FLANGE MANAGEMENT TRAINING PROGRAM

SATAH AL RAZBOOT FIELD DEVELOPMENT PROJECT PKG-4

HYUNDAI ENGINEERING AND CONSTRUCTION Co. LTD

June 2017

Prepared by:
Francisco Habon Jr

1
 FLANGE MANAGEMENT TRAINING PROGRAM

I. PURPOSE

The purpose of this internal training program is to train HDEC pe

rsonnel involved in all Flange Management Inspection by providi
ng sufficient knowledge in flange face inspection, bolt torqueing
and tensioning.

This training will focus on the project specification, procedures,

method statement and general practices.
FLANGE MANAGEMENT TRAINING PROGRAM

II. REFERENCE PROCEDURES, SPECIFICATIONS, AND CODES

1. Procedures & Method Statement s

AD204-600-G-09513 Rev 0 Flange Management System
AD204-600-G-09690 Rev B Method Statement for Bolt Tensioning and Torqueing

2. Project Specifications
AD204-600-G-02727 Rev 2 Piping Classification Addendum to SP 1131

3. Governing Codes
ASME B16.5 Pipe Flanges and Flanged Fittings NPS ½” Through NPS 24
ASME B16.47 Large Diameter Steel Flanges NPS 26” Through NPS 60
ASME/ANSI B107.14 Hand Torque Tools
PFI ES 03 Fabricating Tolerances
ASME PCC-1-2010 Guidelines for Pressure Boundary Bolted Flange Joint Assem
bly
FLANGE MANAGEMENT TRAINING PROGRAM

III. TRAINING PARTS

A. Flange Face Inspection

1. General Requirements
2. Permissible Imperfections
3. Fabricating Tolerance
4. IPCS Report
B. Bolt Torqueing
1. General Requirements
2. Recommended Bolt Torqueing Sequence
3. Torque Values
4. IPCS Report
C. Bolt Tensioning
1. General Requirements
2. Assembly Instruction
3. Tension Values
4. IPCS Report
FLANGE MANAGEMENT TRAINING PROGRAM

A. FLANGE FACE INSPECTION

General Requirements
The following criteria shall be checked prior to closing flange mating parts:

 Check internal cleanliness prior to bolt tightening.

 For orifice flanges, ensure that internal flush grinding is completed prior to bolt tightening.
 Check materials in accordance to approved ISO drawings:
a. Gasket type, size, color code
b. Bolt size, grade, length, color code
c. Flange type, rating, size
 Check the flange face condition prior to bolt tightening. It must be clean and free from damag
es. (See ASME B16.5 Table 3. Permissible Imperfections in Flange Facing Finish)
 Ensure alignment is acceptable prior to bolt tightening. (Refer to PFI ES-3)
FLANGE MANAGEMENT TRAINING PROGRAM
GUIDELINES FOR DEFECTS as per ASME PCC-1-2010
FLANGE MANAGEMENT TRAINING PROGRAM

ASME PCC-1-2010 Appendix-E

FLANGE MANAGEMENT TRAINING PROGRAM

FLANGED JOINT ALIGNMENT GUIDELINE

ASME PCC-1-2010 Appendix-E

FLANGE MANAGEMENT TRAINING PROGRAM
ASME B16.5 Table-3 (Permissible Imperfections in Flange Facing Finish)
FLANGE MANAGEMENT TRAINING PROGRAM

Fabricating Tolerance: Refer to PFI-ES-3 Fig 1

FLANGE MANAGEMENT TRAINING PROGRAM

IPCS Report

Review Points for Flange Face Inspection Report:

 ISO Dwg. No.

 Revision
 Material class
 Flange size
 Stage of inspection
 Gasket type
 Bolt/Nut size, grade, length
FLANGE MANAGEMENT TRAINING PROGRAM
IPCS Report

SAMPLE: FLANGE FACE INSPECTION REPORT

FLANGE MANAGEMENT TRAINING PROGRAM
B. BOLT TORQUEING
General Requirements/Check points for Bolt Torqueing:
 Basic Requirements for Bolt Torqueing:
 Bolt sizes less than 1.25” are required bolt torqueing.
 Bolt torqueing can proceed only if Flange Face Inspection is completed.
 Bolt length shall be evenly distributed.
 Bolt torqueing shall be carried out as per AD204-600-G-09690 (Method St
atement for Bolt Tensioning/Torquing):
FLANGE MANAGEMENT TRAINING PROGRAM
Recommended Bolt Torqueing Sequence
FLANGE MANAGEMENT TRAINING PROGRAM
Torque Values
 Torque values shall be in accordance to Appendix A of AD204-600-G-02725.
 For GRE piping, torque values shall be as per vendor’s recommendation.
 For Kroll & Ziller type gasket, torque values shall be as per vendor’s
recommendation.

Bolt torque value for Glass-Fiber Reinforced Epoxy as per FPI

recommendation.
FLANGE MANAGEMENT TRAINING PROGRAM

SAMPLE: BOLT TORQUING INSPECTION REPORT

FLANGE MANAGEMENT TRAINING PROGRAM

General Requirements/Check Point for Bolt Tensioning:

 Bolt sizes 1.25” and larger are required bolt hydraulic bolt tensioning.
 Prior to tensioning bolts, hydraulic pump, interconnection hose, bridge, puller,
head and socket shall be checked for any damage or imperfections.
 Bolt tensioning can proceed only if Flange Face Inspection is completed.
 Soft brushing of stud bolts and nuts will be required to remove solid particles.
 Bolt tensioning shall be carried out as per AD204-600-G-09690 (Method
Statement for Bolt Tensioning/Torqueing)
 Always check calibration certificates of the gage installed on the hydraulic pump.
FLANGE MANAGEMENT TRAINING PROGRAM

Assembly instructions:

 Bolts shall be free running and in good engagement with the tensioner.
 Assemble the bolt with minimum one bolt diameter on the end to be
tensioned and minimum one thread at un-tensioned end.
 Position the socket over the hexagon nut
 Place the hydraulic head and bridge assembly over the bolt.
 Locate the end of the bolt with the puller and screw down onto the ram.
 Connect the hydraulic coupling. Apply the tightening oil pressure. Turn the
hexagon nut using a tommy bar until the nut tightens onto the flange.
 Remove the tool.
Above instruction shall be repeated as per the tensioning plan until all bolts are
evenly tensioned.
FLANGE MANAGEMENT TRAINING PROGRAM

Assembly instructions: (by HI-FORCE)

FLANGE MANAGEMENT TRAINING PROGRAM
FLANGE MANAGEMENT TRAINING PROGRAM
FLANGE MANAGEMENT TRAINING PROGRAM

Tension Values:

 The amount of pressure to be set on the hydraulic pump is calculated by

using vendor software (Asset55). The parameters considered for calculation
are as follows:

1. Flange spec/type/size/rating/facing
2. Gasket type
3. Bolt Qty., thread type, grade
4. Operating service conditions
5. Decision b/n 50% or 25% depending on availability of load
cells
FLANGE MANAGEMENT TRAINING PROGRAM

Snap shot of Asset 55 for calculating pressure to be applied on the hydraulic pump.
FLANGE MANAGEMENT TRAINING PROGRAM

Tension Values: Sample calculated tension value

Pass 1 Pass 2 Pass 3 Pass 4
/Check Pass

Tension 480 380 Note 1 Note 2

Tool Press
ure
1500 1000 Note 1 Note 2

Note 1 Values available for 25%

Note 2 Value for checking Pass 1, 2, &3. Equivalent to Pass 4

Acceptance Criteria:
Tensioning is acceptable after application of check pass to
Pass 1, 2, & 3 and all nuts are tight. If found loose, the whole
sequence shall be repeated until check pass is satisfied.
FLANGE MANAGEMENT TRAINING PROGRAM

Decision of tensioning percentage/pass

FLANGE MANAGEMENT TRAINING PROGRAM
SAMPLE: BOLT TENSIONING INSPECTION REPORT
FLANGE MANAGEMENT TRAINING PROGRAM
Flange Traceability Identification Tagging

An identification tag shall be installed on every flange joint after the completing the
torque/tensioning work displaying the joint number, torque value applied, tightening
technician and date of joint torque completed.

This requires the joint to be physically tagged so that its identity is clear and visible at
the joint location including a unique Joint ID number in order that it can be
recognized the joint database in IPCS.
FLANGE MANAGEMENT TRAINING PROGRAM
FLANGE MANAGEMENT TRAINING PROGRAM
IPCS DATA CONTROL

Flange Face Inspection

Step 2. Enter joint information

Step 1. Select joints to notify
Step 3. Notify for inspection

- Input all data for Bolt Torqueing except torqueing value (by construction)
FLANGE MANAGEMENT TRAINING PROGRAM

Step 4. QC input inspection

result
FLANGE MANAGEMENT TRAINING PROGRAM

Steps 1,2,3 & 4 above shall be repeated for

Bolt Torqueing/ Tensioning considering the
following stages:
 Flange Inspection= For Flange Face Inspection
 Construction= For Bolt torqueing / tensioning
 Reinstatement= After Hydro test
 Commissioning= for flanged joints dismantled
and reinstated by commissioning team (mostly
for cleaning purposes)