FLANGE GUARD INSTALLATION PROCEDURE

Doc. No.: AP-GSME-PL-CP-001 Total Pages: 16

CLIENT : PT. AIR PRODUCT INDONESIA

CONTRACTOR : PT. GREGAH SUKSES MANDIRI ENGINEERING

PROJECT NAME : SMIP Offsite Project

LOCATION : Sei Mangkei Industrial Park, Bosar Maligas,

Simalungun, North Sumatera,

JOB NO. : EN-24-1187

0 8/5-24 OT CHY CHY

REV DATE DESCRIPTION Prep Check App Rev Check Ap

PT. GSME PT. AP

TABEL OF CONTENT

Page 1 of 16
 No. Description Page
1.0 INTRODUCING 2
2.0 PURPOSE 2
3.0 SCOPE 2
4.0 REFERENCE 2
5.0 RESPONSIBILITY 3
6.0 SURVEY 3
7.0 COMPONENTS Of FLANGE INSULATON 4
8.0 TYPES Of INSULATING GASKET 4
9.0 INSTALLATION 8
10.0 FLANGE & SPECIFIED TO OTHER 11
11.0 ILLUSTRATION (Flange Guard Content Illustration) 15

Page 2 of 16
1.0. INTRODUCING
1.1. The safety protector & flange protector are relative simple product, it is
important to have a clear one understanding of what is needed (aims &
shields type) and which areas of the plant and pipes it passes through
need a shield.
1.2. Consideration of various issues is necessary to ensure success, otherwise the
protection project may encounter problems, usually during the survey,
installation phase, including in particular the location at the point where
the pipe flange meets the underground and above ground or at a later
date when additional protection is required.

2.0. PURPOSE
The purpose of flange isolation kits is to prevent the (electrolytic) corrosion of
flanges and flanged joints that static currents present on a piping system may
induce. The gasket isolation kit consists of a special gasket, isolation sleeves for
all the stud bolts and nuts, and special washers. Flange Insulation kits are
designed for electrically insulating the flange and act as an insulator between
dissimilar metallic flanges.

3.0. SCOPE
The scope of this procedure is to need isolate sections of pipework (dissimilar
metals) electrically in the cathodic protection systems. Thus preventing the
electrostatic charge flow along the pipelines as they remove the possibility of
galvanic cell system creation, then which specific pipe connections pose a
significant risk, flanges, valves, expansion joints, couplings, hoses. Including all
malicious processes protected line, perhaps the first priority should be whether it
is above concentration, pressure, or certain temperature.

4.0. REFERENCESE
4.1. Client properties/ AP Specification
SPEC-ENG-MS056
4.2. ASME PCC-1
Guidelines for Pressure Boundary Bolted Flange Joint Assembly

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 4.3. ASME B16.5
Butt Welding Ends
4.4. ASME B16.47
Large Diameter Steel Flanges
4.5. ASME B18.2.1.
Square and Hex Bolts and Screws
4.6. ASME B18.2.2.
Square and Hex Nuts
4.7. ASME B16.20
Metallic Gaskets for Pipe Flanges

5.0. RESPONSIBILITY
5.1. The QC Inspector shall be responsible for the maintenance of this
procedure.
5.2. The Field Supervisor shall be responsible for the monitoring process in
accordance with the requirements of this procedure.
5.3. The Project Manager or his designee shall be responsible for inspection and
documentation requirement in accordance with project requirements.

6.0. SURVEY
Safety shields are made to fit specific flange & fitting sizes. As such, for retrofits,
the next step is to perform a site survey.
6.1. Shield location and process line
Measuring a flange is easy enough but fitting a box full of shields is
impossible if you don’t know where they are supposed to go! We highly
recommend recording specific areas and pipe-runs within the plant. If
pipe-runs are complex, especially on the piping flanges meet between
underground and aboveground.
6.2. Individual flange and shield identification
Some customers create individual flange & shield ID tags. The ID schedule
makes routine inspection and replacement orders much easier. We can
supply individual tag numbers on the shield labels if requested.

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 6.3. Process information
For shield compatibility, it is critically important to note certain process
information:
■ Process liquid (eg. sulphuric, caustic, lube oil, fuel oil, steam, solvent etc)
■ Concentration if applicable
■ Maximum temperature
■ Maximum pressure (unless you already state pipe class, eg. 150lb)
6.4. Surveying and Installing
If the surveyor knows he/she are also installing the shields, they will generally
have a greater attention to detail, both in taking measurement and
location information.
6.5. Draiwing, photos and model/part numbers
We recommend that you take as much information as possible for non-
standard items. Noting down model/part number can help us in identifying
dimensions. Accompanying photographs or sketches are also very helpful.

7.0. COMPONENTS Of FLANGE INSULATON:

A typical flange insulation kit comprises
■ One central flat or oval section gasket,
■ One insulation sleeve per-bolt
■ Two insulating steel washers per-bolt
■ Two plated steel washers per-bolt

In order to achieve optimum results it is essential that Flange insulation kits

follow certain design criteria. The electrical resistance properties of the
components are balanced for the purpose and location in the insulation
system. The components are manufactured from insulation materials with high
compressive strength and good stability. Insulation kits are generally available
till 24 inches, but custom made higher nominal sizes can be produced on the
requirement.

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8.0. TYPES Of INSULATING GASKET
Four major types of gasket isolation kits that are are available in the market are
F, E, D, & O. Each type of flange kit fits flanges with a specific type of flange
faces (RF, FF and RTJ).
8.1. Type “F” Gasket
Type F isolation gaskets (ring type) fit raised face flanges (RF). The external
diameter of an F type gasket is smaller than the flange face surface.
Special band protectors can be added to the flanged joint to further
strengthen the cathodic isolation created by the flange isolation kit
(foreign material may accumulate otherwise). Type F gaskets are
manufactured from 1/8″ thick fabric based phenolic sheet either without
coating or a with a nitrile rubber coating on the two faces. Type F gaskets
are also available in non-asbestos fibers with high isolation capacity.

A= 3,2mm (1/8inch) Thick. Plated Steel Washer

B= 3,2mm (1/8inch) Thick. Insulating Washer

C= Full Length Insulating Sleeve

D= Inner Bolt Circle Gasket

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 8.2. Type “E” Gasket
Type “E” gaskets (full face type) have an outside diameter matching the
diameter of the flange, i.e. they cover the whole flange surface area. This
design helps to keep foreign material outside the flanged joint and
enhances the isolation properties of the kit. Type E flange insulation kits are
available in phenolic, neoprene-faced phenolic, and high temperature
materials.

A= 3,2mm (1/8inch) Thick. Plated Steel Washer

B= 3,2mm (1/8inch) Thick. Insulating Washer

C= Full Length Insulating Sleeve

D= Full Face Gasket

Page 7 of 16
 8.3. Type “D” Gasket
Type “D” isolation gaskets fit flanges with ring joint face, as they suit the ring
joint groove of RTJ flanges (style R, RX, and BX). Type D gaskets are
available in phenolic grade. This type of gasket is also called “API ring joint”.

A= 3,2mm (1/8inch) Thick. Plated Steel Washer

B= 3,2mm (1/8inch) Thick. Insulating Washer

C= Full Length Insulating Sleeve

D= Insulating Ring Type Joint

8.4. Type “O” Gasket

Type O Gaskets feature an extra sealing element on both sides of the
device, generally, PTFE, Nitrile or Viton Rubber, and are available in both
ring and full face design (type E and F). Type O Gaskets are manufactured
with phenolic and G-10 materials. The materials for insulation sleeves are,
by default, polyethylene or phenolic.

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9.0. INSTALLATION
9.1. Flange Insulation Kit
9.1.1. Check and Clean
Remove all the impurities and debris from gasket, fasteners (bolts,
studs, nuts) and washers. Check all fasteners (bolts, studs, nuts) and
washers, make sure they are free of defects like burrs and cracks.
Check the flange surfaces, make sure they are free of defects.
9.1.2. Align Flanges
Make sure the flanges and bolts’ holes coaxial coincide. Min flange
gap is 10 mm. Insert the gasket parallel and carefully. Do not use
jointing compounds, grease or lubricants with gasket and flange
surface. These compounds can affect the friction between the
gasket and the flange and can lead to premature joint failure.
9.1.3. Install Flange Kits
Apply bolt lubricant to the bolt and nut threads and to the face of
nut to be tightened, assembly the steel washer, insulation washer
and insulation sleeve to the bolts by turn (make sure the steel washer
always close to the nut). Insert the bolts holes. No force used (like
hammer), it will damage the sleeves. Please check the alignment of
flange surface and size of sleeve if installation it’s difficult. Put
insulator washer, steel washer and nut into bolts on another side of
flange. Tighten all the bolts until the flange meet the gasket.
9.14. Tightening
Please use calibrated torque wrench or other tool which have
control functions. Be installed in accordance with the
recommended torque. Tighten the nut always in accordance with
the symmetrical cross drawing.

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 There are 5 steps should be followed:
1) Initial tighten all nuts by hand, the big nut can us small wrench.
2) Tighten each nuts by 30% of recommended torque.
3) Tighten each nuts by 60% of recommended torque.
4) Tighten each nuts by 100% of recommended torque.
5) Tighten all nuts in clockwise direction to make sure all the nuts
reach required torque.

9.2. Flange Cover

Here are few steps to be followed when installing flange covers.
9.2.1. Selection of Best Flange Cover
Like different kinds of flanges, flange covers are also available in
varied dimensions, sizes, and materials. You can choose a flange
cover that is most suitable for your flange type depending upon your
flange thickness. Flange covers are usually made up of plastic and
are available in various categories like vinyl, polyethylene,
polyurethane, etc. The same goes for different types of flanges.
Some are made up of plastics like vinyl and composites, while many
of the flanges are made up of stainless steel to withstand corrosion
and any damage. Therefore, you can always choose from the
flanges that are best suitable for your needs. Some of the most
important factors to be considered while purchasing flange covers
are quality, durability, design, price, and resistance.
9.2.2. Installation of Flange Cover
Flange covers are straightforward to install, provided you follow all
the guidelines correctly. A wide range of flange covers is available
in the market based on different flange weights, thicknesses, and
dimensions. Once you select the perfect flange cover for your
flange system, it’s time you start working to install them. Installing
flange covers is quite an easy task. Here are a few steps or points for
installing the flange covers:

Page 10 of 16
 1. When you plan to install Flange covers, make sure you have all
the materials required and have worn proper safety equipment
gear. Wearing gloves is highly important while installing flange
covers to reduce the risk of hand damage, cuts, and abrasion.
2. It would help if you also had a proper flange cover guide and
design booklet before installing the covers. Ensure you follow all
the guidelines written in the booklet and strictly abide by the
manufacturer’s specifications. You can also remove and install
the flange covers with your hand or use any other kind of
specialized equipment.
3. Make sure your flanges are in good condition; if they are
corroded or so, firstly replace them with new flanges and then
install the flange cover.
4. Soft and flexible flange covers can be slid over the flange like a
sock, whereas those having stiff rings need to be installed by an
experienced worker. The use of pins can also fasten flange
covers.
5. You can also buy adhesive flange covers that do not require any
fasteners or bolts if you want. Therefore, it is easier to install without
any stress of fitting and tightening the bolts.
6. Some flanges also come with an interlocking design making the
DIY installation relatively easier and faster.
7. You can choose from varied ranges of flange dimensionsand
types. Some of the popular flange cover designs are Split flange
covers, push-in flange covers, whole face flange protectors, Self-
locking flange covers, Bolthole flange protectors, raised face
flange protectors, etc.

Installing flange covers requires a proper understanding of flange

wall thickness, flange dimensions, designs, and applications.
Different kinds of flanges have diverse requirements and are suitable
for various flange applications. Make sure you consult an expert
before e buying a flange cover for your flange system. You have to

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 choose from different kinds of materials based upon the
environment and type of flange used. After proper research and
consultation from a plumber or an expert, you can select the flange
cover that is best for you. Also, make sure you follow the proper
installation guide step by step and undertake all the safety
precautions like wearing gloves, avoid contact with eyes,
etc. Remember the most important rule – safety first!

10. FLANGE & SPECIFIED TO OTHER

The assembly drawings will indicate the bolt length, diameter and material
type and rating. Flange faces shall be cleaned to remove preservations and
the gasket surfaces shall be inspected for defects. Any rust or burrs shall be
removed using a hand wire brush and / or a hand file. Particular attention shall
be paid to seating for ring type joints.
10.1. Principles of Flanged Joint Assembly
1. Flange faces shall conform to the relevant specifications.
2. Flange faces and bolts holes are correct and free of any foreign
material.
3. Bolt holes of mating flanges shall be aligned using a spud wrench or
similar tool. Lateral alignment shall be checked by considering that
bolts and studs can be inserted without force and that the alignment
tool is not required to impart a significant force to achieve alignment.
4. Sealing faces flat, parallel, aligned properly and in good condition and
free of defects.
5. Gasket of the correct type shall be used and shall be in proper position.
Type, pressure rating, material and size of the gasket shall be checked.
6. Correct lubricated stud and nut material; correct stud length shall be
used.
7. Free-running studs and nuts, in good condition, free from corrosion and
thread damage shall be used.
8. For flanges installed on horizontal lines, in order to retain the gasket the
lower bolts should be installed first.

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 9. Parallelism of the flanges shall then be checked to confirm they
are within the tolerances as per the project specifications.
10. The remaining bolts and nuts shall be installed and hand tightened with
the flange faces parallel. Care should be taken to assure proper
seating and centring of the gasket within the allowable tolerances.
11. Bolts shall be tightened by torque wrench and inspected for tightness
in accordance with this procedure. Stud bolts should have an equal
protrusion through the nuts on both sides of the flanges of between 3
and 5 threads. Material, coating and size of the stud-bolts shall be
checked.
12. All flanges will be aligned so that the bolt holes straddle the natural
centre line.
13. Visually check the flanges for equal gap. If a larger gap appears on
one side of the flange, tighten the bolt, which corresponds with the
larger gap first.
14. The gaskets are then to be centered between the flanges. Nuts shall
be hand tightened to hold the gasket in place. When flanged joints are
in horizontal lines gaskets without centring devices such as ring joints,
shall be lowered to the bolts for retention and then raised into position.
15. Bolts and nuts shall be supplied with the precise specification.
16. If any doubts exist job shall be stopped and cross-reference shall be
with the responsible Engineer.
17. If any case of flange joints to be disturbed during or after testing shall
be replaced with gaskets.

10.2. Torqueing Specific

Torqueing Specific
1. Good quality lubricant shall be used. Erection, and Inspection, Testing
and Cleaning
2. Lubricant properly applied to Working surfaces only
3. Sequential tightening, in stages to 100 % of specified full load, using the
cross-bolt tightening method.

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 4. Flanges checked for squareness after each pass
5. Final tighten at 100 % of full load.

10.3. Gaskets

Gaskets shall be checked for size, rating, material specification and clean
lines before installation by qualified pipe fitters. Remove any grease, burrs
and rust from the gasket and trial fit against the flange gasket seating
surface. Under no circumstances should gasket compound or grease be
applied to the gasket or flange faces. Spiral Wound Gaskets shall not be
re-used, since not enough resilience is left in the gasket material to give a
leak-proof joint when compressed second time.
Gasket Preservation:
Gaskets and seal rings shall be;
1. Stored in their original packing until to be used
2. Kept horizontal and flat
3. Where applicable, left on their original packing until to be used

Installation of gaskets:
After pipe fitting, the two flange ends of a flanged joint are to be checked
for alignment by use of a precision level indicator placed touching the
two flanges. If the alignment values are within allowable ranges as
indicated in procedure, the lower bolts are first placed in place then
gasket will be placed from the upper side. If the gasket does not fit
smoothly into position pipe alignment is to be re-checked. Gasket shall
never be forced into position.
10.4. Bolting

Bolts shall be checked for correct length, diameter and conformance

with material specification. Studs and nuts shall have an approved
lubricant installed before installation. Only clean rust-free stud bolts and
nuts should be used for making up the flange joint. Bolts and nuts can only
be reused if it is known that they have not been over loaded or exceeded
their yield point. Material type stamp on the bolts should be in one
direction. Ensure that nuts are installed in the proper orientation.

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 The application of lubricants will have a substantial impact on the torque
applied. The lubrication properties vary from one lubricant to the other
and shall be taken into account when torque is applied. Hydraulic bolt
tensioning provides more uniform bolt stress and eliminates variations due
to different lubricant. On completion of the tightening activities, bolts
should extend 1 1/2 to 2 threads through their nuts.

10.5. Tightening
Torque wrenches shall be calibrated as per calibration schedule and
have a valid certificate that must be revalidated after the wrench has
been inspection and recalibrated. There are various types of tools
available to achieve the proper torque value. The manufacturer’s
instructions shall be followed for the operation and maintenance of all
Torque wrenches used to perform tightening procedure. The pressure on
the gasket shall be uniformly distributed in order to provide sealing
requirements. To make sure that, the bolts shall be tightened in the
following sequence:
1. Hand-tighten all nuts. (Place a duet tape around the circumference
of the flange and number all the bolts)
2. Tighten bolts according to proper sequence indicated in procedure
at 30 % of torque value.
3. Tighten another pair of bolts approximately 90° further round the
circumference.
4. Repeat steps 2 and 3 to 60 % of the required bolt stress.
5. Repeat steps 2 and 3 to 100 % of the required bolt stress.
6. Flange alignment is completed, inspected and accepted, gasket
can be placed in position.

10.5. Flange Tag Details

The flanged joints are uniquely numbered on isometric drawings
according to pneumatic test packs. The flanges need to be tagged in
order to be visibly traceable. Tags should be made from suitable non-
perishable material and shall contain following details,

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 1. Line Class
2. Joint Reference and size
3. Torque Value Applied as per Flange Protocol List
4. Assembled / Torqued By
5. Date and Signature
6. Remarks

11.0. ILLUSTRATION
(Some Illustration of Flange Insulation)

APPENDIX
(Flange Insulation Content)

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