FLANGE MANAGEMENT

PROCEDURE

JG Summit Stage 1 A4-JGS1EP-EPC1-QP-016

Rev: A Page 1 of 21
Expansion Project

FLANGE MANAGEMENT PROCEDURE

PROJECT NAME : JG Summit Stage 1 Expansion Project

OWNER : JG SUMMIT OLEFINS CORPORATION

CONTRACTOR : VENTANAS PHILIPPINES CONSTRUCTION INC.

LOCATION : Barangay Simlong, Batangas City

DOCUMENT NO. : A4-JGS1EP-EPC1-QP-016

A 02-04-2019 Issued for Review MJ LEE SN KANG SW LEE

PREPARED CHECKED APPROVED
REV. DATE DESCRIPTION
BY BY BY
 FLANGE MANAGEMENT
PROCEDURE

JG Summit Stage 1 A4-JGS1EP-EPC1-QP-016

Rev: A Page 2 of 21
Expansion Project

TABLE OF CONTENTS

Page

1.0 SCOPE…………………………………………………….………………...3

2.0 REFERENCES……………………………………………………………...3

3.0 RESPONSIBILITIES……………………………………………………….3

4.0 DEFINITION OF TERMS……………………………………………….....4

5.0 SAFETY CONSIDERATIONS ……………………………………………4-5

6.0 PROCEDURE ……………………………………………………………. .5-10

7.0 QA/QC VERIFYING DOCUMENTS…………………………………... 10

8.0 ATTACHMENT/APPENDIX……………………………………………...10-21
 FLANGE MANAGEMENT
PROCEDURE

JG Summit Stage 1 A4-JGS1EP-EPC1-QP-016

Rev: A Page 3 of 21
Expansion Project

1.0 SCOPE

This procedure covers the basic requirements for flange management including
proper storage, inspection, tightening to be performed by subcontractors under JG
SUMMIT STAGE 1, EXPANSION PROJECT in SIMLONG, BATANGAS CITY,
PHILIPPINES.

2.0 REFERENCES
1) ASME B31.3: ASME Design code for Process Piping
2) ASME B16.5: ASME Pipe Flanges and Pipe Fittings
3) ASME B16.47: Large Diameter Steel Flanges: NPS 26 through NPS 60 Metric/Inch
Standard
4) ASME PCC-1: Guidelines for Pressure Boundary Bolted Flange Joint Assembly

3.0 RESPONSIBILITIES AND AUTHORITY

3.1 Project Manager - Person authorized to approve this procedure

3.2 Construction Manager
3.3 QA Manager
3.4 Piping Supervisor
3.5 QA/QC inspector
3.6 Piping Engineer
.
– responsible for reviewing new or amended
procedure responsible for implementing and
enforcing this procedure
– responsible for ensuring all site leads obtain the
latest revision of this procedure. He is responsible
for the revision of the procedure and forms required
by the client.
- responsible for ensuring that the procedure is
followed while performing the task assigned to them.
Responsible on updating the Flange management
monitoring log to determine the completeness of
flange management.
- ensure that the activity is in accordance with this
procedure and inspected as per the approve
procedure.
– responsible for identifying critical flange joints &
answer all technical queries.
 FLANGE MANAGEMENT
PROCEDURE

JG Summit Stage 1 A4-JGS1EP-EPC1-QP-016

Rev: A Page 4 of 21
Expansion Project

4.0 Definition of Terms

4.1 Client - JG SUMMIT

4.2 Contractor - VPCI
4.3 Subcontractor - AG&P or PHILSPEC
4.4 Flange Joint Management – is a system whereby certification of all flange
joints for completeness in term of use of proper
gasket, bolts & nuts, marking-up of flange is
controlled, monitored and recorded. This scope
includes provision of proper qualified supervision
and expertise at site.
4.5 Bolt torqueing – is a process of accurate tightening of bolts with
pre-determined value using calibrated torque
wrenches (manual or hydraulic). Correct
lubrication shall be applied to the threads of both
bolts, nuts and to the contact faces of nuts.
4.6 Bolt Tensioning – is another method of accurate tightening of bolts
using hydraulic bolt tensioning equipment, with
calibrated pressure gauges to achieve a uniform
tightness on every joint.
4.7 Joint Tag – is used to identify a flange joint after tightening to
detail joint status for quick on-site verification and
traceability. Joints will be tagged after all flange joint
activities are done in accordance to this procedure.
4.8 Flange Management checklist – is used to identify flange joint that is ready to be
tightened and the inspection process has been
completed.
4.9 Flange Management Report – is the official record on how the joint was made.

5.0 SAFETY CONSIDERATIONS

5.1 It is the responsibility of the company’s project manager, engineer, supervisors

and or technicians to ensure that before the implementation of the job specific
procedures, that they comply with the company’s policy to work in a safe and
effective manner.
5.2 Before and during the implementation stage of operational activities, it is required
that all safety precautions provided are undertaken and enforced to safeguard the
integrity of personnel, equipment and property
5.3 Mandatory considerations are to be addressed as applicable for the scope of work
and site location. These mandatory considerations may include but not limited to:
 FLANGE MANAGEMENT
PROCEDURE

JG Summit Stage 1 A4-JGS1EP-EPC1-QP-016

Rev: A Page 5 of 21
Expansion Project

5.3.1 Job Hazard & Risk Assessment is undertaken.

5.3.2 Working at heights Safety protocols.
5.3.3 Barriers and warning signages to prevent unauthorized entry on work area.
5.3.4 Gas Test if working on Vessels must be checked.
5.4 JHA must are to be reviewed and approved prior the start of activity.
5.5 Only personnel with adequate training and knowledge shall execute the bolting
operations.
5.5 Subcontractors shall follow Client’s Permit to Work System.

6.0 PROCEDURE

6.1 Material Storage

6.1.1 Flanges shall be stored above the ground on pallets or in packing crates.
6.1.2 Flanges that are stored by stacked, subcontractor shall provide cardboard,
plywood or wooden battens between each layer to protect gasket mating
surfaces.
6.1.3 All Stainless-Steel Flanges shall be separated from all carbon steel flanges.
6.1.4 All Flanges shall have covers to protect faces from damage during
handling and storage.
6.1.5 Gasket shall be stored in containers, on racks and segregated by gasket
type and item code number for easy identifications.
6.1.6 All gaskets should be stored away from direct sunlight/heat and humidity.
Store away from water, oils and chemicals.
6.1.7 Hanging gaskets is prohibited to avoid distortions in the rings shape.
6.1.8 Bolts shall be stored in such away to prevent thread damage. Bolts shall
be segregated by type for easy identifications.
6.1.9 Stainless steel bolts shall be stored separately from carbon steel bolts.
6.1.10 Receiving and Releasing of Items shall always be monitored.
6.1.10 Good Housekeeping shall be maintained at all time.

6.2 General Requirements

6.2.1 All technicians shall be competent to perform the disassembly, reassembly

and tightening of flange joints.
6.2.2 All personnel involve on this activity shall be aware on this procedure &
project requirement.
6.2.3 All technicians shall be competent in flange management, including flange
face cleaning, gasket selection, flange alignment requirements, bolt
lubrication and selection of correct torque or tension values and tightening
sequence.
6.2.4 Subcontractor shall inform the contractor if there any damage found on
flange surface before box-up. No rectification shall be done without
Contractor’s approval.
 FLANGE MANAGEMENT
PROCEDURE

JG Summit Stage 1 A4-JGS1EP-EPC1-QP-016

Rev: A Page 6 of 21
Expansion Project

6.2.5 Subcontractor shall ensure that gasket to be installed are new, not damage.
6.2.6 Subcontractor shall ensure correct gasket, bolt & nuts are used.
6.2.7 Marking shall be done on the bolts to indicate that the flange joint has been
tightened to the required value.

6.3 Flange Management Flow Chart

START

Subcontractor propose & Rectify the Joint

provide a plan/schedule of
flange ready for box
up/inspections

Onsite inspection by QA/QC

no
ACCEPTED Issue Flange Management
checklist (rejected)

yes

Tag the joints

Accomplish Flange Management Checklist Update FM monitoring

Log

Proceed Controlled Bolting

Issue Flange Management Report

Flange management report

to be signed by QA/QC &

END
 FLANGE MANAGEMENT
PROCEDURE

JG Summit Stage 1 A4-JGS1EP-EPC1-QP-016

Rev: A Page 7 of 21
Expansion Project

6.3 Flange Box-up and Inspection

6.3.1 Subcontractor shall notify and submit schedule to contractor.

6.3.2 Inspect flanges faces for defects and thoroughly clean flange face.
6.3.3 Check the flange face alignment to meet the requirement identified in flange
alignment tolerance.
6.3.4 Check that the bolt material and length are as per specification. New or re-
used bolts and nuts shall be inspected to ensure that they do not show any
signs of yield, thread damage or excessive corrosion. Nuts must be free
running on the bolts. Damage bolts shall be replaced with same bolt
required.
6.3.5 As a rule of thumb, nut width should be equal the bolt diameter.
6.3.6 Bolts that there is no identification shall be rejected.
6.3.7 Check that the gasket is of the correct type, size, rating and is not damaged.
Re-use of old and damage gasket is strictly prohibited.
6.3.8 Ensure no debris is left inside the pipe immediately prior to flange assembly.
Grinding or any other mechanical means to remove debris is not allowed
on any flanges. Damage on the flanges should be observed. Any damages
found shall be reported to the contractor for further inspection and
evaluation.
6.3.9 When cleaning of flange faces prior to assembly of joints use same material.
Ex. Stainless steel flanges shall only be treated with stainless bristles.
6.3.10 ALWAYS brush in the directions of the grooves and not at right angles to
prevent damage on the grooves.
6.3.11 Any protective or mill coating to be removed from the gasket mating
surfaces prior to installation of gaskets.
6.3.12 Scratches running “radially” from inside to outside of the spiral groove shall
be avoided.
6.3.13 Gasket Mating surfaces of both flanges shall be checked for flatness both
radially and circumferentially, and be clean of paint, grease and dirt.
6.3.14 Apply lubricant if required to the bolts.
6.3.15 Avoid bolt lubricants contact with gasket mating surfaces as it will impact
on gasket seating capability.
6.3.16 Insert all the bolts. Ensure that the nuts run freely on the bolt threads and
tighten the nuts “hand tight”.
6.3.17 Install bolts and nuts with “stamp” of each bolt facing one side only. i.e.
facing the most convenient side for easy access during inspections.
6.3.18 Bolts shall be able to pass through each bolt hole without any force being
applied..
6.3.19 Stud ends shall extend at least 3 thread or 3 mm (whichever is greater)
beyond the nuts.
 FLANGE MANAGEMENT
PROCEDURE

JG Summit Stage 1 A4-JGS1EP-EPC1-QP-016

Rev: A Page 8 of 21
Expansion Project

6.3.20 If a bolt tensioning is going to be employed on the joint the bolt length shall
be exposed a minimum of one bolt diameter beyond one nut to allow for
tensioning device.
6.3.21 Subcontractor shall prepare the flange management checklist ensuring all
items installed are correct and shall be signed/approved by QA/QC
representative of the contractor before any final bolt tightening commence.
6.3.22 Piping supervisor shall update all flange management done on flange
management monitoring log to ensure proper monitoring of the
completeness of system flange management.
6.3.23 Torque tightening of pipe flange bolts shall be performed with calibrated
manual and hydraulic wrenches or bolt tensioning equipment. Spanners
shall be used for smaller pipe flanges of low rating to prevent over tightening
and damage to the gasket. Use of adjustable spanners is totally not allowed.
6.3.24 After finishing the final bolt tightening following the correct procedures and
bolt sequence. Subcontractor shall prepare the Flange management
Report and shall be signed by QA/QC representative of the contractor who
witness the bolt tightening.
6.3.25 Piping supervisor shall update all flange undergone acceptable final bolt
tightening.
6.3.26 In case a flange undergone flange management and final bolt tightening is
disassembled. It shall be inspected again follow the same procedure and
make sure old gaskets are been replaced by a new gasket and bolt threads
are been inspected.

6.4 Methods of Bolt Tightening.

6.4.1 Hand Wrench Tightening

6.4.1.1 Always start by hand tightening.
6.4.1.2 Ensure gap is uniform before continuing with wrench tightening.
6.4.1.3 Proceed with Wrench tightening following proper bolt sequence.
6.4.1.4 Visual check, check the gap around the circumference of the
flange assembly for uniform gap after each round of tightening.
If uneven gap, selective tightening to address the issue.
6.4.1.5 Gap shall be measured at 4 equal locations after each round of
tightening.
6.4.1.6 At each round of tightening check gasket to ensure it is NOT
being “pinched” at any location around the circumference.

6.4.2 Manual & Hydraulic Torque Wrench Control

6.4.2.1 Always start by hand tightening.
6.4.2.2 Ensure gap is uniform before continuing with torque control
method.
6.4.2.3 Ensure that proper bolt sequence will be followed.
 FLANGE MANAGEMENT
PROCEDURE

JG Summit Stage 1 A4-JGS1EP-EPC1-QP-016

Rev: A Page 9 of 21
Expansion Project

6.4.2.4 Ensure that multi-pass tightening is carried out from 25,50,75

and 100 % final torque values.
6.4.2.5 Check gap after each pass.
6.4.2.6 Do not exceed on final torque values.
6.4.2.7 Final torque values applied must be uniform on each bolt and
nut.
6.4.2.8 Final “reverse run” using correct bolt sequence shall also be
conducted using the 100% target bolt torque values to ensure
that previously tightened bolts have not relaxed.
6.4.2.9 Finally, after 2 to 4 hrs. Repeat the reverse run. This will restore
any short-term creep relaxation.
6.4.3 Stud Tensioning
6.4.3.1 It shall be carried out by competent sub - Contractors (3rd Party).
& manufacturer’s recommended practices and procedures.
6.4.3.2 Method Statements shall be issued by sub-contractor for
approval before work commences.

6.5 Bolt Tightening Sequence

6.5.1 Two bolts shall be installed diametrically opposite to each other, one bolt
tighten halfway for retaining the gasket. The nut shall then be engaged.
6.5.2 The gasket shall be inserted and centered between the flanges and ensure
the use of correct gasket. Nuts shall be hand tightened to hold the gasket
in place. Monitor that the gasket between flanges is properly seated on the
seating surfaces. Install bolt in opposite direction for bolts no. 3,4.5 & 6 as
per sample figure below.
 FLANGE MANAGEMENT
PROCEDURE

JG Summit Stage 1 A4-JGS1EP-EPC1-QP-016 Page 10 of

Rev: A
Expansion Project 21

6.5.3 The remaining bolts and nuts shall be installed, and hand tightened at the
opposite direction following the bolt sequence. Care shall be taken to
assure proper seating and centering of the gasket. Nuts shall be positioned
on the stud bolts such that all nut threads are fully engaged when assembly
is completed.
6.5.4 Do a preliminary pass, set a torque value of 25 % of the final torque.
6.5.5 2nd pass shall be carried out at a torque value of 50 % of final torque.
6.5.6 3rd pass shall be carried out at a torque value of 75% final torque.
6.5.7 Final pass shall be carried out at 100% torque value.
6.5.8 Continue tightening the bolts following a circular clockwise pattern until no
further nut rotation occurs at the target torque value.
6.5.9 In case there will be other bolting sequence or method proposed other than
those patterns stated on ASME PCC-1 (see appendix F of ASME PCC-1
for alternative patterns), it shall be reviewed and approved first before
commencing of work.

7.0 QA/QC Verifying Documents

7.1 Flange Management Checklist (see Appendix)

7.2 Joint Completion Certificate (see Appendix)

8.0 Attachments/Appendix

8.1 Flange Management /Final bolting Tag

8.2 Flange Management Checklist.
8.3 Joint Completion Certificate
8.4 Flange Management Monitoring Log
8.5 Gasket Acceptance Guidelines (as per ASME PCC-1)
8.6 Flange Alignment Guidelines (as per ASME PCC-1)
8.7 Bolt Torque values (as per ASME PCC-1)
 FLANGE MANAGEMENT
PROCEDURE

JG Summit Stage 1 A4-JGS1EP-EPC1-QP-016

Rev: A Page 11 of 21
Expansion Project

8.1 Flange Management /Final bolting Tag

 FLANGE MANAGEMENT
PROCEDURE

JG Summit Stage 1 A4-JGS1EP-EPC1-QP-016 Page 12 of

Rev: A
Expansion Project 21

8.2 Flange Management Checklist

 FLANGE MANAGEMENT
PROCEDURE

JG Summit Stage 1 A4-JGS1EP-EPC1-QP-016 Page 13 of

Rev: A
Expansion Project 21

8.3 Flange Management Report

 FLANGE MANAGEMENT
PROCEDURE

JG Summit Stage 1 A4-JGS1EP-EPC1-QP-016 Page 14 of

Rev: A
Expansion Project 21

8.4 Flange Management Monitoring Log

 FLANGE MANAGEMENT
PROCEDURE

JG Summit Stage 1 A4-JGS1EP-EPC1-QP-016 Page 15 of

Rev: A
Expansion Project 21

8.5 Gasket Acceptance Guidelines

 FLANGE MANAGEMENT
PROCEDURE

JG Summit Stage 1 A4-JGS1EP-EPC1-QP-016 Page 16 of

Rev: A
Expansion Project 21
 FLANGE MANAGEMENT
PROCEDURE

JG Summit Stage 1 A4-JGS1EP-EPC1-QP-016 Page 17 of

Rev: A
Expansion Project 21
 FLANGE MANAGEMENT
PROCEDURE

JG Summit Stage 1 A4-JGS1EP-EPC1-QP-016 Page 18 of

Rev: A
Expansion Project 21
 FLANGE MANAGEMENT
PROCEDURE

JG Summit Stage 1 A4-JGS1EP-EPC1-QP-016 Page 19 of

Rev: A
Expansion Project 21

8.6 Flange Alignment guidelines

 FLANGE MANAGEMENT
PROCEDURE

JG Summit Stage 1 A4-JGS1EP-EPC1-QP-016 Page 20 of

Rev: A
Expansion Project 21

8.7 Bolt Torque Values

 FLANGE MANAGEMENT
PROCEDURE

JG Summit Stage 1 A4-JGS1EP-EPC1-QP-016 Page 21 of

Rev: A
Expansion Project 21