Flange Management

Document Title: In-Service Flange Integrity Guideline
COPI Doc No.: ID-G-BU-00000-00000-01548
Originator: COPI
COPI Group Owner: UO- Asset Integrity - OEE
Area: General
Location: Business Unit
System: General
Document Type: Guideline
Discipline / Subdiscipline: Asset Integrity/General
Old COPI Document No.: COPI-OPR-OM-00036
ID-G-BU-00000-0000
0-01548.pdf
Wawan
Gunawan/ Didik Idham H.S Not
5 IFU 13 Jul 15 Re-Issued for Use T A Haekal
Muhdi Wibisono Purba Req’d
Sujatmiko
Wawan
Iman Gunawan/ Didik Idham H.S Not
4 IFU 8 Jan 14 Re-Issued for Use
Sugihartoto Muhdi Wibisono Purba Req’d
Sujatmiko
Muhdi Wawan Didik Agus Not
3 IFU 22 Oct 12 Re-Issued for Use
Sujatmiko Gunawan Wibisono Wijaya Req’d
Juli
Karyanto/
PT. Wood
Wawan Anggiat Agus Not
2 IFU 9 Dec 10 Re-Issued for Use Group
Gunawan/ Sihotang Wijaya Req’d
Indonesia
Muhdi
Sujatmiko
1 IFU 21 Dec 05 Issued For Use PA AMS CCC
Unit Snr. VP
Rev Status Issue Date Reason for Issue Prepared Checked Owner Manager Ops
Approvals
Printed initials in the approval boxes confirm that the document has been signed.
The originals are held within Document Management.
Guideline: ID-G-BU-00000-00000-01548 Rev. 5
In- Service Flange Integrity Guideline
ConocoPhillips Indonesia Page 2 of 32
Revision Sheet
ConocoPhillips Indonesia Inc. Ltd
REVISION DATE DESCRIPTION OF CHANGE

1 21 Dec 05 Issued for used
Issued for used (reformat, added flange requirement and procedure as
2 9 Dec 10
per A&OI audit recommendations)
Issued for used.
Change statement in
Para 4.1.4 : change statement “…. the remaining portion of the tag
removed from the flange to prevent confusion during future
maintenance”.
3 22 Oct 2012
Para 4.2 and 4.3: added additional recommended practices.
Para 6 RACI Chart for Flange Management Requirement and

Procedure. Additional task of number 13 is added.
4 8 Jan 2014 Para 4.2.5 : added specific requirement for Insulation Gasket
Para 4.1.4: added statement “the remaining portion of the tag removed
5 13 Jul 2015 from the flange to prevent confusion during future maintenance.”
Appendix C: added Joint Disturbed Register Form
Additional Approvers (If Applicable)
Name Designation Signature Date
Tasdikin Lead Asset Integrity QAQC
Previous Endorsement
img-118140544-0001
.pdf
Table of Contents
Table of Contents....................................................................................................................................... 3
1 Introduction............................................................................................................................ 5
1.1 Purpose................................................................................................................................... 5
1.2 Scope...................................................................................................................................... 5
1.3 References.............................................................................................................................. 5
2 Definition................................................................................................................................ 5
3 In-service Routine Inspection............................................................................................... 6
3.1 Visual Inspection..................................................................................................................... 6
3.2 Fugitive Emission (FE) Survey................................................................................................ 7
3.3 Alternative Method................................................................................................................... 7
3.3.1 Advanced Inspection............................................................................................................... 7
3.3.2 Identified Damage Assessment............................................................................................... 8
4 Flange Management Requirement and Procedure.............................................................9
4.1 Flange Joints Disturbance Procedure......................................................................................9
4.1.1 Reference Documentation....................................................................................................... 9
4.1.2 Breaking Flange Joints............................................................................................................ 9
4.1.3 Making Joints......................................................................................................................... 10
4.1.4 Tagging Procedure................................................................................................................ 10
4.2 Flange General Requirements............................................................................................... 12
4.2.1 Bolting.................................................................................................................................... 12
4.2.2 Thread Lubricants and Preservatives....................................................................................13
4.2.3 Flange Faces......................................................................................................................... 13
4.2.4 Gaskets................................................................................................................................. 14
4.2.5 Insulation Gasket Sets and Specialty Gasket........................................................................14
4.3 Tightening.............................................................................................................................. 15
4.3.1 Tightening Methods............................................................................................................... 15
4.4 Hot Bolting and Preventative Bolting.....................................................................................17
4.4.1 Hot Bolting Requirement........................................................................................................ 17
4.4.2 Hot bolting procedure............................................................................................................ 18
4.4.3 Preventative Maintenance Bolting......................................................................................... 18
4.4.4 Preventative Maintenance Bolting Procedure........................................................................19
5 Flange System Records...................................................................................................... 19
6 Responsibilities................................................................................................................... 19
APPENDIX A. Flange Management Procedure Flowchart....................................................................21
APPENDIX B. Flange Disturbance Tag.................................................................................................. 22
APPENDIX C. Joint Disturbed Register & Controlled Tightening Report Form.................................23
APPENDIX D. Lubricant Information...................................................................................................... 24
APPENDIX E. Flange Bolting Charts...................................................................................................... 26
APPENDIX F. Bolt Torque/Tensioning Values........................................................................................ 29
APPENDIX G. Guideline For Evaluating Failure in Flanged Joints.....................................................31
List of Figures
Figure 1. Flange Disturbance Tagging....................................................................................................... 11
Figure 2. Tightening Sequence.................................................................................................................. 16
List of Table
Table 1. Summary of Key Issues................................................................................................................. 8
Table 2. Stud and Nut Compatible............................................................................................................. 13
Table 3. Torque/Tension Guidance based on bolt size and flange class....................................................15
Table 4. RACI Chart for In-Service Routinve Inspection............................................................................19
Table 5. RACI Chart for Flange Management Requirement & Procedure..................................................20
1 Introduction
Asset and Operating Integrity Recommended Practice (A&OI RP) recommends each BU
must have integrity program which include a flange joints aspect as part of asset integrity
inspection program. To meet this challenge, ConocoPhillips Indonesia (COPI) would like to
have in place a system/guideline to positively and actively manage the integrity of flange
joints.
COPI intends to examine all within their integrity facility of each asset. One of components is
flanges, where fluid leakage often occurs, both within ConocoPhillips companies, and in
broader oil and gas operation.
1.1 Purpose
This document is intended as a guide on how to inspect flanged joints in service for plant and
facilities. It provides a framework to achieve this based on working with correctly designed
joints.
This document also provides guideline when works disturb a flanged joint
(repair/replacement) to ensure integrity and quality requirements are met upon reinstatement.
In order to avoid failure it is very important that the relevant specifications for materials and
components are adhered to in full.
1.2 Scope
This guideline shall be applied within COPI facility when works disturb flange joints
(interference from original conditions) for the following type of asset:
 all piping flange bolting
 all flange bolting of connecting piping to flanged equipment (pressure vessel, heat
exchanger, valve, pipeline and tank)
This document doesn’t cover the following:
 Cast Iron flanges
 Glass-line vessels and piping flanges
 Plastic pipe flanges
 Other non standard flanges
1.3 References
1. API 570, Inspection, Repair, Alteration, and Rerating of In-service Piping Systems
2. API 510, Pressure Vessel Inspection Code: In-service Inspection, Rating, Repair and
Alteration
3. API 686, Recommended Practice for Machinery Installation and Installation Design.
4. API 574, Inspection Practices for Piping System Components
5. API 572, Inspection of Pressure Vessels
6. ASME PCC-1 Guidelines for Pressure Boundary Bolted Flange Joint Assembly
2 Definition
Hot Bolting – The sequential removal and replacement of individual fasteners on piping
flanges with the system still “live”. Existing fasteners are removed in a predetermined
diametrically opposed sequence, are examined for condition and then either cleaned,
lubricated and re-fitted, or replaced by a correctly specified fastener. Each refurbished or new
fastener is then installed and tightened by controlled means before the next fastener in the
sequence is removed.
Preventative Bolting - The practice of checking for looseness and where necessary re-
tightening fasteners in flanged joints on a live (on-line) system. Tightening shall be done by
controlled means even if the bolt is equipped with a load-monitoring device (e.g. Rotabolt).
Tightening - The making tight of a flanged joint by torquing or tensioning the flange bolts.
Torquing - The loading of flange bolts using manual or hydraulic torque equipment
Tensioning - The loading of flange bolts usually using hydraulic equipment.
3 In-service Routine Inspection

Routine inspections (through RBI implementation program, certification program, corrosion
mapping program, specific purposes inspection, etc) are performed several times during the
life of an asset and include assembly and/or in-service inspection of the joints during
operation. Inspections performed during the operation of the system alert maintenance and
operations to developing problems. When leakage is noted, detailed inspections of the
troubled joint, both before and after disassembly, assist in determining the root cause of the
leak. These inspections are essential in determining the proper corrective action required .
The performance of a pressurized gasket bolted flanged joint, either standard or code
designed, is measured in terms of its ability to remain leak free through all anticipated
operations. The following is some of method to inspect flange integrity:
3.1 Visual Inspection

The most common method of in in-service non-destructive inspection is visual inspection,
normally carried out as part of general visual inspection of RBI implementation and/or Migas
certification program. The limitations of this method are that only the external parts of the joint
are visible which will detect loose bolts and corrosion; however the extent of surface
degradation on the strength of the joint is difficult to measure.
Where bolt threads or nuts show the effects of significant corrosion then further investigation
should be undertaken to ensure that the joint is still fit for purpose.
Flange and valve bonnet fasteners should be examined visually for corrosion. Flanged and
valve bonnet joints should be examined for evidence of leakage, such as stains, deposits, or
drips.
Bolts shall be visually examined for evidence of corrosion and other defects (mechanical
damage or cracking). Bolting showing signs of mechanical damage to plain shanks or
threaded portions within the stressed portion or any cracking shall be replaced with new
bolting.
Flanged joints should be examined for evidence of leakage such as stains, deposits, or drips.
Process leaks onto flange fasteners may result in corrosion or environmental cracking. This
examination should include those flanges enclosed with flange or splash-and-spray guards.
Flanged joints that have been clamped and pumped with sealant should be checked for
leakage at the bolts. Fasteners subjected to such leakage may corrode or crack (e.g. caustic
cracking). If re-pumping is contemplated, affected fasteners should be renewed first.
Exposed gasket surfaces should be checked for scoring and corrosion. The surfaces should
be cleaned thoroughly and carefully for a good visual inspection.
The grooves of ring joint flanges should be checked for cracks due to excessive bolt
tightening. Also stainless steel ring joint grooves should be checked for stress corrosion
cracking.
Accessible flange faces should be examined for distortion and to determine the condition of
gasket-seating surfaces. If flanges are excessively bent or distorted, their marking and
thicknesses should be checked against engineering requirements before taking corrective
action.
Flange fasteners should be examined visually for corrosion and thread engagement.
Fasteners should be fully engaged. Any fastener failing to do so is considered not acceptably
engaged if the lack of complete engagement is not more than one thread.
Any damage noted should be accurately sketched, and where possible, digital photographs
taken, and then reported to Asset Owner.
Inspectors should have capability to identify on the findings joints that may require further
assessment. An alternative assessment method is referred to section 3.3.
3.2 Fugitive Emission (FE) Survey

The most likely method of detecting a leaking bolted joint is observation by operations and
maintenance personnel or inspection personnel during routine operation in the plant, or
during leak testing upon closure of pressure equipment such as pressure vessels. There is no
substitute for 'line walking' as most leaks are of relatively small magnitude. The more
significant leaks may also be detected by plant safety systems such as gas detectors or, in
extreme cases, by the process control system.
An emission from a joint with a lower release rate than a leak is described as a seep. These
too should be noted and periodically checked to ensure they have not worsened, and be
entered into the maintenance system for repair at the next scheduled service for that item. It
should also be recorded in the records and data management system.
Any seep or leak should be reported to Supervisor/responsible person.
The purpose of fugitive emission (FE) survey is to get general picture for any potential leaking
occurring in the facilities. Currently the fugitive emission survey has been managed within
SAP as a routine program. Some of conditions may require additional leak survey such as:
1. After plant shut down, unit shut down with major/repair/modification activities
2. Significant mechanical joints modification/replacement
3. During new facility start up
4. After earthquake
5. Any indications suspected of gas fugitive emission through smell.
Standard operating procedure ID-G-BU-00000-00000-01382 for Fugitive gas emission survey
should be followed. Scopes of fugitive emission survey are:
1. To identify invisible VOC (Volatile Organic Compound) i.e. methane, propane, butane
release from the containment.
2. The targets are on the connection such as: flange connections, valves, SDV, panels, X-
mas trees, flow control, pressure control, differential pressure indicator, PSV etc.
3. This survey also measures leaking flow rate with Hi-flow Sampler (if necessary)
4. Inspectors should have capability to identify in the findings Fugitive Emissions that may
require further assessment. An alternative assessment method is referred to section 3.3.
3.3 Alternative Method

The following available methods are used as an option when thorough inspection is required
based on the results from in-service routine inspection/maintenance before
repair/replacement works of flange joints will be made.
3.3.1 Advanced Inspection

If required, an advanced inspection method may be utilized for specific case to further
evaluate flange integrity. A number of more specialized techniques are available which can be
used to check for specific conditions; these include:
 Phased Array Ultrasonic-detects thread wear and cracking from the bottom of the
threads.
 Time of flight (TOF) UT – measures bolt elongation
 Cylindrical Guided Wave Technique (CGWT)-detects corrosion wastage.
 Ultrasonic inspection of flange faces using shear wave transducer-detects flange face
corrosion and erosion.
 Black light NDT of threads and body on bolts that are to be re used on high critical
joints-detects stress cracking
3.3.2 Identified Damage Assessment

In-service inspection of bolted joints is an integral activity to ensure the continued integrity of
the joints and as such should be built in to all relevant inspection programs. This section
looks at the possible damage that can occur, the inspection methods available for detection
of defects and the mitigation measures that can put in place to minimize such degradation. A
summary of the key issues addressed in this section is included in the following table:
Table 1. Summary of Key Issues
Damage Type Typical Condition Inspection Technique Mitigation Measure

A. FLANGE
General Corrosion Exposed areas Visual, sample removal, Material selection,
Cylindrical Guided threat protectors,
Wave Technique coatings, preservation
lubricants
Galvanic Corrosion Dissimilar metals- Visual Flange material
flanges, bolts, gaskets selection
Crevice Corrosion Exposed areas Visual, sample removal Material selection
Fatigue Joints subject to Visual, Phased Array Pipework design
vibration, cyclic loading UT
Flange face corrosion Pipe work containing a Intrusive visual, UT Material selection,
corrosive medium, gasket selection, weld
dissimilar materials overlay
Creep High Temperature Time-of-flight UT Material selection,
applications ASME SA-453
Stress Corrosion A combination of a Phased Array UT Material selection,
Cracking chloride-containing preservation lubricants
environment,
susceptible material and
tensile stress
B.GASKET
Galvanic Corrosion Dissimilar metals- Visual Gaskets material
flanges, bolts, gaskets selection
C. BOLT
General Corrosion Exposed areas Visual, sample removal, Threat protectors,
Cylindrical Guided coatings, preservation
Wave Technique lubricants
Galvanic Corrosion Dissimilar metals- Visual Bolt material selection
flanges, bolts, gaskets
Localized Bolt Dissimilar metals, Sample removal, visual, Material selection
Corrosion exposed areas Phased Array UT,
CGWT
Stress Corrosion A combination of a Phased Array UT Material selection,
Cracking chloride-containing preservation lubricants
environment,
susceptible material and
tensile stress
Damage Type Typical Condition Inspection Technique Mitigation Measure

Hydrogen Hydrogen can form on Visual highlighting any Material selection –
Embrittlement surface during corroded High Strength most common in High
manufacture or be Fasteners for Strength Steels e.g.
caused by Cathodic replacement. ASTM Standards A345
Protection Gr BD, A490 and A547
Thread protectors and
coatings
Liquid Metal Cadmium-plated bolts in General Visual Remove any cadmium
Embrittlement (LME) service above 230°C Inspection for presence plated bolts from service
of cad-plated bolts. above ~220°C (e.g. hot
oil service, etc.)
4 Flange Management Requirement and Procedure

Flange management work flow process is attached in Appendix A. These requirements apply
when flange joints are disturbed for maintenance, repair and/or replacement works.
4.1 Flange Joints Disturbance Procedure

4.1.1 Reference Documentation
Determine the type, size and class of the flange to be bolted. Determine the relevant
specification number of the flange joint. Check the material, coating and size of the stud bolts.
Check the type, pressure rating and size of the gasket. The stud bolts and gasket
specifications for the flanged joint must always match the descriptions in the following
documents:
 Piping specification: isometric, line index, etc
 Pressure vessel specification: data sheet, drawing, MDR, etc.
 P&ID (as built drawings)
 Heat exchanger specification: data sheet, drawing, MDR, etc.
 Tank specification: data sheet, drawing, MDR, etc.
 Pipeline specification: data sheet, drawing, MDR, etc.
 Valve specification: data sheet, drawing, MDR, etc.
Note: if in doubt contact the COPI Asset Engineering for guidance.
4.1.2 Breaking Flange Joints

1. Before commencing work ensure that the permit to work and risk assessments are valid for
the job in hand, and that the correct protective clothing/equipment is worn. Ensure that all
safety precautions and work permit instruction set out in ID-G-BU-00000-00000-00462
Permit to Work are in place and are strictly adhered to.
2. Confirm that the line has been isolated, drained/vented or purged as appropriate before
attempting to break a joint. Ensure beyond all doubt that the line or piece of equipment
being worked upon has been correctly isolated and vented to atmospheric pressure and
flushed and purged if appropriate. the isolation requirement set out in ID-G-BU-00000-
00000-00404 Lock Out – Tag Out must be accomplished through an isolation certificate
3. Ensure that the correct tools for the job are available, used, and comply to HSE document#
ID-G-BU-00000-00000-00391 – Hand Tools.
4. The tagging system is used starting from breaking flange joint.
5. When attempting to break a joint, avoid standing directly alongside or underneath the joint.
Always break the bolt that is furthest away from you first, preferably the bottom furthest
bolt.
6. Continually check for leakage, seepage or signs of pressure in the line – a hissing sound, a
smell of gas, etc. Use a pair of wedges away from you to determine this.
7. If at any stage there is a sign of pressure in the line, stop work immediately. Re-tighten the
joint to contain the leak, if safe to do so, and then report the situation to the maintenance
supervisor or raise alarm. The line isolation will then have to be checked.
8. Never remove nuts from studs until you have ascertained that the considered
pipe/equipment is depressurized and empty.
9. Before finally parting a joint, always assess the forces on the pipe. Will the joint spring
apart? Is one half of the joint unsupported? Temporary supports or restraints may be
required.
4.1.3 Making Joints

All personnel carrying out work on bolted joints should be competent to a level appropriate to
the required technical skills. Similarly, supervisory personnel and assessors should also be
competent to ensure they are aware of the issues involved in achieving a leak free joint. This
includes a process to assure third party vendors and contractors can demonstrate that their
personnel are managed using equivalent competence standards.
1. Before starting, check that the permit to work/risk assessment is valid for the job in hand
and that the correct protective clothing/equipment is worn. Ensure that all safety
precautions and work permit instruction set out in ID-G-BU-00000-00000-00462 Permit to
Work are in place and are strictly adhered to.
2. Check if these are procedure in place for carrying out the intended work – and if so follow
the procedure. This includes using the Flange Disturbance Register and the use of flange
disturbance tags as detailed in section 4.1.4 below.
3. Determine the type, size and class of the flange to be bolted. Determine the referenced
document/specification as described in section 4.1.1 of the concerned joint. Check the
material, coating and size of the stud bolts. Check the type, pressure rating and size of
the gasket. The stud bolts and gasket specifications for the flanged joint must always
match the descriptions in the specification document (as mentioned in section 4.1.1).
4. Only use the correct materials for the job. Never use damaged materials and always uses
a new gasket when making up a joint. It is recommended that nuts/bolts are also
renewed, however, where this is not possible a visual inspection of these parts should be
completed prior to installation.
5. It does not allow to use cut from sheet gasket.
6. Ensure that the correct tools for the job are available and are used. HSE document# ID-
G-BU-00000-00000-00391 – Hand Tools shall be complied.
7. Ensure the joint faces are clean and properly aligned before inserting the gasket.
8. Visually check the flanges for equal gap. If a larger gap appears on one side of the
flange, tighten the bolt which corresponds with the larger gap first.
9. Ensure the flanges are parallel after tightening.
4.1.4 Tagging Procedure

Each disturbed flange shall be ’tagged’ prior to assembly, only one flange tag per flange/joint
will be fitted. The tags are double-sided and comprise four distinct sections, the outer three
sections being perforated to allow tear off (all four sections of the tag are pre-printed with a
unique number). Tag should be made from water proof material e.g. plastic.
Flange disturbance tagging is shown in Figure 1. Flange Disturbance Tagging and Appendix
B for more detail specification.
Section 4 Section 3 Section 2 Section 1
 Section 1 (Flange Not Disturbed)

 Section 2 (Flange Not Tightened)
 Section 3 (Flange Not Tested)
 Section 4 (Main body of tag which will initially remain on the flange)
Figure 1. Flange Disturbance Tagging
When Section 4 has been completed (on both sides), the tag indicates that the flange has
been assembled and tightened competently.
The tag should be fitted using a suitable tie and in a position adjacent to or on the joint.
Section 1 is removed and returned to the Maintenance Supervisor/Work leader to indicate
that flange has been disturbed. Person who disturbs the flange shall fill date and his/her
name complete with Permit work Number.
Section 2 is removed and returned to the Maintenance Supervisor/Work Leader to provide a
visual indication that the flange has been tightened and ready to be leak tested. The Work
Lead responsible for the tightening operation shall advise the Maintenance Supervisor/Work
Leader of the name of the technician tightening each flange and be responsible for the return
of Section 2 to the Construction/Maintenance Supervisor.
Section 3 is removed and returned to the Maintenance Supervisor/Work Leader to provide a
visual indication that the flange has been leak tested. The supervisor responsible for the leak
test operation shall advise the Maintenance Supervisor/Work Leader of the name of the
technician performing the test and be responsible for the return of Section 3 to the
Construction/Maintenance Supervisor. If the result of the leak test is failure due to a leaking
flange, a new tag should be assigned to the joint prior to rework.
Section 4 of the tag will remain on the flange until such time that further PSSR or start up
check list is carried out. This shows visually that both operations have been completed upon
that flange. PSSR or start up check list shall be performed before joints back to online and
operation should perform site verification to check tagging system. After ensuring there is no
leak during normal operation, the remaining portion of the tag should be removed from the
5 flange to prevent confusion during future maintenance.
Side A: This side of tag is completed by the Worker/Technician assembling the flange. The
worker/technician shall print his name and confirm the acceptable condition of the;
a) Flange face cleanliness
b) Flange alignment - Acceptance criteria given in relevant specification.
c) Material and length of the bolts - Acceptance criteria given in relevant document
described in section 4.1.1.
d) Size and material of the gasket.- Acceptance criteria given in document relevant
document described in section 4.1.1.
e) Correctly Lubricated. – See section 4.2.2
Side B: When the flange is ready for bolt tensioning/torquing, the Worker/Technician shall
check Side A of the tag to confirm the flange had been assembled correctly. The
Worker/Technician can then proceed to tighten the flange.
When bolt tightening is completed, the Worker/Technician shall print his name and confirm;
a) System Number
b) Line Number
c) The torque or tension applied. – Measured using hydraulic pressure gauges mounted on
the torque/tensioning machinery or set point on manual torque wrenches.
On completion of the above, Section 2 of the tag is removed and returned to the
Operation/Maintenance Supervisor/Work Leader who will retain it in the work pack for close
out audit.
A similar process is utilized after the flange has been leak tested (for information on leak
testing refers to Pressure and Leak Testing Guidelines).
The leak tests (service tests) are carried out with the pressure system in service, normally
during start-up. The test is normally carried out (but not necessarily always) at maximum
normal operating pressure using the process fluid as the test medium, supplemented by
water or inert gas from an external source if necessary.
When the flange has successfully passed a test, the Leak Test Technician shall confirm and
write on Side B Pressure and date of test then remove Section 2 of the tag and return it to the
Maintenance Supervisor/Work Leader who will insert the perforated ticket in the work pack for
close out audit. Information from both sides of the tag shall be entered into the Flange
Register Database.
On completion of testing the permit to work should be signed off as complete before
handover back to the operations department.
Prior start up, the remaining portion of the flange disturbance tag shall be removed from the
flange to prevent confusion during future maintenance and avoid accidentally paper burning
of the tag.
4.2 Flange General Requirements

4.2.1 Bolting
To ensure consistent performance, it is essential that nuts and bolts are supplied with the
precise specification for tolerance and fit. Studs/Nuts shall be the correct material and
size/length for the application and free of corrosion, damage, dirt and grit. Ensure that the
nuts can run freely down the threads before use.
Confirmation of the above is required to complete Section 4 of Side A of the flange tag.
Bolt Length – Bolts should extend completely through their nuts.
Re-use of Bolts/Studs
Studs and or nuts can only be reused, subject to the following conditions:
 There is no noticeable degradation.
 They are free from obvious defects (corrosion, cracks, etc.).
 There is no sign of yielding (i.e. deformed threads, stud shaft, etc).

 Nuts must run freely by hand on the bolt.
If a stud or nut is found to be unsuitable for re-use, it shall be scrapped
immediately.
For joint assemblies on the critical path of a maintenance or shutdown program (or where
tight time schedules are to be adhered to), it is recommended that replacement bolting be
made available in case the existing bolting is found to be unfit to return to service.
It is essential that when choosing fasteners for a flanged joint the grade of stud and nut used
are compatible and compliant with the piping specification. Matching stud and nut grades are
given in Table below:
Table 2. Stud and Nut Compatible
Stud Compatible Nut

ASTM Material Marking ASTM Material Marking
A193 Grade B7 B7 A194 Grade 2H 2H
A193 Grade B7M B7M A194 Grade 2HM 2HM
A193/A320 Grade B8 Class 2 B8 A194 Grade 8 8
A193/A320 Grade B8M Class 2 B8M A194 Grade 8M 8M
A193 Grade B16 B16 A194 Grade 4 4
A320 Grade L7 L7 A194 Grade 4 or 7 4 or 7
4.2.2 Thread Lubricants and Preservatives

1. The torque/tensioning values given in Appendices F as a general guidance. If required
the calculation should be made by using ASME PCC-1 for a specific flange
2. The use of lubricants with a lower coefficient of friction can lead to excessive bolt stress
being applied and failure of flanges or bolts may result.
3. Friction coefficient (COF) of some preservative lubricant can be referred at Appendix D.
4. When bolt tensioning is complete, to prevent corrosion a liberal coating of lubricant
should be applied to the nuts up to the back of the flange, and to the stud ends protruding
from the nuts. Copperslip, Densotape or nut/thread protectors are considered suitable for
this purpose.
5. The above information is required to complete Section 4 of Side B of the flange tag.
Note: this is particularly important where low alloy bolts are used on unpainted
stainless steel flanges. Marine material bolting should not be lubricated.
4.2.3 Flange Faces

Prior to assembly the flanges should be inspected to ensure the faces are in good condition
(particularly with respect to radial scoring), clean, parallel and axially aligned.
Pipe flange alignment tolerances shall comply with the relevant pipe fabrication/erection
specification.
Any deviation of tolerances shall be put in IAAN process.
Flange alignment is critical to the performance of the bolted joint. No excess pressure should
be exerted to align the bolt holes for the insertions of bolts without engineering approval.
Excess pressure used to assist with the insertion of bolts on flanges on rotating equipment
could have damaging effects on seals, shafts and bearings. For specific information on pipe
alignment on rotating equipment see API 686. General piping alignment specifications can be
found in ASME-PCC-1.
Every effort shall be made to align the joint. Applying large forces, through mechanical
devices or bolting, to align flange joint is bad practice and not permitted. Joints found in this
condition should be reported and seek consultation with COPI Asset Engineering prior to re-
commissioning.
The above information is required to complete Section 4 of Side A of the flange tag.
4.2.4 Gaskets
Gaskets shall be suitable for the operating conditions and remain flexible under a varying
load due to fluctuations in pressure and temperature. The type of gasket used shall comply
with the piping specification.
A new gasket/RTJ/Seal Ring shall be used whenever joints are made or remade. Check the
gasket for damage, nicks, etc.
Ensure that the gasket fits correctly, clean and free from any contamination before use.
Do not cut or deform a gasket to fit a flange. If the gasket doesn’t fit the wrong one has been
chosen.
Check the flange face-to-face separation once the gasket has been installed and the bolts
tensioned. A uniform separation is required. If not, the gasket could be locally crushed or
deformed and will not seal properly.
Where spiral wound gaskets are utilized, extra care shall be taken to protect the face of the
gasket. Most of Spiral Wound gaskets now being used are spiral wound 316 stainless
steel/stainless steel winding and graphite filler. These gaskets have a 316 st/st inner ring and
coated carbon steel outer guide ring, but on some occasion the outer ring could be stainless
steel to provide corrosion resistance to external environment.
When installing the gaskets, ensure the flange and gasket faces are clean and dry. Gaskets
should be of the correct type and correctly positioned. Note that it is not possible to mix and
match gaskets between proprietary clamped connectors (e.g. Graylok/Techloc & Galperti).
4.2.5 Insulation Gasket Sets and Specialty Gasket

Insulation kits are designed to prevent galvanic corrosion between flanges of dissimilar
metals, for example a carbon steel flange bolted to a stainless flange. A conductive liquid
such as water must be present between the two flanges for galvanic corrosion to occur. On
oil and dry gas duties, insulating gasket ARE NOT required. The use of insulation kit to
prevent galvanic corrosion shall be determined by Corrosion Engineer
In the Cathodic Protection system, particularly ICCP system (Impresses Current Cathodic
Protection) insulation gasket is required to prevent undesired current drain leaks from
protected structures to other foreign structure intentionally. This insulation gasket also
protected the CP system from other common CP problem such as stray current and
interferences.
Insulation kits generally require a lesser bolt load to create an effective seal as a result of the
specially designed gasket, with spacers and washers playing an integral role. It is essential
that all components of the insulation kit are fitted to ensure the integrity of the joint and that
the manufacturer’s recommendations are followed when tightening the joint.
Specific procedure for installation of insulating gasket and/or other specialty gasket shall be
developed and addressed the following concern:
 Always use a new insulating kit which has not been removed from the manufacture's
sealed package. Good insulation require installation parts of the kits to be clean and
undamaged.
 Follow manufacture's installation instructions.
 Use a torque wrench or tensioning equipment to tension the stud bolt to the
manufacture's recommendation. This is important as insulating gasket are particularly
susceptible to splitting or crushing if overloaded.
 Ensure that the flange face and stud bolt are clean.
 Check for any conducting path between the two matting flanges which would otherwise
render the insulating gasket in effective.
 Do not re-use old, damaged or unclean insulating kits. These will not provide effective
insulation and may subject to gasket failure.
 Do not mix and match parts from different insulation kits.
 Do not use air driven impact tools when bolting up a flange as these may cause the
insulating washers to crack.
4.3 Tightening
4.3.1 Tightening Methods
The following table is general rule for selection of tightening method. For specialty
arrangement i.e. Pikotek gasket, please refer to manufacturer installation manual.
Table 3. Torque/Tension Guidance based on bolt size and flange class
Bolt Size Flange Class Tension Torque Comments

1 ½ and larger 900# and Yes Tension whenever possible,
above torquing may be utilized only if
tensioning is not possible
1 ½ and larger Below 900# Yes Yes Tension whenever possible,
torquing may be utilized only if
Below 1 ½ 900# and Yes Tension whenever possible,
above torquing may be utilized only if
Below 1 ½ Below 900# Not Required Yes
The equipment must have a valid calibration certificate.
4.3.1.1 Conventional Spanners/Wrenches

Flange bolts may be tightened by hand torque wrenches Conventional spanners/wrenches
may be used on Class 150 Non-Severe System piping systems only.
Note: the flogging of bolts in hydrocarbon systems is not permitted.
4.3.1.2 Torque Wrenches

Flange bolts shall be tightened by torque wrenches on all hydrocarbon systems (all pressure
ratings), and utility systems rated at Class 300 and above.
Controlled torque wrenching shall be carried out using either manual or hydraulic torque
wrenches that are calibrated and “in certification”. The method chosen is dependent upon bolt
loading, access, clearance and tooling availability, which will be determined by the site
personnel. When the bolt loading requires a torque figure greater than 500 lbf.ft (678 Nm) to
be applied, the use of a hydraulic torque wrenches is recommended.
Note: if torque equipment cannot be applied due to access restrictions then the
Operation/Maintenance Supervisor/Lead shall be advised and a Risk Assessment
completed detailing the additional controls required to ensure joint integrity, this may
include using conventional spanners and joint make up verification by a second
Worker/Technician.
4.3.1.3 Torquing Procedure
Figure 2. Tightening Sequence
To achieve joint tightness it is important that the following procedure is adhered to:
1. Check and ensure that the general requirements of Section 4.2 have been satisfied.
2. To achieve uniform joint load/stress distribution the bolts shall be tightened in three
stages, representing 30%, 60% and 100% of the torque values stated in Appendices F.
At each stage of tightening, bolts shall be tightened in a controlled sequence.
3. Finally the bolts shall be chased round using the 100% torque value stated in Appendices
F, until uniform tightening has been achieved. Note: If tightening an RTJ, a second 100%
chase round shall be completed.
4.3.1.4 Hydraulic Jack Bolt Tensioning Equipment

Where more stringent control of joint stresses is required, flange bolting should, whenever
practical, be tightened using hydraulic jack tensioning equipment. This technique is strongly
recommended for the following services and pressure ratings, (also see Appendices H)
1. Bolt diameters of 2 inches and above in all services with pressure ratings up to and
including Class 900.
2. Bolt diameters of 1½ inches and above in all services with pressure ratings Class 1500
and above.
3. Bolt diameters of 1 inch and above in critical applications. Critical applications are
considered to be joints exposed to cyclic stress i.e. frequent changes of pressure and/or
temperature.
The bolt tensioning operation must be carried out in accordance with the tension equipment
manufacturer’s specified procedure and the load loss factors should be recorded. Ideally
tensioning should be applied simultaneously to all studs in one operation. Where this is not
possible, tensioning should be applied in phases using differing pressures as per supplier’s
guidelines.
Note: if tensioning equipment cannot be applied due to access restrictions then the
Operation/Maintenance Supervisor/Lead shall be advised and a Risk Assessment
completed detailing the additional controls required to ensure joint integrity, this may
include using conventional spanners and joint make up verification by a second
Worker/Technician.
4.4 Hot Bolting and Preventative Bolting

4.4.1 Hot Bolting Requirement
The practice of hot bolting (see definitions) is a potentially hazardous operation and must not
be undertaken unless all other options have been considered and there remains an
outstanding, and fully justified, operational reason to carry out hot bolting in a safe manner. A
risk assessment shall be carried out, and a plan developed to achieve isolation of the joint in
the event of a problem during the hot bolting operation. Changing bolts by hot bolting simply
to save time during a forthcoming shutdown is not an adequate reason for hot bolting.
However, partially backing off and re-tightening one nut at a time is permitted to identify bolts
that may be difficult to remove in a later shutdown, but shall be subject to the same safety
review, and risk assessment and controls as for hot bolting.
Holt bolting work should be approved by site manager and site specific procedure should be
developed.
Hot bolting may only be considered on systems in the following duties:
1. Seawater and Service water
2. Fire water ring mains
3. Cooling medium
4. Crude Oil systems provided the system pressure does not exceed 5.0 barg.
5. Diesel fuel
6. Drains systems
7. Low-pressure mud conveying systems associated with drilling.
8. The operating pressure must be less than 75% of the MAWP (Maximum Allowance with
Pressure) of the piping or process system to be hot bolted).
Hot Bolting is NOT permitted on the following systems:
1. Hydrocarbon gas
2. High pressure Water Injection >25 barg
3. Toxic fluids
4. Fluid temperature > 90 degrees C

5. Intermittent flow or surging flow
6. Flange with bolt less than eight (8).
4.4.2 Hot bolting procedure

Before any work commences ensure that hot bolting has been fully justified; that a risk
assessment has been performed and approved; that a permit to work states that hot bolting
on the joint is permitted; and that a contingency plan exists to isolate the joint in the event of
a problem during the hot bolting operation.
The hot bolting procedure given below shall be followed:
1. Latest past history records of the joints in question shall be consulted to identify any
anomalies or previous problems with the joint.
2. To anticipate any fastener or flange or gasket relaxation an attempt shall first be made to
evenly re-tension each fastener before attempting to loosen any single fastener. Both the
tightening and slackening activities shall be carried out by controlled means (if extra
length studs have been fitted, bolt tensioning is strongly recommended over torquing
during hot bolting as it maintains a more accurate gasket seating stress, and is less likely
to result in an overloaded bolt). Bolt tension and bolt torques shall be in accordance with
Appendix F.
3. The break out torque shall be recorded for every fastener. If the break out torque is
significantly less than the torque specified in Appendix F it may indicate a loose or
overstressed joint. In such cases the system shall be isolated, depressurized, purged and
vented prior to any further fastener being removed. In this instance please notify the COP
onshore maintenance responsible engineer.
4. Proceed to slacken the first fastener (on the side furthest away from personnel),
monitoring for leakage continuously. Under no circumstances shall two bolts be
slackened simultaneously. In the event of the gasket leaking the joint shall be
immediately re-tightened.
5. The removed stud and nut should be cleaned, examined for damage or strain, lubricated
with Copperslip only, reinstalled and re-tightened. If in doubt the stud and nut should be
replaced.
6. Only one fastener shall be removed and replaced at a time working in the diametrically
opposite sequence as shown in Table 1 of this procedure. Each fastener shall be
replaced immediately and shall be tightened to the torque or tension as specified in
Appendix F.
7. Continue with this procedure (6) until all the fasteners have been changed out.
8. When all fasteners have been replaced their exposed nuts and threads shall be given a
liberal coating of grease in order to prevent corrosion.
9. Any jacking bolts that have been removed to improve access should be greased and
refitted.
10. Verify that the joint is totally leak-free.
4.4.3 Preventative Maintenance Bolting

The practice of checking for looseness and where necessary re-tightening fasteners in
flanged joints on a live (on-line) system is a potentially hazardous operation. It must not be
undertaken on a joint in a hydrocarbon, hazardous or toxic fluid system, unless all other
options have been considered and there remains an outstanding, and fully justified,
operational reason to perform preventative maintenance bolting in a safe manner. A risk
assessment shall be carried out, and a plan developed to achieve isolation of the joint in the
event of a problem during the operation. The joint must have a minimum of 8 bolts. This
preventive works shall get approval from site management representative.
4.4.4 Preventative Maintenance Bolting Procedure

1. Bolt tightening shall be carefully performed by controlled means. Bolt tensioning shall be
used if possible (if extra length studs have been fitted), otherwise bolt torquing shall be
used. Controlled tightening shall be used even if the bolt is equipped with a load-
monitoring device (e.g. Rotabolt).
2. Re-tensioning and re-torquing of the flange bolting shall be performed in accordance with
Appendix F, and bolt torquing shall be in the bolt sequence shown in Table 1 of this
procedure. It should be noted that although the thread lubricant may have dried out which
will increase friction losses, the bolt torque applied must not exceed the values stated in
Appendix F.
3. Monitor the joint during the operation for leakage, and at the end of the work verifies that
the joint is totally leak-free.
5 Flange System Records

The certainty of a successful joint being made up increases if data is controlled and historical
data exists on the activities carried out in the past. Recording traceable data encourages best
practice at the time of the activity, and will provide useful planning data for the next time the
joint is disturbed.
Learning from incident is important. A gathering relevant data, which should be collected by
everyone involved in flanged joints and periodically reviewed to establish trends, performance
and improvement. This can be achieved if records and data are kept as part of a
management control process.
It is recommended that as a minimum keeps records for all joints those on other services
which have a history of leakage, or potential to leak, and that this is kept with any relevant
procedures for monitoring specific joint. To minimize the possibility of the problem resurfacing,
methods for countering the leak should be included within the individual joint records.
Any changes from original specification should be maintained through MOC process.
6 Responsibilities
Table 4. RACI Chart for In-Service Routinve Inspection

InspectorsAsset Integrity
Maintenance/Operation
IN-SERVICE ROUTINE INSPECTION

Asset Integrity/Pipeline
Offshore Installation
Asset Integrity Mgr.

Mechanical Lead /
Supervisor/Lead
Technician
RACI
Engineer
Manager
R Responsible
A Accountable
C Consult
I Inform
No Activity
1 Perform Visual Inspection I I I C R A
2 Perform Fugitive Emission I I I C R A
3 Perform Snoop Leak Detector R C A I I
Table 5. RACI Chart for Flange Management Requirement & Procedure

Operation Supervisor/Lead
Maintenance Spt./ Pipeline

FLANGE MANAGEMENT
InspectorsAsset Integrity
Specialist Flange Vendor
Manager/ Operation Spt./
Asset Engineering Team

Work/Technician Leader
Asset Integrity/Pipeline
Offshore Installation
REQUIREMENT & PROCEDURE
Worker / Technician
Supervisor/Lead
Superintendent
Field Manager
Maintenance
Engineer
RACI
R Responsible
A Accountable
C Consult
I Inform
No Activity
Overall accountability for compliance with this

1 R A C C I
guideline
Site Accountability for compliance with this

2 R A C I I I
procedure
3 Determine Flanges to be disturbed during each task C R A I I C
4 Completion of Side A of Flange disturbance Tag R R C C A I I I
5 Confirm Method of tightening to be used R R C C A I I I
6 Torque/Tension to correct Value R R C C A I I I
7 Complete disturbed flange tightening report R R C C A I I I
8 Complete Side B of flange disturbance Tag R R C C A I I I
9 Leak Test As Required R R C C A I I I
Close out entry within flange management database

10 R R C C A I I I
and complete flange disturbance register
11 Close Work Order within SAP C C C R A I
Original of P&ID’s/Isometric, Flange Tag, and

12 C C C R A I I I I
controlled tightening reports to be kept.
All flange disturbance tagging is removed prior start

13 R R R A I
up
APPENDIX A. Flange Management Procedure Flowchart
L:\2.0 Project\16
Material & Corrosion\160079.01 COPI A&OI SIP 2010\11.0 ENGINEERING\SIP\SIP #3\WOR
APPENDIX B. Flange Disturbance Tag
L:\2.0 Project\16
Material & Corrosion\160079.01 COPI A&OI SIP 2010\11.0 ENGINEERING\SIP\SIP #3\Flang
APPENDIX C. Joint Disturbed Register & Controlled Tightening Report

Form
Form 2 - Controlled
Tightening Report.doc
APPENDIX D. Lubricant Information
No. Lubricant's Product Producer Coefficient Of Friction

1 API Bull 5A2 - 0.13
2 Anti Seize Acheson Colloids 0.09
3 Anti Seize (paste) Chesteron 0.14
International
4 Beldamite ASC Beldonite 0.13
5 Berutex FH-34 R.S. Clare 0.16
6 Berutex FH-35 R.S. Clare 0.16
7 Biral BASC Sieben Technical 0.11
8 Castrol Nucleol S202 Castrol 0.08
9 Copaslip National Chemical Co 0.12
10 Coppercrest Illex Lubricant 0.14
11 Copper Ease Comma Oil & 0.14
Chemical
12 Coppergrease Chemodex 0.15
13 **Coppergrease Chemofina 0.11
14 Copperslip Belzona Molecular Ltd 0.09
15 **DAG156 Acheson Colloids 0.15
16 DAG580 (Dry Lubricant) Acheson Colloids 0.16
17 Easyrun100 K.S Paul 0.08
18 Fel-ProC-102 Fel-Pro Inc 0.16
19 Fordec Copper Anti Seize Fordec 0.15
20 Gleitmo165 Gleitmo 0.1
21 HP anti seize Belzona Molecular Ltd 0.15
22 LFCP 5006 Maxol (Irish) 0.2
23 Molykote Cu-7439 Dow Corning 0.15
24 Molykote1000 Dow Corning 0.11
25 Molykote Q5-7405 Dow Corning 0.04
26 Molykote G-Rapid Dow Corning 0.08
27 Molykote G-Rapid Plus Dow Corning 0.09
28 Molykote HSC Dow Corning 0.11
29 Molykote Ti 1200 Dow Corning 0.12
30 Molykote 7443 Dow Corning 0.13
31 Molykote P37 paste Dow Corning 0.12
32 Molyslip AS60 Molyslip 0.07
33 Never seez Std grade Bostik Ltd 0.18
(NS160)
No. Lubricant's Product Producer Coefficient Of Friction

34 Never seez Spl grade Bostik Ltd 0.18
(NS165)
35 Nickel-Eez Swan Chemical 0.12
36 OKS 235 OKS 0.11
37 OKS 240 OKS 0.12
38 OKS 250 OKS 0.08
39 OKS 503 OKS 0.06
40 OKS 504 OKS 0.09
41 OKS 505 OKS 0.1
42 OKS 506 OKS 0.11
43 OKS 507 OKS 0.1
44 Omega 99 Sovereign Lubricants 0.13
45 Omega 99N Sovereign Lubricants 0.09
46 Omega 95 Sovereign Lubricants 0.12
APPENDIX E. Flange Bolting Charts
Series 150 Flange *For standard flanges only, Add

length when washers or Double Nuts are used
Pipe Wrench Flange Bolts
Size Size
Number Diameter Raised Face Ring Joint
Length Length Ring#
1 ⅞ 4 ½ 2½ 3 R15
1½ ⅞ 4 ½ 2¾ 3¼ R19
2 1 1/16 4 ⅝ 3¼ 3¾ R22
3 1 1/16 4 ⅝ 3½ 4¼ R29
4 1 1/16 8 ⅝ 3½ 4¼ R36
6 1¼ 8 ¾ 4 4½ R43
8 1¼ 8 ¾ 4¼ 4¾ R46
12 1 7/16 12 ⅞ 4¾ 5½ R56
14 1⅝ 12 1 5¼ 6 R59
16 1⅝ 16 1 5¼ 6 R64
18 1 13/16 16 1⅛ 6 6½ R68
20 1 13/16 20 1⅛ 6¼ 7 R72
24 2 20 1¼ 7 7¾ R76

Size Size
Length Length Ring#
1 1 1/16 4 ⅝ 3 3¼ R16
1½ 1¼ 4 ¾ 3½ 4 R20
2 1 1/16 8 ⅝ 3½ 4¼ R23
3 1¼ 8 ¾ 4¼ 5 R31
4 1¼ 8 ¾ 4½ 5¼ R37
6 1¼ 12 ¾ 4¾ 5¾ R45
8 1 7/16 12 ⅞ 5½ 6¼ R49
10 1⅝ 16 1 6¼ 7¼ R53
12 1 13/16 16 1⅛ 6¾ 7½ R57
14 1 13/16 20 1⅛ 7 7¾ R61
16 2 20 1¼ 7½ 8¼ R65
18 2 24 1¼ 7¾ 8½ R69
20 2 24 1¼ 8 9¼ R73

Size Size Number Diameter Raised Face Ring Joint
Length Length Ring#
1 1 1/16 4 ⅝ 3½ 3½ R16
1½ 1 ¼ 4 ¾ 4¼ 4¼ R20
2 1 1/16 8 ⅝ 4¼ 4½ R23
3 1 ¼ 8 ¾ 5 5¼ R31
4 1 7/16 8 ⅞ 5¾ 6 R37
6 1⅝ 12 1 6¾ 7 R45
8 1 13/16 12 1⅛ 7¾ 8 R49
10 2 16 1¼ 8½ 8¾ R53
12 2 20 1¼ 8¾ 9 R57
14 2 3/16 20 1⅜ 9¼ 9½ R61
16 2⅜ 20 1½ 10 10 ¼ R65
18 2 7/16 20 1⅝ 10 ¾ 11 R69
20 2 7/16 24 1⅝ 11 ½ 11 ¾ R73

Size Size
Length Length Ring#
1 1 7/16 4 ⅞ 5 5 R16
1 ½ 1⅝ 4 1 5½ 5½ R20
2 1 7/16 8 ⅞ 5¾ 6 R24
3 1 7/16 8 ⅞ 5¾ 6 R31
4 1 13/16 8 1⅛ 6¾ 7 R37
6 1 13/16 12 1⅛ 7¾ 8 R45
8 2 3/16 12 1⅜ 7¾ 9 R49
10 2 3/16 16 1⅜ 9¼ 9½ R53
12 2 3/16 20 1⅜ 10 10 ¼ R57
14 2⅜ 20 1½ 10 ¾ 11 ¼ R62
16 2 9/16 20 1⅝ 11 ¼ 11 ¾ R66
18 2 15/16 20 1⅞ 13 13 ½ R70
20 3⅛ 20 2 13 ¾ 14 ½ R74

Size Size
Length Length Ring#
1 1 7/16 4 ⅞ 4¾ 4¾ R16
1 ½ 1⅝ 4 1 5¼ 5¼ R20
2 1 7/16 8 ⅞ 5½ 5¾ R24
3 1 13/16 8 1⅛ 6¾ 7 R35
4 2 8 1¼ 7½ 7¾ R39
6 2 3/16 12 1⅜ 10 10 ¼ R46
8 2 9/16 12 1⅝ 11 ¼ 11 ¾ R50
10 2 15/16 12 1⅞ 13 ¼ 13 ½ R54
12 3⅛ 16 2 14 ¾ 15 ¼ R58
14 3½ 16 2¼ 16 16 ¾ R63
16 3⅞ 16 2½ 17 ½ 18 ½ R67
18 4¼ 16 2¾ 18 ¼ 20 ¼ R71
20 4⅝ 16 3 21 22 ¼ R75

Size Size
Length Length Ring#
1 1 7/16 4 ⅞ 5¾ 5¾ R18
1 ½ 1 13/16 4 1⅛ 7 7¼ R23
2 1⅝ 8 1 7¼ 7½ R26
3 2 8 1¼ 9 9¼ R32
4 2⅜ 8 1½ 10 ¼ 10 ¾ R38
6 3⅛ 8 2 13 ¾ 14 ½ R47
8 3⅛ 12 2 15 ¼ 16 R51
10 3⅞ 12 2½ 19 ½ 20 ½ R55
12 4¼ 16 2¾ 21 ½ 22 ½ R60
APPENDIX F. Bolt Torque/Tensioning Values
The following table covers the Torquing / Tensioning Details for the following Bolting Materials:
Carbon Steel, Duplex Stainless Steel, Super Austenitic Stainless Steel, B7 & Equivalent (Bolt Stress is
approx 310 Mpa (45000 psi)) using a Coefficient of Friction (COF) 0.10
Stud Bolt Details Required Required Torque Recommended Tool

Bolt Tension Details
Bolt Size Thread (lbf) Ft.lbs N.m
¼ UNC 1672 6 8 Manual Wrench

5/16 UNC 2700 12 16 Manual Wrench
⅜ UNC 3952 20 27 Manual Wrench
½ UNC 7157 46 62 Manual Wrench
⅝ UNC 11322 90 120 Manual Wrench
¾ UNC 16584 150 205 Hydraulic Wrench
⅞ UNC 22778 240 325 Hydraulic Wrench
1 UNC 27681 330 450 Hydraulic Wrench
1⅛ UN8 36537 480 650 Hydraulic Wrench
1¼ UN8 45529 660 890 Hydraulic Wrench
1⅜ UN8 56110 880 1200 Hydraulic Tensioner
1½ UN8 67796 1150 1550 Hydraulic Tensioner
1⅝ UN8 81307 1500 2000 Consult
1¾ UN8 94480 1850 2500 Consult
1⅞ UN8 109478 2300 3100 Hydraulic Tensioner
2 UN8 125581 2700 3700 Hydraulic Tensioner
2¼ UN8 161101 4000 5400 Hydraulic Tensioner
2¾ UN8 245394 7200 9800 Hydraulic Tensioner
3 UN8 294167 9400 12700 Hydraulic Tensioner
3½ UN8 404967 15000 20200 Consult
3¾ UN8 466994 18400 25000 Hydraulic Tensioner
4 UN8 533439 22400 30300 Consult
B8M Class 2 (Bolt Stress is approximately 65% of yield load) using a Coefficient of Friction (COF) 0.10
Stud Bolt Details Required Bolt Required Torque Recommended Tool

Tension (lbf) Details
Bolt Size Thread Ft.lbs N.m
¼ UNC 2295 8 11 Manual Wrench
⅜ UNC 5423 27 37 Manual Wrench
½ UNC 9821 62 85 Manual Wrench
⅝ UNC 15537 120 165 Manual Wrench
¾ UNC 22756 210 280 Hydraulic Wrench
⅞ UNC 26321 275 375 Hydraulic Wrench
1 UNC 31987 380 520 Hydraulic Tensioner
1⅛ UN8 34304 450 610 Hydraulic Tensioner
1⅜ UN8 40524 640 860 Hydraulic Tensioner
B8M Class 2 Yield Strength:
ASTM Material - Size Yield Strength 65% Yield Strength

(psi) (psi)
ASTM A193 – B8M Class 2 – For ¾” and under 95000 61750
ASTM A193 – B8M Class 2 – For ¾” to 1” 80000 52000
ASTM A193 – B8M Class 2 – For 1” and to 1 ¼” 65000 42250
ASTM A193 – B8M Class 2 – For 1 ¼” to 1 ½ “ 50000 32500
In-Service Flange Integrity Guideline
APPENDIX G. Guideline For Evaluating Failure in Flanged Joints
The following table listed possible failure modes in flanged joints.
Failure Mode Cause Corrective Actions
FLANGE
Flange surface scarred  Installation error in the tools  Renew sealing surface
used to insert or remove the
gasket
 Damaged flange was not
inspected during make up
Flanged bowed  Over torque  Revise assembly
 Flange pressure rating is procedure
too low for service conditions
 Flange material is not
adequate for service conditions
Flange rotation  Over torque  Revise assembly
 Flange pressure rating is procedure
too low for service condition  New Flange
GASKET
Gasket crush all around  Over torque  Install a proper new
 Gasket is too soft: low gasket
modulus of elasticity
 Gasket is too thick
Gasket crush on one end  Excessive pipe moments  Additional passes
only  Pipe misalignment  In tightened correctly
 Incorrect bolt up procedure refer to Asset Integrity
Engineer
Gasket crush on outer edge  Flange rotation  Crush control
 Over torque  Stretch control
 Gasket is too hard: high  Low stress gasket
 Flange pressure rating is
too low
Gasket cut  Installation error in the tools  Provide gasket
used to insert the gasket; handling instruction and
mishandling the gasket during fixtures
installation
 Damaged gasket was not
inspected at installation
Gasket disintegration  Incorrect gasket Material  Change gasket
 Contamination of the flange material
and/or gasket
Gasket blowout  Flange surface is too  Machine
smooth
 Incorrect gasket material
Gasket extrusion  Gasket is too soft; low  Stretch control
In-Service Flange Integrity Guideline
Failure Mode Cause Corrective Actions
modulus of elasticity  Gasket control

 Over torque
Localized corrosion  Localized contamination of  Renew sealing surface
the flange and/or gasket
 Damaged surface
Generalized corrosion  Generalized contamination  Change gasket
of the flange and/or gasket material
No gasket compression (not  Under torque  Increase torque
seated for full  Gasket is too hard: high  Measure fastener
circumference) modulus of elasticity strength
 Gasket is too thin  Softer gasket
BOLT
Loose bolts on one end only  Pipe misalignment  Align the pipe
 Excessive pipe moments  Additional passes
 Incorrect bolt up procedure
All bolt loose  Bolt relaxation; bolt creep  Reestablish the load
 Gasket relaxation; gasket  Install spacers or
creep Belleville springs
 Under torque  Metal-to-metal contact
with controlled gasket
deflection
Random bolts loose  Incorrect bolt up procedure  Additional passes
 Bolt relaxation; if some low  Vary the stretch
yield bolts have been mixed with patterns
the correct bolting
Bolts elongated  Over torque  Revise assembly

 Incorrect bolting material procedure
 Gasket is too hard; high  New gasket
More detail about trouble shooting of flanged joint could be found in Appendix P of ASME PCC-1 (2010).
A series of diagnostic tables is provided with each dedicated to a specific type of leak event includes:
 Leak during Hydro Test (LHT)
 Leak during heat-up or initial operation (LIO)
 Leak corresponding to thermal or pressure upset (LCU)
 Leak after several months operation (LTO)
 Leak during shutdown (LDS)

Flange Management

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Flange Management

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Document Title: In-Service Flange Integrity Guideline

COPI Doc No.: ID-G-BU-00000-00000-01548

REVISION DATE DESCRIPTION OF CHANGE

Para 6 RACI Chart for Flange Management Requirement and

Additional Approvers (If Applicable)

Name Designation Signature Date

Tasdikin Lead Asset Integrity QAQC

3 In-service Routine Inspection

3.1 Visual Inspection

3.2 Fugitive Emission (FE) Survey

3.3 Alternative Method

3.3.1 Advanced Inspection

3.3.2 Identified Damage Assessment

Table 1. Summary of Key Issues

Damage Type Typical Condition Inspection Technique Mitigation Measure

Damage Type Typical Condition Inspection Technique Mitigation Measure

4 Flange Management Requirement and Procedure

4.1 Flange Joints Disturbance Procedure

4.1.2 Breaking Flange Joints

4.1.3 Making Joints

4.1.4 Tagging Procedure

Section 4 Section 3 Section 2 Section 1

 Section 1 (Flange Not Disturbed)

Figure 1. Flange Disturbance Tagging

4.2 Flange General Requirements

 There is no sign of yielding (i.e. deformed threads, stud shaft, etc).

Stud Compatible Nut

4.2.2 Thread Lubricants and Preservatives

4.2.3 Flange Faces

4.2.5 Insulation Gasket Sets and Specialty Gasket

Bolt Size Flange Class Tension Torque Comments

The equipment must have a valid calibration certificate.

4.3.1.1 Conventional Spanners/Wrenches

4.3.1.2 Torque Wrenches

4.3.1.3 Torquing Procedure

Figure 2. Tightening Sequence

4.3.1.4 Hydraulic Jack Bolt Tensioning Equipment

4.4 Hot Bolting and Preventative Bolting

4. Fluid temperature > 90 degrees C

4.4.2 Hot bolting procedure

4.4.3 Preventative Maintenance Bolting

4.4.4 Preventative Maintenance Bolting Procedure

5 Flange System Records

Table 4. RACI Chart for In-Service Routinve Inspection

IN-SERVICE ROUTINE INSPECTION

Asset Integrity Mgr.

1 Perform Visual Inspection I I I C R A

2 Perform Fugitive Emission I I I C R A

3 Perform Snoop Leak Detector R C A I I

Table 5. RACI Chart for Flange Management Requirement & Procedure

Maintenance Spt./ Pipeline

Manager/ Operation Spt./

Asset Engineering Team

Overall accountability for compliance with this

Site Accountability for compliance with this

3 Determine Flanges to be disturbed during each task C R A I I C

4 Completion of Side A of Flange disturbance Tag R R C C A I I I

5 Confirm Method of tightening to be used R R C C A I I I

6 Torque/Tension to correct Value R R C C A I I I

7 Complete disturbed flange tightening report R R C C A I I I

8 Complete Side B of flange disturbance Tag R R C C A I I I

9 Leak Test As Required R R C C A I I I

Close out entry within flange management database