Supplier Name: PT.

BAHARU PENTA KENCANA

Purchase Order Title: TEMPORARY UTILITY SYSTEM
Equipment Tag Number(s): N/A
Supplier (Internal) Document No:
Linked to Global Agreement No: N/A

CSTS Document No: 870310-S-1150102-CST-H99-0008

Company Project Document Number

Project
PO Number SDR Code Seq. No
Code

FLANGE MANAGEMENT
DOCUMENT TITLE:
DOCUMENT REVIEW STATUS
CODE: A B C D E
NAME: Agus Iwan S

SIGNATURE:
DATE: May,10, 2017

Review Legend
Document is accepted as Final. Supplier shall proceed with manufacture. Any changes to the document shall require
CODE A
resubmission to Company.
Signifies general acceptance of both quality and content of the document but with minor points to be amended by Supplier.
CODE B Providing that the comments are incorporated, Supplier may continue with manufacture pending full acceptance. A revised copy
shall be returned for final acceptance.
The quality and content are considered by Company to be non-compliant and/or unfit for purpose. Such documents shall be
CODE C reviewed by Supplier to take note of the reasons for rejection and revise them accordingly. The revised document(s) shall then
be resubmitted.
Document has been cancelled or voided and does not need to be progressed further. No further action required at time of
CODE D
submission
Signifies that prior Company approval is not required and the documents will be incorporated into the EDMS “as is”. Individual
Code E documents given Code 4 status may be required to be included in a data manual, which will be subject to a collective review
and subject at that time to Company approval. No further action required at time of submission.

Comments Summary

Issue Record

Crys Suryo Prayogo Crys Suryo Prayogo

02 17-Apr-2017 R-Submit for Review Flour Reasman Crys Suryo P Crys Suryo P
01 07-Feb-2017 R-Submit for Review M.Dzauqi Adam Crys Suryo P Crys Suryo P
Company Supp
Date Reason for Issue Prepared Checked Approved
Rev No Rev
The document consists of this front sheet plus 19 pages.
Tangguh Expansion Project – LNG EPC
Flange Management

REVISION HISTORY

Amendment Revision Amender Name Amendment

Date Number
07/02/2017 Rev. 01 M.Dzauqi Adam

17/04/2017 Rev. 02 Flour Reasman

RELATED DOCUMENT

Document number Document name Description of Content

870310-S-115102-CST-H03- Project Inspection and Test Plan Contains the details of Quality
0001 Control activities to be done
during the execution of the
Temporary utility system

Page 2 of 19 Rev. 01
870310-S-115102-CST-H99-0008 Internal
Tangguh Expansion Project – LNG EPC
Flange Management

TABLE OF CONTENT

1 INTRODUCTION .............................................................................................................................6

1.1 Scope ..........................................................................................................................................6

1.2 Definition and Abbreviations ........................................................................................................6

1.3 Codes and Standart .....................................................................................................................6

1.4 Units ............................................................................................................................................6

1.5 General Requirements .................................................................................................................6

2 WORK EXECUTION .......................................................................................................................7

2.1 Preparation ..................................................................................................................................7

2.2.1. Personnel ...........................................................................................................................7

2.2.2. Tools and Equipment .........................................................................................................8

2.2.3. Bolt & Gaskets....................................................................................................................8

2.2.4. Flange Inspection before Installation ..................................................................................9

2.2.5. Cleaning ...........................................................................................................................10

2.2.6. Safety ...............................................................................................................................10

2.2 Performing Work ........................................................................................................................10

2.2.1. Flange Assembly ..............................................................................................................10

2.2.2. Bolt Tightening .................................................................................................................11

3 ATTACHMENT .............................................................................................................................12

3.1 Flange Inspection and Reinstatement Inspection Record..........................................................12

3.1.1. Preparation- Inspection/Flange Inspection .......................................................................12

3.1.2. Final Reinstatement Inspection ........................................................................................12

3.2 Flange Management and Botin Sizing & Torque .......................................................................13

3.2.1. Bolt Size. ..........................................................................................................................13

3.2.2. Torque Size ......................................................................................................................14

3.2.3. Torque Wrench Sizes .......................................................................................................15

3.2.4. Gasket Size ......................................................................................................................15

3.2.5. Requirement for Bolt Tightening .......................................................................................16

4 APPENDIX 1 .................................................................................................................................19

Page 3 of 19 Rev. 01
870310-S-115102-CST-H99-0008 Internal
Tangguh Expansion Project – LNG EPC
Flange Management

FIGURE

Figure 1 Alignment of Bolt Requirement ....................................................................................................9

Figure 2 Three Quadrant of Flange Joints ...............................................................................................10

Page 4 of 19 Rev. 01
870310-S-115102-CST-H99-0008 Internal
Tangguh Expansion Project – LNG EPC
Flange Management

TABLE

Table 1 Flange Management and Bolting Size and Torque .....................................................................13

Table 2 Describe of Torque Size..............................................................................................................14
Table 3 Torque Wrench Sizes..................................................................................................................15
Table 4 Gasket Size .................................................................................................................................15
Table 5 For 4 Set Bolt Flange ..................................................................................................................16
Table 6 For 8 Set Bolt Flange ..................................................................................................................16
Table 7 For 12 Set Bolt Flange ................................................................................................................17
Table 8 For 16 Set Bolt Flange ................................................................................................................17
Table 9 For 20 Set Bolt Flange. ...............................................................................................................18

Page 5 of 19 Rev. 01
870310-S-115102-CST-H99-0008 Internal
Tangguh Expansion Project – LNG EPC
Flange Management

1 INTRODUCTION

1.1 Scope
This document covers the bolt and stud tensioning and bolting up requirement for pipe and
pressure vessel flange joints for all Process Lines. This procedure is to be used by the
Construction team for all installed piping joints and by the Precommissioning and
Commissioning teams for re-connected or repaired flange joints.

1.2 Definition and Abbreviations

Definitions within the content of this Flange Management Work:

a) “COMPANY / CLIENT” means BP Berau , Ltd

b) “CONTRACTOR” herein after refers as CSTS (Chiyoda, Saipem, Tripatra, SAE).

c) “SUBCONTRACTOR” PT. BAHARU PENTA KENCANA.

d) “PROJECT” Tangguh Expansion Project”.
e) “WORK” Flange Management.

Abbreviations

ASTM - American Society for Testing and Materials

1.3 Codes and Standart

All materials and procedures shall be in accordance with this procedure, and as applicable
the latest edition of the following documents which are made part of this procedure and
incorporated herein by reference.

American Society of Mechanical Engineers:

ASME B31.3 - Process Piping

ASME B16.5 - Pipe Flanges and Flanged Fittings

1.4 Units
The unit which be applied as the measurement system shall be as mentioned in documents
and drawings. Nominal size of piping components shall be measured in Inches for which the
abbreviation is NPS.

1.5 General Requirements

- The SUBCONTRACTOR shall responsible for the supervision of all face of flange pipe
cleaning work which shall be to satisfaction of the CONTRACTOR’s representative and
the certifying authority.
- Project documentation of face of flange pipe cleaning work shall be provided by
SUBCONTRACTOR

Page 6 of 19 Rev. 01
870310-S-115102-CST-H99-0008 Internal
Tangguh Expansion Project – LNG EPC
Flange Management

- Tools & equipments that to be used shall be tested prior being to be used this is to
ensure that the equipment and/ or tools are not to damage the face of flange which is to
be cleaned.
- Valves shall be re-assembled in clean condition for both inside and out side sections.
- Valves having flow direction shall be installed to confirm the flow direction in accordance
with piping drawings.
- If the work to be performed in the vicinity of instrument control and/or power cable an
adequate protection of cables shall be provided.
- Openings such as flanged joint of equipment shall be kept covered within metal plate or
other solids blinds with a handle to prevent dust and/or foreign material from entering
into the machine.
- Contractor should be fixed truely to have disconnected of any flanges joint connection
that is suspected misalignment for inspection. This inspection may have a result of work
rectification.
- The using of adjustable spanner is prohibited for tightening the bolts.
- Adjustable spanner can be used only for holding the nuts.

2 WORK EXECUTION

2.1 Preparation

2.2.1. Personnel
Sub CONTRACTOR personnel shall be responsible for the execution and
implementation of this procedure during installation stages. Pre-
commissioning/commissioning group shall take control after the mechanical
completion.

 Engineer.
Mechanical engineers provide efficient solutions to the development of
processes and products, ranging from small component designs to
extremely large plant, and machinery.

 Performing Authority
PA ensuring only personnel authorized by the permitt participate in the
work and noun authorized interference takes place. Inform his team that
all member have the obligation to “Stop the Job” if anyone feels unsafe;
when in doubt or any change from the initial plan. Whenever any
deviation found from the initial Permit conditions or the operations
changed the work shall be stopped and re-assessed.

Page 7 of 19 Rev. 01
870310-S-115102-CST-H99-0008 Internal
Tangguh Expansion Project – LNG EPC
Flange Management

 Foreman
Support end user to supervising of each installation work team during
facilities phases of the work. And Ensure that the work in each team is
performed in accordance with the design, in a safe and efficient manner,
and to an acceptable industry standard.

 Fitter
Pipe Fitter must attend and passed the certification of HSE orientation,
first aid training/ firefighting training and working at height.

Performing Authority, foreman, fitter and engineers involved in Flange

Management shall be qualified.

2.2.2. Tools and Equipment

• A sub CONTRACTOR will be appointed for supply of Specialty
tools/equipment
• Bolt with diameter smaller than 1” diameter will be tightened using Manual
Torque Wrenches
• Bolt with diameter of 1” and larger will be tightened using Hydraulic Torque
Wrenches

2.2.3. Bolt & Gaskets

• Bolt length should be as per Project Specification
• All bolting material shall be inspected before installation for damage and to
confirm that the material is the correct type/class
• All threads and bearing surfaces shall be free from dirt, chips or any other
foreign material which may influence the torque during tightening
• Always a new gasket will be used when making a flange joint
• Any visual defect, defects would be a basic for rejection
• Gasket shall not be re-used whenever a joint is broken for repair or
commissioning and testing activity
• Gasket shall be checked for size, conformance to specifications and leanliness.
• Gasket must be positioned and aligned to the centerline of flanges.
• Special attention is required to ensure gaskets are fitted properly for spacer &
blinds.

Page 8 of 19 Rev. 01
870310-S-115102-CST-H99-0008 Internal
Tangguh Expansion Project – LNG EPC
Flange Management

2.2.4. Flange Inspection before Installation

Flange Inspection before installation including to Material receiving inspection
report (post fabricated).

1) Flanged joints shall be aligned as described in subparas at below:

 Before bolting, mating gasket contact surfaces shall be aligned to each
other within 1 mm in 200 mm ( 1/16 in. / ft), measured across any
diameter.
 The flanged joint shall be capable of being bolted such that the gasket
contact surfaces bear uniformly on the gasket.

1
Flange bolt holes shall be aligned within 3 mm ( /8 in.) maximum offset.

Figure 1 Alignment of Bolt Requirement

• Flange shall be checked for size, material & rating to drawing and
specification.
• Flange faces shall be visual inspected to :
- To ensure smoothness of the flange
- To ensure no scratch and corrosion on it.

Page 9 of 19 Rev. 01
870310-S-115102-CST-H99-0008 Internal
Tangguh Expansion Project – LNG EPC
Flange Management

2.2.5. Cleaning
• Flange faces should be thoroughly cleaned and the gasket surface
inspected from any defects. All rust and burst shall be completely removed.
Particular attention shall be paid to the seating surfaces of gaskets.
• Solvent cleaning should be used for removing grease and/or oil the flange
faces such as acetine, alcohol, WD-40 or equal with manual wire brush.
• Special attention should be taken to prevent foreign matter entering pipe
during flange face cleaning.

2.2.6. Safety
• PPE & Safety fully body harness should be used for personnel who work at
high.
• Work Permit & JSA should be provided prior to commence the work

2.2 Performing Work

2.2.1. Flange Assembly

• Check flange alignment
• Flange should be pre-assembled as follows:
- Stud bolt holes of flanges shall be aligned.
- Three stud bolt shall be installed on three quadrants of flange joint
allowing the insertion of gasket, ie bolts # 1,3 and 7 see detail 1.

Figure 2 Three Quadrant of Flange Joints

- The gasket should be inserted and centered between the flanges. Nuts
shall be hand tightened to hold the gasket in place
- The remaining stud bolts and nuts shall be installed and hand
tightened with the flange faces parallel.

Page 10 of 19 Rev. 01
870310-S-115102-CST-H99-0008 Internal
Tangguh Expansion Project – LNG EPC
Flange Management

2.2.2. Bolt Tightening

• During Site inspection CONTRACTOR full surveillance, COMPANY reviewed
and shall be inspected by PT. Baharu Penta Kencana.
• The first step of bolt tightening is by using turn of the Nuts Method manually
and then continued by Torque Method.
• The tightening of bolts should be made in pairs using the following cross
tightening sequence. The pair of bolt shall always be diametrically opposed.
• The stud bolts should be tightened in a minimum of 3 steps, using
approximately 30%, 60% and finally 100% of the final torque (see Table 1 )
- The first pair of stud bolts shall be tightened either simultaneously or in
direct sequence. Continued to other pair. Care shall be taken to
prevent over tightening one side of the flange which may result in
gasket crushing.
- This procedure should be repeated until all stud bolts have been fully
tightened.
• After the third tightening step is complete, a rotational tightening sequence
(see Detail 2 on Attachment 4) should be used until it is verified that all the
stud bolts have reached the indicated final torque.
• If required joints will be tagged after flange joint activity is done.
• Tag will indicate the Names of personnel who were involved in the flange
make-up activity and also date of tightening execution.
• A yellow color paint should be applied in the edge of bolts as indication that
Flange Management has been performed on this flange joint.

Page 11 of 19 Rev. 01
870310-S-115102-CST-H99-0008 Internal
Tangguh Expansion Project – LNG EPC
Flange Management

3 ATTACHMENT

3.1 Flange Inspection and Reinstatement Inspection Record.

Inspection Check List (include to material Inspection report and final box up report)

3.1.1. Preparation- Inspection/Flange Inspection

1) Ensure that outside flange surface have been cleand using proper wire
brush.
2) Ensure that the flenge surface is smooth and does not have any deep
scratch/damage/corrosion.
3) Ensure that outside flange surafce have been cleaned using proper solvent
(as per procedure)
4) Ensure outside flange surface is clean from grease or any other foregin
material
5) Ensure Bolts and Nuts for the flange is of correct size & material; in good
conditions and complete.
6) Ensure gasket dor the is of correct size, rating & material; and is in good
conditions.

3.1.2. Final Reinstatement Inspection

1) Ensure that the flange connection is aligned properly.
2) Ensure that bolts and Nuts is tightened using the proper sequence and
torque (as per Procedure).
3) Ensure that the tightening Bolts is painted in yellow color at both end of the
bolts.

Page 12 of 19 Rev. 01
870310-S-115102-CST-H99-0008 Internal
Tangguh Expansion Project – LNG EPC
Flange Management

3.2 Flange Management and Botin Sizing & Torque

3.2.1. Bolt Size.

Table 1 Flange Management and Bolting Size and Torque
FLANGE

NO SIZES FLANGE RATING (ANSI CLASS)

(INCHES)

150 300 600 900 1500 2500

1 1/2 1/2 1/2 1/2 3/4 3/4 3/4

2 3/4 1/2 5/8 5/8 3/4 3/4 3/4

3 1 1/2 5/8 5/8 7/8 7/8 7/8

4 1 1/2 1/2 3/4 3/4 1 1 1 1/8

5 2 5/8 5/8 5/8 7/8 7/8 1

6 3 5/8 3/4 3/4 7/8 1 1/8 1 1/4

7 4 5/8 3/4 7/8 1 1/8 1 1/4 1 1/2

8 6 3/4 3/4 1 1 1/8 1 3/8 2

9 8 3/4 7/8 1 1/8 1 3/8 1 5/8 2

10 10 7/8 1 1 1/4 1 3/8 1 7/8 1 1/2

11 12 7/8 1 1/8 1 1/4 1 3/8 2 2 3/4

12 14 1 1 1/8 1 3/8 1 1/2 2 1/4

13 16 1 1 1/4 1 1/2 1 5/8 2 1/2

14 18 1 1/8 1 1/4 1 5/8 1 7/8 2 3/4

15 20 1 1/8 1 1/4 1 5/8 2 3

16 24 1 1/4 1 1/2 1 7/8 2 1/2 3 1/2

17 26 3/4 1

18 28 – 30 3/4 1

19 32 – 36 3/4 1

20 38 – 48 7/8 1 1/8

21 50 – 60 1

above 1 1/8

Page 13 of 19 Rev. 01
870310-S-115102-CST-H99-0008 Internal
Tangguh Expansion Project – LNG EPC
Flange Management

3.2.2. Torque Size

Table 2 Describe of Torque Size

BOLT DIA NUT SIZE BOLT TORQUE (NM)

NO
(INCH) (MM) B7 M & L 7M B8 CL1

1 1/2 20 55 40

2 5/8 27 112.5 81.25

3 3/4 32 198.75 142.5

4 7/8 36 319.375 227.5

5 1 41 480 345

6 1 1/8 46 703.125 506.25

7 1 1/4 50 987.5 706.25

8 1 3/8 55 1333.75 962.5

9 1 1/2 60 1762.5 1267.5

10 1 5/8 65 2275 1633.125

11 1 3/4 75 2861.25 2056.25

12 1 7/8 75 3562.5 2559.375

13 2 80 4350 3130

14 2 1/4 90 6277.5 4511.25

15 2 1/2 95 8725 6262.50

16 2 3/4 11701.25 8415

17 3 15360 11010

18 3 1/2 24605 17692.50

Page 14 of 19 Rev. 01
870310-S-115102-CST-H99-0008 Internal
Tangguh Expansion Project – LNG EPC
Flange Management

3.2.3. Torque Wrench Sizes

Table 3 Torque Wrench Sizes

NO TORQUE WRENCH NUT SIZE

1 MANUAL TORQUE WRENCH ≤ 1”

2 HYDRAULIC TORQUE WRENCH ≥ 1”

3.2.4. Gasket Size

Table 4 Gasket Size
FLEXITILIC
INITIAL GASKET RECOMMENDED CENTERING RING
GASKET
THICKNESS COMPRESSED THICKNESS THICKNESS
TYPE

Metric Imp Metric Imp Metric Imp

STYLE 625 1.6 mm 0.625” 1.3 1.4 mm 0.05 0.55” NA N/A

2.5 mm 0.100” 1.9 2.0 mm 0.075 0.08”

3.2 mm 0.125” 2.3 2.5 mm 0.09 0.10” 2.3 mm 0.09”

R & RIR 4.4 mm 0.175” 3.2 3.4 mm 0.125 0.135” 3.2 mm 1.8”

CG & CGI 6.5 mm 0.250” 4.6 5.1 mm 0.18 0.22”

7.2 mm 0.285” 5.1 5.6 mm 0.20 0.22”

Page 15 of 19 Rev. 01
870310-S-115102-CST-H99-0008 Internal
Tangguh Expansion Project – LNG EPC
Flange Management

3.2.5. Requirement for Bolt Tightening

Table 5 For 4 Set Bolt Flange

TORQUE BOLT SEQUENCE

STAGE REMARKS
SETTING 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

Table 6 For 8 Set Bolt Flange

TORQUE BOLT SEQUENCE REMARKS

STAGE
SETTING TIGHTENING

I 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

Page 16 of 19 Rev. 01
870310-S-115102-CST-H99-0008 Internal
 Tangguh Expansion Project – LNG EPC
Flange Management

Table 7 For 12 Set Bolt Flange

5
TORQUE 1
BOLT SEQUENCE
5 1
STAGE
SETTING TIGHTENING
REMARKS 9 11
3 7 3 8
1-2-3-4;5-6-7-8;
I 30%
9-10-11-12 7 4
8 4
12-11-10-9;8-7-6-5; 12 10
II 60% 2 6 2 6
4-3-2-1

1-2-3-4;5-6-7-8;
III 100%
9-10-11-12

8-5-12;7-6-11;
IV 100%
4-2-10;3-1-9

Table 8 For 16 Set Bolt Flange

9 1
TORQUE BOLT13SEQUENCE
1
STAGE 5 9
REMARKS 5 15
SETTING 17 TIGHTENING 19
13 7
5 1 11 7
11 1-2-3-4;5-6-7-8;
3 12
8 I 30%
3 16
9-10-11-12;13-14-15-16
4 15 4 11 4
10 16-15-14-13;12-11-10-
60% 8
12
2 6 II 8 14
9;8-7-6-5;4-3-2-1
20 18
16 6
10 6
2 14 2 10
1- 2-3-4;5-6-7-8;
III 100%
9-10-11-12;13-14-15-16

1-12-8-13;2-11-7-14;3-
IV 100%
9-5-15;4-10-6-16

Page 17 of 19 Rev. 01
870310-S-115102-CST-H99-0008 Internal
 Tangguh Expansion Project – LNG EPC
Flange Management

Table 9 For 20 Set Bolt Flange.

13 1
TORQUE BOLT SEQUENCE 5 9
STAGE REMARKS
SETTING TIGHTENING 17 19

5 1 5 1 11 7
9
1- 2-3-4;5-6-7-8;
11
3 I
7 30% 3 8 3 16
9-10-11-12;13-14-15-
7 16;17-18-19-20 4 15 4
8 4
12 10
2 6 2 6
20-19-18-17;16-15- 8 12

II 60% 14-13;12-11-10-9;8- 20 18

7-6-5;4-3-2-1 10 6
2 14

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

III 100%
9-10-11-12;13-14-15-
16;17181920

8-1-20-12;7-2-19-
IV 100% 11;6-4-18-10;5-3-17-
9;16-15-14-13

Page 18 of 19 Rev. 01
870310-S-115102-CST-H99-0008 Internal
Tangguh Expansion Project – LNG EPC
Flange Management

4 APPENDIX 1

BOLT TIGHTENING CHECK

PT. BAHARU PENTA KENCANA

PT. Baharu Penta Kencana

Project Title Tangguh Expansion Project Sub-Contractor
Job No 870310 Report No. -
Client BP Berau, Ltd Date -
Main Contractor CSTS (Chiyoda, Saipem, Tripatra, SAE) Page of

Drawing No : Equipment / Location :

Revision :
Sheet :

(STRUCTURE / EQUIPMENT BOLT TENSION STD. RESULT

BOLT CHECK LOCATION
NAME) SPEC./SIZE (NM) ACCEPTED REJECTED

Performed By Reviewed By If Required

Involvement Party
BPK CSTS TPI

Signature

Name
Sign Date
Job Title
Form Code : SNO-Q-BPK-001 Rev.A

Page 19 of 19 Rev. 01
870310-S-115102-CST-H99-0008 Internal