Flange Management Procedure Fix - Copy

Document Title:

Flange Management Procedure

COPI Doc No.:

ID-G-BU-XXXXX-XXXXX-XXXXX

Originator: COPI Group Owner: Area: Location: System: Document Type: Discipline / Subdiscipline: Old COPI Document No.:

0A

IFC

18 June 2012

Rev

Status

Issue Date

PT. Wijaya Karya (Persero). Tbk Engineering-Onshore Sumatra Suban Suban Station General Flange Management Procedure Piping / Piping

Issued for Comment

Reason for Issue

AR

FAD

AGN

Prepar ed

Check ed

Approval

MER / HS OEE / Project Approvals

Printed initials in the approval boxes confirm that the document has been signed. The originals are held within Document Management.

Unit Owner

Flange Management Procedure Piping /piping ConocoPhillips Indonesia

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Revision Sheet ConocoPhillips Indonesia Inc. Ltd

REVISION

DATE

0A

18 June 2012

DESCRIPTION OF CHANGE Issued for Comment

Flange Management Procedure Piping /piping ConocoPhillips Indonesia

Contents 1. Purpose 2. Scope 3. Reference 4. Safety Precautition 5. Equipment and man power 5.1. Equipment 5.2. Man power 6. Bolt Tightening 6.1. Tightening Preparation 6.2. Recommended Bolt Tightening Procedure 6.3. Table for Bolt Tightening 7. Appendix

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Flange Management Procedure Piping /piping ConocoPhillips Indonesia 1

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PURPOSE 1.1. This procedure describes the requirement for bolt tightening for piping system perform by Wika in accordance with Company in the scope of contract of Suban Condensate Tank.

2

SCOPE

2.1. The procedure defines the method for bolt tightening using manual/hand torque wrench, hydraulic torque wrench and hydraulic stud bolt tensioner.

2.2. Application of bolts tightening tool shall be done as per the following scope : Bolt Diameter < 2” : General torque wrench (Manual/hand Torque Wrench or Hydraulic torque wrench if applicable)

3

4

REFERENCE 3.1.

ASME B16.5 Pipe,Flange, and Fitting

3.2.

ASME B16.47 Large Diameter Steel Flange

3.3.

ASME B31.3 Proses Piping

3.4.

Manufacture Recommended (Hi-Force)

SAFETY PRECAUTIONS Special attention shall be paid to this work as it utilizes high-pressure hydraulic oil (maximum 15,000 psi). Supervisor must be present at location to supervise the worker prior to bolt tightening activity. Tools and equipment should be inspected before use to ensure good working condition. The working area shall be roped off and warning notices shall be displayed. For high elevation or remote area work, adequate scaffolding shall be erected for safety. Operators shall handle components during placing or removing the bolt tightening equipment as per manufacturers recommendation. Operators shall also be equipped with safety glasses, hard hats, gloves and safety shoes. Additional safety equipment shall be worn as advised by the Project HSE Department.

Flange Management Procedure Piping /piping ConocoPhillips Indonesia

5

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EQUIPMENT AND MAN POWER 5.1

Equipment a. Hi-Force Including Accessories.

5.2

6

b.

Manual/Hand Torque Wrench

c.

Hand Tools

Manpower a.

Mechanical Supervisor

b.

Safety man

c.

Mechanic/Helper

BOLT TIGHTTENING 6.1

Tightening Preparation a. Flanged joints shall be properly aligned before torquing and maximum allowable translation of flange centerline & faces should be specified. Maximum allowable run out’ between flange faces should also be specified. (To be noted as max values/tolerances according to the relevant spec’s). see Appendix for dimensional tolerance. b. Prior to tightening, all equipment shall be checked for any damage or imperfections. After cleaning, studs should be lubricated with an approved compound. c.

The operator shall set the correct hydraulic pressure to achieved the required bolt torque for each stud bolt size according to appendix 1 (recommended tensioning pressure table).

d. COMPANY reserves the right to witness the applied pressure for the torquing of the joint during reinstatement 6.2

Recommended Bolt Tightening Procedure a. Install the gasket on the flange face and bring the flanges together until contacting the gasket. b. Install all bolts and studs, making sure they are free from dirt and grit and that the threads and under nut faces are well lubricated. c.

Run up nuts finger tight

d. Mark the proper tightening sequence on the studs with chalk as per diagram on Para 5.3 or as per recommended by the equipment manufacturer e. Determine the torque value for the studs or bolt to be tightened. 1. First tightening stage should be limited to a maximum of 30% of final torque setting.

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2. Second tightening stage should be limited to a maximum of 60% of final torque setting. 3. Third tightening stage should be carried out at the 100% torque setting. Note : 1, 2 & 3 should be tightened using the diagonal bolt sequence shown in the diagram f.

On the fourth and final tightening sequence change from diagonal tightening to adjacent bolt-to-bolt tightening using the 100% torque setting value

6.3

Table for Bolt Tightening a. For 4 set Bolt Flange STAGE

TORQUE SETTING

BOLT SEQUENCE TIGHTENING

I

30%

1-2-3-4

II

60%

4-3-2-1

III

100%

1-2-3-4

IV

100%

3-4-1-2

REMARKS

b. For 8 set Bolts Flange STAGE

TORQUE SETTING

BOLT SEQUENCE TIGHTENING

I

30%

1-2-3-4;5-6-7-8

II

60%

8-7-6-5;4-3-2-1

III

100%

1-2-3-4;5-6-7-8

IV

100%

2-6;1-5;4-8;3-7

REMARKS

Flange Management Procedure Piping /piping ConocoPhillips Indonesia c.

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For 12 set Bolt Flange

STAGE

TORQUE SETTING

BOLT SEQUENCE TIGHTENING

I

30%

1-2-3-4;5-6-78;9-10-11-12

II

60%

12-11-10-9:8-76-5-;4-3-2-1

III

100%

1-2-3-4;5-6-78;9-10-11-12

IV

100%

8-5-12;7-6-11;42-10;3-1-9

REMARKS

d. For 16 set Bolt Flange STAGE

TORQUE SETTING

BOLT SEQUENCE TIGHTENING

I

30%

1-2-3-4;5-6-7-8;9-1011-12;13-14-15-16

II

60%

16-15-14-13;12-1110-9:8-7-6-5-;4-3-2-1

III

100%

1-2-3-4;5-6-7-8;9-1011-12;13-14-15-16

IV

100%

1-12-8-13;2-11-714;3-9-5-15;4-10-6-16

REMARKS

e. For 20 set Bolt Flange STAGE

TORQUE SETTING

BOLT SEQUENCE TIGHTENING

I

30%

1-2-3-4;5-6-7-8;910-11-12;13-14-1516;17-18-19-20

II

60%

20-19-18-17;16-1514-13;12-11-109;8-7-6-5;4-3-2-1

III

100%

1-2-3-4;5-6-7-8;910-11-12;13-14-1516;17-18-19-20

IV

100%

8-1-20-12;7-2-1911;6-4-18-10;5-317-9;16-15-14-13

REMARKS

Flange Management Procedure Piping /piping ConocoPhillips Indonesia

f.

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For 24 set Bolt Flange STAGE

TORQUE SETTING

I

30%

II

60%

III

100%

IV

100%

BOLT SEQUENCE TIGHTENING 1-2-3-4;5-6-78;9-10-1112;13-14-1516;17-18-1920;21-22-2324 24-23-2221;20-19-1817;16-15-1413;12-11-109;8-7-6-5;4-32-1 1-2-3-4;5-6-78;9-10-1112;13-14-1516;17-18-1920;21-22-2324 3-5-21-13;46-22-14;1716-1-9;18-152-10;24-1220-8;23-1119-7

REMARKS

Flange Management Procedure Piping /piping ConocoPhillips Indonesia

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g. For 28 set Bolt Flange STAGE

TORQUE SETTING

I

30%

II

60%

III

100%

IV

100%

BOLT SEQUENCE TIGHTENING 1-2-3-4;5-67-8;9-10-1112;13-14-1516;17-18-1920;21-22-2324;25-26-2728 28-27-2625;24-23-2221;20-19-1817;16-15-1413;12-11-109;8-7-6-5;4-32-1 1-2-3-4;5-67-8;9-10-1112;13-14-1516;17-18-1920;21-22-2324;25-26-2728 17-13-3-5-925;18-14-4-610-26;16-208-1-28-11;1519-7-2-2719;21-22-2324

REMARKS

Flange Management Procedure Piping /piping ConocoPhillips Indonesia

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h. For 32 set Bolt Flange

STAGE

TORQUE SETTING

I

30%

II

60%

III

100%

IV

100%

BOLT SEQUENCE TIGHTENING 1-2-3-4;5-67-8;9-10-1112;13-14-1516;17-18-1920;21-22-2324;25-26-2728,29-30-3132 32-31-3029;28-27-2625;24-23-2221;20-19-1817;16-15-1413;12-11-109;8-7-6-5;4-32-1 1-2-3-4;5-67-8;9-10-1112;13-14-1516;17-18-1920;21-22-2324;25-26-2728,29-30-3132 32-6-2414;31-5-2313;30-7-2215;29-8-2116;28-4-1810;27-3-209;26-1-1712;25-2-1811

REMARKS

Flange Management Procedure Piping /piping ConocoPhillips Indonesia

7

APPENDIX 7.1

Recommended flange bolt torque.

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Appendix 7.1.

7.1 Size ½” ¾” 1” 1 ½” 2” 3” 4” 6” 8” 10” 12” 14” 16” 18” 20” 24”

7.2

Size ½” ¾” 1” 1 ½” 2” 3” 4” 6” 8” 10” 12” 14” 16” 18” 20” 24”

Recommended flange bolt torque for ANSI 150 RF Bolt Size U-1/2 U-1/2 U-1/2 U-1/2 U-5/8 U-5/8 U-5/8 U-3/4 U-3/4 U-7/8 U-7/8 U-1 U-1 U-1 1/8 U-1 1/8 U-1 1/4

Min Torque 0.16 0.24 0.33 0.65 0.64 1.10 1.57 2.14 3.09 3.6 4.91 5.15 6.5 7.63 9.11 13.84

Max Torque 3.61 3.61 3.61 3.61 7.2 7.2 7.2 12.84 12.84 20.72 20.72 31.09 31.09 45.83 45.83 64.61

Bolting Torque (Kg.m) Adopted Step 1 Torque 2.0 1.0 2.0 1.0 2.0 1.0 2.0 1.0 5.0 1.0 5.0 2.0 5.0 3.0 8.0 3.0 8.0 4.0 11.0 5.0 12.0 6.0 17.0 6.0 18.0 8.0 26.0 9.0 27.0 10.0 39.0 15.0

Step 2 2.0 2.0 2.0 2.0 5.0 5.0 5.0 8.0 8.0 11.0 12.0 17.0 18.0 26.0 27.0 39.0

Recommended flange bolt torque for ANSI 300 RF

Bolt Size U-1/2 U-1/2 U-1/2 U-1/2 U-5/8 U-5/8 U-5/8 U-3/4 U-3/4 U-7/8 U-7/8 U-1 U-1 U-1 1/8 U-1 1/8 U-1 1/4

Min Torque 0.38 0.70 0.97 2.30 1.50 3.08 4.41 5.00 8.48 9.79 14.79 13.58 19.04 19.85 23.72 38.86

Max Torque 3.61 7.2 7.2 12.84 7.2 12.84 12.84 12.84 20.84 31.09 45.83 45.83 64.61 64.61 64.61 116.25

Bolting Torque (Kg.m) Adopted Step 1 Torque 2.0 1.0 4.0 1.0 4.0 2.0 8.0 3.0 5.0 3.0 8.0 4.0 9.0 5.0 10.0 6.0 15.0 10.0 22.0 11.0 30.0 16.0 30.0 15.0 32.0 20.0 32.0 21.0 33.0 25.0 76.0 40.0

Step 2 2.0 4.0 8.0 5.0 8.0 9.0 10.0 15.0 22.0 30.0 30.0 32.0 32.0 33.0 76.0

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7.3 Recommended Flange bolt torque for ANSI 600 RF

Size ½” ¾” 1” 1 ½” 2” 3” 4” 6” 8” 10” 12” 14” 16” 18” 20” 24”

Bolt Size U-1/2 U-1/2 U-1/2 U-1/2 U-5/8 U-5/8 U-5/8 U-3/4 U-3/4 U-7/8 U-7/8 U-1 U-1 U-1 1/8 U-1 1/8 U-1 1/4

Min Torque 1.26 2.31 3.17 7.55 4.92 10.12 16.91 21.92 35.63 40.21 53.98 54.50 75.04 84.76 101.28 159.55

Max Torque 3.61 7.2 7.2 12.84 7.2 12.84 20.72 31.09 45.83 64.61 64.61 87.92 116.25 150.08 236.21 289.49

Bolting Torque (Kg.m) Adopted Step 1 Torque 3.0 2.0 6.0 3.0 6.0 4.0 12.0 8.0 6.0 6.0 12.0 11.0 19.0 17.0 30.0 23.0 44.0 36.0 60.0 41.0 80.0 55.0 100.0 56.0 120.0 76.0 120.0 86.0 200.0 102.0 250.0 160.0

Step 2 3.0 6.0 6.0 12.0 6.0 12.0 19.0 30.0 44.0 60.0 60.0 80.0 100.0 120.0 120.0 200.0