FLANGE MANAGEMENT

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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
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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
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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

3.0RESPONSIBILITIES AND AUTHORITY

3.1 Project Manager - Person authorized to approve this procedure

3.2 Construction Manager
3.3 QA Manager
3.4Piping Supervisor
them.
3.5QA/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
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.
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4.0 Definition of Terms

4.1Client
4.2Contractor
4.3Subcontractor
4.4 Flange Joint Management
4.5 Bolt torqueing
4.6 Bolt Tensioning
4.7 Joint Tag
4.8 Flange Management checklist
4.9 Flange Management Report
- JG SUMMIT
- VPCI
- AG&P or PHILSPEC
– 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.
– 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.
– 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.
– 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.
– is used to identify flange joint that is ready to be
tightened and the inspection process has been
completed.
– 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
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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:

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,
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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.
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

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Flange management report to

be signed by QA/QC & Client

END

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”.
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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.
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.
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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.
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 (3 rd
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.
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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)
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8.1 Flange Management /Final bolting Tag

Flange Management Tag

Test Pack no. DATE
ISO DWG
Sub-Con
Flange Joint ID
Flange INSPECTED
Condition clean aligned
Material type & size acc rej
Bolt
Condition clean aligned WITNESSED
Material type & size acc rej
Gasket
Condition clean aligned
Material type & size acc rej
Final Bolt tightening Tag
Test Pack no. DATE
ISO DWG
Sub-Con
Flange Joint ID
METHOD INSPECTED
TORQUED MANUAL HYDRAULIC
TENSIONED
TORQUE VALUE
25% 50% 75% 100% WITNESSED

TORQUE EQUIP. SERIAL NO.

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Report No.:
Flange Management Checklist
Page : OF

Project Name : Job No. :

Area / Unit : Date :

8.2 Flange Management Checklist
Hydro Pakage No : Subcon. Name :

1 Test Package no.

2 Isometric dwg no.

3 Line Class

4 Flange Material Specification

5 Flange Joint ID

6 Flange Size & Rating

7 Gasket Type/Material Specification

8 Gasket Size

9 Bolt & nut Material Specification

10 Bolt & nut size & quantity

No. Item to check Date Result No. Item to check Date Result

Correct Bolt Thread

1 Flange Joint ID is correct 9
Protrusion(at least 3 thread
Flange Faces are free form Bolt & nut Thread Condition(free
2 10
damage, oil & grease from damage & rust)
Correct Flange Size & Rating as Correct Washers are installed (if
3 11
per ISO required)
Correct Flange Material
4 12 Correct Flange gap & alignment
Specification as per ISO
5 Correct Gasket Type Installed. 13 Lubrication (if required)
Gasket Condition.(must be new
6
& free from damage)
7 Correct Bolt & nut type and size

       8 Correct Bolt & nut Quantity

REMARKS:

Inspected By Witnessed By Reviewed By

Sub-Con. Sign / Date VPCI Sign / Date Owner Sign / Date

Form No. : ITRF-PP-08 (Rev. 0) VENTANAS PHILIPPINES CONSTRUCTION INC.

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8.3 Flange Management Report

Report No.:
Flange Management
Report Page : OF

Project Name : JGS Expansion PKG 1 Job No. :

Area / Unit : Date :

Subcon. Name :

General Details
1 Test Package no.
2 Class.
3 ISO DWG no.
4 Flange Joint ID
Flange Details
1 Material Specs.
2 Type
3 Size & Rating
4 Flange Alignment Accept Reject
5 Flange Condition Accept Reject
Gasket Details
1 Material Specs.
2 Type
3 Size & Rating
4 Gasket Condition Accept Reject
Bolt & Nut Details
1 Material Specs.
2 Type
3 Size & Rating
4 Bolt & nut Condition Accept Reject
Torque Details
Torque Method Manual Hydraulic Tensioned
1 Torque Equip S/N Calibration Due Date
2 PASS NO. 1ST @ 25% 2ND @ 50% 3RD @ 75% FINAL
3 Torque Value Req.
4 Torque Value Result
Remarks

Inspected By Witnessed By Reviewed By

8.4 Flange Management
Sub-Con. Sign / Date Monitoring
VPCI Log
Sign / Date Owner Sign / Date

Form No. : ITRF-PP-09 (Rev. 0) VENTANAS PHILIPPINES CONSTRUCTION INC.

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FLANGE MANAGEMENT MONITORING LOG SHEET

ITEM FLANGE FLANGE DETAILS BOLT DETAILS LUBRICANT FINAL TORQUE VALUE DATE INSPECTED WITNESSED
TEST PACKAGE NO. AREA ISOMETRIC DWG GASKET TYPE REPORT NO. SUBCON
NO. JOINT ID MATERIAL SIZE RATING MATERIAL DIA. X LENGTH QTY APPLIED (IF REQ) REQUIRED ACCEPTED BY: BY

8.5 Gasket Acceptance Guidelines

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8.6 Flange Alignment guidelines

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8.7 Bolt Torque Values

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