Total sheets 23 sheets

(Including this coversheet)

Employer : Nghi Son Refinery and Petrochemical LLC

Contractor : JV AMECC & MEGARIG INDUSTRIES

Area :

Project name : NSRP Complex Project

Contract No. :

Document Title : Flange Management Procedure

Contractor’s Doc. No. : JVAME-PRD-001 Revision No.:0

Issue Purpose : IFA

NGHI SON REFINERY AND PETROCHEMICAL PROJECT
Contractor Doc. No:
Title: Flange Management Procedure Rev.0

FLANGE MANAGEMENT PROCEDURE

Document Class:

Issue purpose For Approval

0 20-Dec-2017 For Approval K.N.C H.C D.H.H

Rev. Date Revision Status Prepared by: Checked by: Approved by:

Responsible Company Prepared by: Checked by: Approved by:

AMECC/MEGARIG Khoa Nang Cong Hoang Chuong Doan Huy Hoang

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REVISION RECORD SHEET

No. Rev. Date of Revised Content of Revision
No Revision pages

1 0 20-Dec-2017 - First issue

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TABLE OF CONTENTS

1.0 PURPOSE................................................................................................................................................ 4

2.0 SCOPE .................................................................................................................................................... 4

3.0 REFERENCES ......................................................................................................................................... 4

4.0 DEFINITIONS/ACRONYMS ..................................................................................................................... 4

5.0 RECOMMEDATIONS ............................................................................................................................... 5

6.0 FLANGE MANAGEMENT PROCEDURE ................................................................................................. 5

7.0 BOLT TIGHTENING PROCEDURE ......................................................................................................... 9

ATTACHMENTS ..........................................................................................................................................................13

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1.0 PURPOSE

This procedure defines the strategy and methodology of flange management for Nghi Son Refinery &
Petrochemical Project. It details the method of obtaining the desired torque & tension value to the
gasket to achieve sealing of joint and the way that this data is managed to retain full traceability for all
completed joints.

2.0 SCOPE

- This Procedure covers permanent metallic joint and GRE/GRP joint for both onshore and offshore
but do not include the joints inside vendor packages.

- With reference Specification for Piping Fabrication, Installation, Inspection and Testing for flange
Joints with Stud bolts diameter 1+1/2‟‟ and above, hydraulic bolt tightening (either Torqueing
or Tensioning) will be made to ensure the integrity of joints. This scope covers only for
Projects being carried out in Nghi Son Refinery & Petrochemical Project.

- Contractor will update the tensioning pressure values which depend on tensioning equipment,
gasket and stud bolt specification.

- The scope of this specification is for use by Contractor personnel for project related works
when undertaking works for Flange Classes 150# up to 1500# (ASTM B16.5, ASTM B16.47).

3.0 REFERENCES

ASTM A193 Alloy Steel Bolting.

ASTM A194 Carbon and Alloy Steel Nuts.
ASTM A320 Stainless Steel Bolting.
ANSI B16.5 Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24
ANSI B16.47 Large Diameter Steel Flanges: NPS 26 through NPS 60
ASME B31.3 ASME CODE for Process Piping
S-000-1670-0006V General Requirements for Field Fabrication of Piping
S-000-1676-0001V Inspection and Test Plan for Piping
VV3160-008-A-103 Method Statement for Hydro test of Piping

4.1 DEFINITIONS/ACRONYMS

- EMPLOYER Nghi Son Refinery and Petrochemical Complex project

- CONTRACTOR JV AMECC and MEGARIG INDUSTRIES
- ASME American Society of Mechanical Engineer.
- ANSI American National Standard Institute.
- API American Petroleum Institute.
- ID Identification
- P&ID Piping & Instrumentation Diagram
- Test Flange: Any adapter, blank or other piece of metal required to be bolted to a valve
flange during a Cryogenic or High Pressure Testing Process.
- Flange Management: System to control, monitor and record all stages of making up flanges.
Allows track progress & traceability of all joints.
- Bolt Torqueing: Process of tightening bolt on joint to deliver required torque figures to the
gasket to achieve sealing of joints.
- Bolt Tensioning: Hydraulic method to tighten bolt to deliver torque to the gasket to achieve
sealing of joints
- Process lines: Main Piping system to process

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5.0 RECOMMEDATIONS

This procedure provides CONTRACTOR‟s recommendations for torque and tension values for
ANSI B16.5, ANSI B16.47 and API 6A Flanges.
The torque pressures specified are based on co-efficient of friction for lubricant values of 0.12 (K =
1.2).
The bolt load is also included to compensate for factors such as externally applied loads, creep,
relaxation, etc.
The additional load has no detrimental effect on the flanged joint or bolt materials.

6.0 FLANGE MANAGEMENT PROCEDURE

6.1 General

This procedure shall be followed for the assembly of all flanged joints that are required to operate at
elevated pressures. Every person involved in the assembly of flange joints shall be aware of the
requirements of this procedure and shall adhere to these as the minimum required standard.

6.2 Flange Management Set-up.

6.2.1 Organization

Flange Management
Team

QC Team

Leak Test Bolting Disassembly and Flange Re-facing

Team Team Reinstallation Team Team

Reporting
Hierarchy

Interface

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6.2.2 Scheduling & interface

1) The Leak Test Team identifies the Test Package (with Client) for testing and based on the
Client’s Procedure of Testing.
2) The Test Result is issued with following information:
a. The Test Pressure whichever is applicable.
b. The Leak Joins.
3) The Bolting Team liaises with the Test Pressure Team to ensure that flange joints are
torqued or tensioned with prospered value.
4) The Bolting Team will issue a Request for Inspection to Client QA/QC to witness the
Torqueing/Tensioning activity.
Whereas, Client QA/QC shall witness bolt tightening as per required.
With refer to Test Result which witness by Client QA/QC, the further step for leak joins
rectification will be considered (increasing the torque value for bolting or disassembly for
checking flange surface, changing new gasket and re-bolting or any other repairing if
need).
Flange Re-facing service will be applied with all damaged flange.
5) Flange bolting to be controlled as per Attachment #1. For Class 900 and above with bolt
diameter 1-1/8” shall be subjected to bolt torque control as per Attachment #2. For others
remained, bolt tightening is as per Attachment #3.
6) After all changing and rectification, The Pressure Test Team will issue a Request for
Inspection to Client QA/QC to witness the testing activity again. The result with acceptant
and witness by Client QA/QC will be issued and consider as the Final and Job
Completion.

6.3 Flange Management Preparation

6.3.1 All joints shall be uniquely identified by engineering in isometric drawings and inputted in a
database, so that all flanged joints can be controlled. The flange joint identification information,
includes the following:
A. ISO Drawing Number
B. P&ID Number
C. Flange Joint Number
D. Flange Type
E. Gasket Type
F. Bolt Material and Size
G. Torque/Tensioning Control Record Number
6.3.2 Where equipment is being supplied as a part of a vendor package (or skid), the vendor
isometrics shall have all tie-in joints to their packages submitted. Information from vendor shall
include the following:
A. Size, class and type of tie-in
B. Medium carried through the tie-in joints (liquid or gas)
C. Required bolt material, size and length
D. Required gasket material, size and class

6.3.3 All flanged connections to vendor packages (skid, vessels, etc.) must also be captured and
assigned joint identification numbers.

6.3.4 Once the Flange Management database is populated, the status of bolt tightening shall be
inputted based on the Torque/Tensioning Control Record (see Attachment #4). The Flange
Management database shall provide the current status of the bolt tightening scheme.

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6.4 Tagging of Flanged Joints

6.4.1 Joint tags are to be fitted to all joints that are torqued or Tension
6.4.2 Joint tags are to be fitted immediately after completion of joint torquing/ tensioning
6.4.3 The tag to be used shall be plastic sticker which shall contain the following information
A. Line Number including revision number
B. Flange Joint Number and Torque Value/Tension Value
C. Operator’s Name and Date of Bolt Tightening
D. Signatures of CONTRACTOR/ “Contractor” Inspectors

6.5 Test Flanges/Temporary Blind Flange

6.5.1 When carrying out pressure testing on piping components, appropriate test flanges shall be
used. The test flanges shall be fitted and bolt tightened in accordance to the requirements of
this procedure.
6.5.2 The responsibility of test flanges and ensuring tightness for pressure testing purpose is the
scope of Client.

6.6 Qualification

6.6.1 Prior to use, all personnel shall be trained and assessed in proper equipment usage. Only
trained technicians are allowed to operate the bolt Torqueing equipment/Tension
equipment. A qualified technicians‟ list shall be prepared and updated, as necessary, and
made available for verification or review purpose at any time.

6.7 Onsite Assembly

6.7.1 Ensure all members of the site team have completed the Site Induction Training.
6.7.2 All necessary personnel at site shall be informed of all work taking place.
6.7.3 Conduct a Job Hazard Analysis prior to commencement of any work. Cordon off the work area
and follow the safety measures identified by the risk analysis.
6.7.4 Ensure that adequate safety gear is being worn by the workers.
6.7.5 Before using any hydraulic Torqueing/Tensioning, check for any defects such as hose cracks or
damage. When first applying pressure to the system, recheck for any leakage of hydraulic
fluid.
6.7.6 Check calibration certificate of the equipment (Torque Wrench) before use.
6.7.7 Instrumentation and equipment that could be damaged during the bolt torqueing/
Tensioning process should be removed.
6.7.8 Assemble the flange joint and perform bolt tightening.

6.8 Work Flowchart

(see next page)

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Not yet
Re-bolting
Re-bolting
Leak
Leak Test

No Leak Already
Disassembly for Change gasket
Re-bolting Flange Ok
flange surface and re-install with
and gasket following this
checking procedure

Job
Completion
Flange Not Ok

Flange re-facing

6.9 Bolt Tightening Scheme

6.9.1 To effectively seal the medium contained in the piping system, it is very important to have
uniform distribution of force over the gasket circumference at the flange connection. This can
be achieved through the proper bolt tightening of flange connection.
6.9.2 The contractor’s QA/QC Inspector shall ensure that all bolt tightening equipment are calibrated
and inspected prior to its use. The equipment shall be in good condition and safe to be utilized
for the intended work.
6.9.3 Equipment as a minimum, the bolt tightening equipment to be inspected prior to usage are as
follows:

A. Torque Wrench completed with associated accessories, i.e., socket wrench and
torque multiplier. Calibration certificates shall be made available for verification.
B. Air and/or electrical operated hydraulic torque wrench completed w i t h s o c k e t
Wrenches. Calibration certificates shall be made available for verification.
C. Ring/Box/Socket spanners.
D. Bolt Tensioning Equipment complete with associated accessories. All the tensioning
equipment, hydraulic hoses, and hydraulic gauge supply need to have the calibration
record no more than 06 month prior mobilization and shall inspect by “Contractor”
Inspector

6.9.4 Check sheet

A. The Torque/Tensioning Control Record shall be completed by the Bolt Tightening Team
as witnessed by both CONTRACTOR and Client’s Inspectors.
B. At least 1 day before the bolt tightening activity, the Bolt Tightening Team shall issue a
Request for Inspection to Client QA/QC which shall then provide a copy of the request to
“Contractor”.
C. The completed check sheet will be submitted to the Flange Management Administrator
who shall update the register to reflect completion of bolt tightening of the joint.
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6.9.5 Inspection prior to bolt tightening

The following elements shall be checked prior to bolt tightening:
A. Ensure that the pipe work is free from internal pressure.
B. Ensure that all surfaces of flange connections are free from any foreign matter that may
prevent surface contact or damage the gasket.
C. Ensure that the gasket is new and correct type and has been inserted and centered in the
bolted flange connection.
D. Ensure that the bolt and nut threads are free from dirt and rust and should have at least
2.5 threads extending beyond the nut on either side.
E. Ensure that the alignments of the flanges are within acceptable tolerances as requirement
of ASME B31.3- 335.1.1 Alignment prior to tightening the bolts and nuts.
F. Determine the category and tool applicable to the flange joint to be tightened.
G. Prior to applying the Torque/Tension, the bolts and nuts shall be initially hand tightened
and shall be numbered to facilitate a consistent sequence during tightening. Refer to
Figure 1 or 2
6.9.6 Bolt Tightening Method
Tightening of the bolted flange shall be done by trained technicians assisted by helpers. This
is to ensure the correct usage of tools and avoid damage and mis-alignment between the
mating flanges. The different categories and applicable tools for the flange ratings and sizes
are followed “Flange Bolting Control” table as Attachment #1.

With GRP/ GRE material; Butterfly Valve; Package Equipment and Rotary Equipment,
Contractor is required to follow Vendor‟s recommendation or Manual during bolting
performance.

7.0 BOLT TIGHTENING PROCEDURE

7.1 BOLT TENSIONING

7.1.1 JOB SAFETY & REQUIREMENTS

Areas: Are to be barrier off at a distance or 2-3 meters where practical, where bolt
tensioning/torqueing activities are being performed.

Safety: Prior to commencement of bolt tensioning ensure that:

All necessary safety precautions have been carried out

Personnel involved in bolt tensioning are competent and fully trained in the use of bolt
tensioners and tightening techniques.

The procedure and data to be used is authorized by a responsible Engineer.

The joints/pipe work to be worked on are not “live”. Joints must be at zero pressure and free
from hazardous substances.

Bolt tensioning pressures, specific to the flanged joint to be tightened, are available.

The maximum pressure that can be applied will be calculated to ensure that either 65% of bolt
material yield is not exceeded or the maximum tool pressure is not exceeded, whichever is the
lower. Pump must be pre-set to achieve this.

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7.1.2 PROTECTIVE PERSONAL EQUIPMENT (P.P.E.)

Protective Equipment must be worn at all times, i.e. overalls, eye protection, safety helmet,
boots and gloves.
When assembling puller sleeve of the bolt tensioner, ensure that there is at least one bolt
diameter of thread engaged.

The maximum tool working pressure must never be exceeded.

Never stand in the direct line of the tensioning tools when pressuring.

Do not pressurize unconnected couplings, and ensure all quick release couplings are fully
engaged when attached to tensioning tools.

7.1.3 TENSIONING PROCEDURE USING 50% TOOL COVERAGE

The following tensioning procedures are only for use with Hydraulic Bolt Tensioners and are
specifically compiled for tension tightening of standard pressure containing flanged joints.

The object of each procedure is to accurately achieve a pre-determined residual bolt stress.

Stage 1 Numbering each bolt starting with No 1 on the top of the flange and counting
follow clockwise.

Stage 2 Square up the flanged joint using hand tools, or if necessary bolt tensioners.

Stage 3 Assemble the tensioning tools to 50% of the bolts. Do leak test at 1000 PSI
(i.e. all odd numbered bolts). Do leak test at 1000 PSI with hydraulic system, if
system do not leak, start apply the „Pressure 1‟ as indicated in the bolt
tensioning data. Whilst maintaining the system under pressure, turn down the
flange nuts using a toggle bar. Always tap the toggle bar using a hammer
to firmly seat the nut against the flange surface.

Stage 4 Release the system pressure and repeat STAGE 3 twice further, i.e. apply
„Pressure 1‟ and turn down nuts three times.

NOTE: It is often advisable to continuously re-apply „Pressure 1‟, especially with Ring
Type Joints, until no further movement of the flange nuts can be obtained.
Also, it may be beneficial to allow a few minutes between each pressurization
to allow the gasket to bed in.

Stage 5 Move the tensioning tools onto the remaining 50% of bolts (all even
numbered bolts). Do leak test at 1000 PSI with hydraulic system, if system did
not leak, start apply the „Pressure 2‟ as indicated in the bolt tensioning data.
Turn down the flange nuts follow clockwise.

Stage 6 Release the system pressure and repeat STAGE 5 twice further, i.e. apply
“Pressure 2‟ and turn down nuts three times. Check until no nut can move at Stage
5, we can remove the tensioning equipment.

Stage 7 As a check to see if an excessive load has been lost in the initial 50% of bolts
tightened (odd numbered bolts), assemble two tensioning tools to randomly
selected but diametrically opposite odd numbered bolts. Apply “Pressure 2‟ and
attempt to further tighten the flange nuts. If the nuts cannot be further
tightened, then tensioning is complete and the tensioners may be removed.
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If the flange nuts can be further tightened, then reassemble the tensioning
tools onto all of the odd numbered bolts. Apply „Pressure 2‟ and turn down the
flange nuts once more.
The bolt tensioners may now be removed.

Stage 8 As a final check, using a small hammer, “ring‟ each bolt to ensure that no
loose bolts remain (this action also understand as “tap test”)

Note: “ Pressure 1‟ and „Pressure 2‟ are pressure be calculated for particular

tensioning machines.

7.1.4 DE-TENSIONING PROCEDURE

When de-tensioning, specific tool pressures are not normally available as it is not always
possible to calculate the pressure at which the flange nut will break free.
As a guide, if the original flange bolt tightening pressures are available, the de-tensioning
pressure is usually marginally higher than the original tensioning pressure (but not always)

Stage 1 Assemble the tensioning tools to the bolts. With the pulling sleeve fully
screwed down and seated on the piston, unscrew the pulling sleeve through
one half turn. This will prevent the pulling sleeve becoming locked onto the
piston when the bolt tension is released.
Stage 2 Insert a toggle bar through the tensioner bridge window and into a hole in the
nut rotating ring. Apply hydraulic pressure to the system until the flange nuts
can be rotated, ensuring that the piston does not exceed maximum stroke or
system pressure does not exceed that indicated in the safety notes above.
Stage 3 Turn back each flange nut through one full turn (6 holes on the nut rotating
ring).
Stage 4 De-pressurize the system and check to see that the flange nuts are still free
to rotate.
Stage 5 Remove the bolt tensioners. If the pulling sleeve cannot be unscrewed and
the flange nut is also tight, then pulling sleeve has locked onto the top face of
the flange nut – see STAGE 6. If the pulling sleeve cannot be unscrewed but
the flange nut is free, then the pulling sleeved has locked onto the piston –
see STAGE 7.
Stage 6 Pulling sleeve locked onto top face of nut – If the flange nut is unscrewed
further than that indicated in STAGE 3, it can cause the nut to become
locked onto the pulling sleeve when bolt tension is released. To release the
pulling sleeve/flange nut, the hydraulic pressure must be re-applied and the
flange nut rotated clockwise (to tighten) half a turn (3 holes on the nut
rotating ring). Upon de-pressurization the pulling sleeve should be free to
rotate.
Stage 7 Pulling sleeve locked onto piston – This occurs if the pulling sleeve has not
been unscrewed sufficiently in STAGE 1 (half a turn may be insufficient for
fine threaded bolts) causing the pulling sleeve to become locked onto the
piston as the tension is released in the bolt. To release the pulling sleeve,
re-apply the hydraulic pressure and turn down the flange nut. Upon
depressurization, the pulling sleeve should freely rotate. Unscrew the pulling
sleeve a further half turn and repeat STAGES 2 TO 5.

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Figure 1: Typical Bolt Tensioning Numbering

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Attachment #1. Summary Table of Bolt Tightening.

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Attachment #2. Recommended and Maximum Bolt Tensioning Table.

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7.2 BOLT TORQUE TIGHTENING

7.2.1 SCOPE

This is a general tightening procedure for use with hydraulic torque wrenches for the torque
tightening of standard pressure containing flanged joints fitted with standard gaskets. (i.e.
Spiral Wound, RTJ, CAF, etc).

The procedure has been compiled accurately, and efficiently achieves a pre-determined
residual bolt stress.

7.2.2 INSPECTION PRIOR TO BOLT TORQUE TIGHTENING.

Bolt tightening work shall be done prior to hydro testing were appropriate. The following
inspections shall be conducted prior to the tightening of bolts and nuts.
Ensure that the pipe-works shall be free from internal pressure.
Ensure that all flange surfaces of flange connections and equipment tie-ins are free from any
foreign material that may prevent surface contact or damage the gasket.
Ensure that the gasket is of correct type and has been inserted and centered in the bolted
flange connections.
Ensure that the bolt and nut threads are free from dirt and rust and should have minimum one,
maximum five threads extending beyond the nut on either side.
Ensure that the alignments of the flanges or platform equipment tie-ins (tightening work for
equipment tie-ins to be done after hydro test) are within acceptable to tolerances prior to
tightening the bolts and nuts.
Torque valve selected must be based upon the lubricant applied. Lubricant brand name will be
confirmed when tightening work is performed practical at site.
Prior to applying the torque, the bolts and nuts shall be initially hand tightened and shall be
numbered to facilitate a consistent sequence during tightening. (Figure 1: Typical “Criss-Cross”
Bolt Tightening Sequence" – page 13 of 25)

7.2.3 METHOD AND SEQUENCE BOLT TORQUE TIGHTENING.

Tighten diametrically opposed bolts following the sequence shown in Typical “Criss-Cross” Bolt
Tightening Sequence on page 18 of 25

Stage 1 Number each bolt 1, 2, 3,... like in figure 1: Typical “Criss-Cross” Bolt
Tightening Sequence.

Stage 2 Repeating the above noted tightening sequence, apply approximately 30% of
the torque value specified in the torque data.

Stage 3 Using the same noted tightening sequence, apply approximately 60% of the
torque value specified in the torque data.

Stage 4 Using the same noted tightening sequence, apply the full torque value
specified in the torque data.

Stage 5 Using the same noted tightening sequence, apply the full torque value
specified in the torque data for last checking.

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Figure 2: Typical “Criss-Cross” Bolt Tightening Sequence

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Attachment #3. Recommended Bolt Torque Table (CL150, 300, 600, 900, 1500, 2500)

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Attachment #4. Torque/Tensioning Control Record

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