1.0
5.0
2.0
5.0
3.0
8.0
3.0
8.0
4.0

Step 2
2.0
2.0
2.0
2.0
5.0
5.0
5.0
8.0
8.0

10
12
14
16
18
20
24
7.2
Size

1
1
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

3.6
4.91
5.15
6.5
7.63
9.11
13.84

20.72
20.72
31.09
31.09
45.83
45.83
64.61

11.0
12.0
17.0
18.0
26.0
27.0
39.0

5.0
6.0
6.0
8.0
9.0
10.0
15.0

11.0
12.0
17.0
18.0
26.0
27.0
39.0

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
0.38
0.70
0.97
2.30
1.50
3.08
4.41
5.00
8.48
9.79
14.79
13.58
19.04
19.85
23.72
38.86

Max
Torque
3.61
7.2
7.2
12.84
7.2
12.84
12.84
12.84
20.84
31.09
45.83
45.83
64.61
64.61
64.61
116.25

Bolting Torque (Kg.m)

Adopted
Step 1
Torque
2.0
1.0
4.0
1.0
4.0
2.0
8.0
3.0
5.0
3.0
8.0
4.0
9.0
5.0
10.0
6.0
15.0
10.0
22.0
11.0
30.0
16.0
30.0
15.0
32.0
20.0
32.0
21.0
33.0
25.0
76.0
40.0

Step 2
2.0
4.0
8.0
5.0
8.0
9.0
10.0
15.0
22.0
30.0
30.0
32.0
32.0
33.0
76.0

7.3 Recommended Flange bolt torque for ANSI 600 RF

Size

1
1
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
1.26
2.31
3.17
7.55
4.92
10.12
16.91
21.92
35.63
40.21
53.98
54.50
75.04

Max
Torque
3.61
7.2
7.2
12.84
7.2
12.84
20.72
31.09
45.83
64.61
64.61
87.92
116.25

Bolting Torque (Kg.m)

Adopted
Step 1
Torque
3.0
2.0
6.0
3.0
6.0
4.0
12.0
8.0
6.0
6.0
12.0
11.0
19.0
17.0
30.0
23.0
44.0
36.0
60.0
41.0
80.0
55.0
100.0
56.0
120.0
76.0

Step 2
3.0
6.0
6.0
12.0
6.0
12.0
19.0
30.0
44.0
60.0
60.0
80.0
100.0

18
20
24

U-1 1/8
U-1 1/8
U-1 1/4

84.76
101.28
159.55

150.08
236.21
289.49

120.0
200.0
250.0

86.0
102.0
160.0

120.0
120.0
200.0