Professional Documents
Culture Documents
N.S.Binh/T. T.
01 14.03.16 1st Revised N.B. Huy
Kimura Sugimura
N.S.Binh/T. T.
02 21.03.17 2nd Revised N.B. Huy
Kimura Sugimura
N.Q.Tung Ferdy C.
03 14.10.17 3rd Revised N.B. Huy
/N.S.Binh Valencia
5. REFERENCE
Chapter 10.
ISRS V8.1 Book of Knowledge
Asset Management
MD-02-MT-PR-001 Principle for Maintenance Division
VV3163-101-A-109 Method statement for U/G pipe coating & wrapping work
Dismantling the flange and removing the gasket, all indications of previous gasket installation
from the gasket contact surfaces shall be removed by using approved solvents and/or soft-
wire brushes. Using carbon steel brushes on stainless steel flange is prohibited.
Flanges which have leakage in history or any damages of gasket contact surface such as
scratches, nicks, gouges and burrs shall consider to be assessed. The results of the
assessment shall satisfied fully requirement of ASME PCC-1 appendix C and D. All flanges
with damage which are outside of ASME PCC-1 requisition shall be repaired or replaced.
Pulling the flanges into position could cause unacceptable loads and deflections in other parts
of the system, and mean that bolt load is being used to pull the flanges together instead of
compressing the gasket. Flanges should align initially in the un-stressed condition without any
external force applied unless stipulated within the design
During alignment of bolted flange joints, the following requirements of 04 parameter should be
met:
- Centerline high/low: the tolerance is measured at 04 points around the flange and it should
not exceed 1.5 mm. Refer to figure 1 below
Figure 1
- Parallelism: The tolerance is usually determined by measuring the closest and farthest
distance between the flanges and comparing. An acceptable practice is a difference no
Figure 2
- Rotational - two hole: The tolerance is measured by observing a 90-deg angle where the
fastener passes through the flanges or the holes are within 3 mm. Refer to figure 3 below
Figure 3.
- Excessive spacing or gap: This parameter is not greater than twice the thickness of the
gasket. Refer to figure 4 below
Torque value for manual tightening and torque wrench have to be applied for tightening
with priority following:
1st. Vendor document such as data sheet and approved drawing for equipment, package
(including piping in package).
2nd. For piping:
- Values in attachment 08 will be applied for all area except AC00.
- Values in attachment 10 will be applied for AC00.
For special case such as out of standardized size and pressure refer to sub-contractor
procedure in table 1.
3nd. ASME-PCC1 will be referred for calculation and recommended torque in table 1M
(page 3, ASME-PCC 1-2013) can be applied.
Torque value for tensioner must be followed the values indicated in attachment 12.
Toque value for non-metallic flange or non-metallic flange connect to full face steel flange using
gasket or O-ring seal: Attachment 07 gives referential torque values.
All torque results shall be recorded as in Attachment 11.
Table 1
EPC Contractor's Flange Management Procedures for each Area
Zone Subcontra Category Area Document Remarks
ctor Number
LILAMA SMP AC00(020) VV3160-001-A- exception of
146 standardizati
on
LILAMA SMP AF00(022,023,024,025,08 VV3160-001-A- Standardized
1,124,130) 103
PMS SMP A200(086,087,088,089,09 VV3160-001-B- Standardized
1 0,091,092,093)/A300(084) 016
/
A400(028)
PC1 SMP A800(040,042,043)/A900( VV3160-001-C- Standardized
041) 676
LILAMA UGP Zone 1 & Zone 2 Common VV3163-101-A-
109
LILAMA SMP AA00(061)/AB00(010,011, VV3160-002-A- Standardized
2
012)/A100(080)/AD00(013 628
Half bolting can be used for the removal of every other bolt (so the flange is left with half
the number of bolts) during plant depressurization, usually when the system is close to
atmospheric pressure. This hot bolting shall not only start when system is depressurized
to 50% of operating pressure.
Noted: When conducting half bolting removal procedures, the risks of fluid leakage are increased
due to reduced gasket compression and the possibility that the system may inadvertently be re-
pressurized. For this reason, the system pressure at which half bolting is conducted should be well
below design pressure and preferably at or near atmospheric pressure with local management
controls in place to prevent re-pressurization. Flange clamps can be used to add clamp force if
necessary.
Precommissioning
Checklist
CHECK
ACTIVITIES METHOD TOOL DATE REMARKS
(Yes/No)
1. For Connection status: Does the Connection have any VI
2. Confirm permanent gasket installed (visual check or scale) VI Feeler gauge
3. Confirm gasket type (by color code)
4. Confirm Gasket material (by color code) VI
4a. Spiral wound gasket
4a1. Confirm Winding Material color
4a2. Confirm Filler material color
4a3. Confirm rating/outer ring color VI
5. Check gasket assembly status VI
6. Flange check
6a. Visual check Bolt/nut grease VI
Hammer,
6b. Bolt/nut tightening check VI
feeler gauge
6c. Position of flange VI
6c1. Alignment
6c2. Offset VI
6c3. Angle
7. Others VI
Winding Material Color Filler Material Color Rating / Outer Ring and Ring Joint Gaskets Color
Tightening sequence
Step Loading
Install Hand tighten, then “snug up” to 15 Nm to 30 Nm (not to exceed 20% of
target Torque). Check flange gap around circumference for uniformity. If
the gap around the circumference is not reasonable uniform, make the
appropriate adjustments by selective tightening before proceeding.
Round 1 Tighten to 20% to 30% of Target Torque. Check flange gap around
circumference for uniformity. If the gap around the circumference is not
reasonably uniform, make the appropriate adjustments by selective
tightening/loosening before proceeding.
Round 2 Tighten to 50% to 70% of Target Torque. Check flange gap around
circumference for uniformity. If the gap around the circumference is not
reasonably uniform, make the appropriate adjustments by selective
tightening/loosening before proceeding.
Round 4 Continue tightening the bolts, but on a circular clockwise pattern until no
further nut rotation occurs at the Round 3 Target Torque value. For
indicator bolting, tighten bolts until the indicator rod retraction readings
for all bolts are within the specified range.
Round 5 Time permitting, with a minimum of 4 hours and repeat round 4; this will
restore the short-term creep relaxation/embedment losses. If the flange
is subjected to a subsequent test pressure higher than its rating, it may
be desirable to repeat this round after the test is completed.
Pass #1a: Tighten bolts equally space 180 deg apart on opposite sides of the join to 30%
of target torque, then rotate tools 90 deg and simultaneously tighten these two bolts to
30% of target torque.
Pass #1b: Simultaneously tighten the first two bolts to 60% of target torque, then rotate
tools 90 deg and simultaneously tighten these two bolts to 60% of target torque.
Pass #1c: Simultaneously tighten the first two bolts to 100% of target torque, then rotate
tools 90 deg and simultaneous tighten these two bolts to 100% of target torque.
Pass #1d onward: Tighten all bolts, simultaneously in groups of two 180 deg apart, in
circular passes at 100% of target torque until the nuts no longer turn.
A S M E B 16 . 5 / B 16 . 4 7 F l a n g e R a t i n g No n standard flnage
15 0 l b 300 lb 600 lb 900 lb 15 0 0 l b 2500 lb 2500 lb
N o . o B o l t N o t eN o . o B o l t N o t e N o . o B o l t N o t e N o . o B o l t N o t e N o . o B o l t N o t e N o . o B o l t N o t e N o . o f B o l t D i a .N (oi tn e) N
F l a n g e B o l t D i a . N o . B o l t D i a . ( i Nn )o . B o l t D i a . ( i Nn )o . B o l t D i a . ( i Nn )o . B o l t D i a . N o . B o l t D i a . N o . B o lt
F lange Size N P S
NP S (in) (in) Note (in) (in)
B o lts
Dia.
No . (in)
28 40 3/4 1 36 1 1/ 4 1 28 1 3/4 3 20 3 3
30 44 3/4 1 36 1 3/8 1 28 1 7/8 3 20 3 3
32 48 3/4 1 32 1 1/ 2 1 28 2 3 20 3 1/ 4 3
34 40 7/8 1 36 1 1/ 2 1 24 2 1/ 4 3 20 3 1/ 2 3
36 44 7/8 1 32 1 5/8 1 28 2 1/ 4 3 20 3 1/ 2 3
38 40 1 1 36 1 5/8 1 28 2 1/ 4 3
40 44 1 1 40 1 5/8 1 32 2 1/ 4 3 = A S M E B 16 . 5
42 48 1 1 36 1 3/4 1 28 2 1/ 2 3
44 52 1 1 40 1 3/4 1 32 2 1/ 2 3 = A S M E B 16 . 4 7 S e r i e s B
46 40 1 1/ 8 1 36 1 7/8 1 32 2 1/ 2 3 (N o t e: F langes t o be c o nnec t ed wit h GR P o r res ilient lined but t erf ly v alv es s hall be Series
48 44 1 1/ 8 1 40 1 7/8 1 32 2 3/4 3 = A S M E B 16 . 4 7 S e r i e s A
50 48 1 1/ 8 1 44 1 7/8 1 32 3 3
Notes
1 F l a n g e b o l t i n g t o b e t i g h t e n e d t o r e c o m m e n d e d T o r q u e va l u e f o r t h e s e s i z e s ( G r e e n ) .
2 F l a n g e b o l t i n g t o b e h y d r a u l i c a l l y t e n s i o n e d f o r a l l s e r vi c e s i n t h e s e s i z e s ( B l u e ) .
Th e b o l t l e n g t h s s p e c i fi e d i n c l u d e a n a d d i t i o n a l l e n g t h o f 1 b o l t d i a m e t e r t o fa c i l i t a t e t h e u s e o f b o l t t e n s i o n i n g e q
3 A l l fl a n g e s c o n n e c t i n g t o ro t a t i n g e q u i p m e n t (P u m p / Co m p re s s o r/ B l o we r) s h a l l b e m a n a g e d b y Co n t ro l e d To rq u i n g
va l u e r e g a r d l e s s o f s i z e a n d r a t i n g .
In case the flange is not sealed, it is allowed to increase the bolt torque value 1.5 times
of recommended torque value mentioned in above table.
ATTACHEMNT 10
Torque Value Table for Flange Management
Joint No.:
Report No.
Date:
Page of
Please tick here for hot bolting.
Alignment check:
1 2 3 4
Result of alignment:
1 2 3 4
Before open
After open
CL2500, Ring Joint Gasket, Non standard flange (SK Boiler Unit B400)
Note 1) Static condition means that the system to be kept at a certain pressure without any
commissioning of rotating equipment. Dynamic condition mean the unit to be
maintained at a set pressure with commissioning of rotating equipment.
Note 2) If Licensor/Vendor criteria exist, the more stringent criteria shall be applied
Note 3) Enclosed area: Area where Confined Space Entry procedure is to be applied
ATTACHMENT - 14
Table 1M Reference Values for Calculating Target Torque Values for Low-Alloy
Steel Bolting Based on Target Prestress of 345 MPa (Root Area) (SI Units)
(See section 12 for instructions on how to adjust torque values in this table.)
Target Torque, N·m
Basic Thread Designation Noncoated Bolts [Note (1)] Coated Bolts [Notes (1), (2), and (3)]
M14-2 110 85
M16-2 160 130
M20-2.5 350 250
M24-3 550 450
M27-3 800 650
M30-3 1 150 900
M33-3 1 550 1 200
M36-3 2 050 1 600
M39-3 2 650 2 050
M42-3 3 350 2 550
M45-3 4 200 3 200
M48-3 5 100 3 900
M52-3 6 600 5 000
M56-3 8 200 6 300
M64-3 12 400 9 400
M70-3 16 100 12 200
M76-3 20 900 15 800
M82-3 26 400 20 000
M90-3 35 100 26 500
M95-3 41 600 31 500
M100-3 48 500 36 700
GENERAL NOTES:
(a) The values shown are based on a Target Prestress of 345 MPa (root area). See section 12 (Target
Torque Determination). The root areas are based on coarse-thread series for sizes M27 and
smaller, and 3-mm pitch thread series for sizes M30 and larger.
(b) There are many ways of calculating Target Torque values for bolted pressure joints. The basis for
the torque values in Table 1M are described in the Notes below. When conditions vary, such as dif-
ferent bolt materials or different coatings, from those considered in this table, refer to Appendix K,
or optionally to Appendix J, of these guidelines to compute appropriate torque values.
NOTES:
(1) The tabulated Target Torque values are based on “working” surfaces that comply with section 4
(Cleaning and Examination of Flange and Fastener Contact Surfaces) and section 7 (Lubrication of
“Working” Surfaces). The Target Torque values were computed using nut factors selected to achieve
a Target Prestress of 345 MPa. The torques were adjusted based on industry experience and veri-
fied by bolt elongation measurements.
(2) The coating on coated bolts is polyimide/amide and is considered to be the sole source of
“working” surface lubrication; the application of a lubricant to the coated surfaces can result in a
considerable reduction in the assumed coefficient of friction of approximately 0.12. (See
Appendix K for equivalent nut factor.)
--`,```,,`,,,```,,``,```,,`,,,,`-`-`,,`,,`,`,,`---
(3) Coated torque values apply only for initial tightening of new, coated bolts using the torque-
increment rounds shown in Table 2. For second and subsequent tightening by torquing methods,
use of lubricants and torque values as specified for noncoated bolts is recommended.
3
Copyright ASME International
Provided by IHS under license with ASME Licensee=Nghi Son Refinery & Petrochemical LLC/5989999001, User=Kimura, Toru
No reproduction or networking permitted without license from IHS Not for Resale, 08/16/2015 19:51:42 MDT