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Flange Joint Bolt Tightening Procedure

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Document Title

: PHE-ONWJ-G-PRC-0016

: Flange Joint Bolt Tightening Procedure

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Flange Joint Bolt Tightening Procedure

Table of Contents

CONTENTS ..................................................................................................................... 3

1.

SCOPE ................................................................................................................. 5

2.

REFERENCE ........................................................................................................ 5

3.

SAFETY ............................................................................................................... 5

4.

GENERAL GUIDELINES ..................................................................................... 6

4.1.

Flange System ........................................................................................................ 6

4.2.

Flange Elements ..................................................................................................... 6

5.

METHOD .............................................................................................................. 6

5.1.

Hand Wrench / Manual Torque Wrench . ................................................................ 6

5.2.

Hydraulic Torque Wrench / Bolt Tension ................................................................. 7

6.

CALIBRATION ..................................................................................................... 7

7.

PERSONNEL ....................................................................................................... 7

8.

TOOL FITTING OPERATION ............................................................................... 7

8.1.

Manual Torque Wrench ........................................................................................... 7

8.2.

Hydraulic Torque Wrench ........................................................................................ 8

8.3.

Hydraulic Bolt Tension ...........................................................................................10

9.

ELONGATION MEASUREMENT ....................................................................... 11

10.

FLANGE FIT-UP AND BOLT PREPARATION .............................................. 13

10.1.

Preparation for Bolt-up .......................................................................................13

10.2.

Pre-Assembly of Flanges ...................................................................................14

11.

FLANGE BOLT TIGHTENING SEQUENCE ................................................... 15

11.1.

Torque Tightening Dos & Donts ........................................................................17

11.2.

Bolt Tensioning

Dos and Donts ......................................................................18

Figure 5 ........................................................................................................................ 19

Figure 6 ........................................................................................................................ 20

Figure 7 Typical Criss -Cross Bolting Tightening Sequence for bolts 24 & bolts

28 .................................................................................................................................. 21

Figure 8 Typical Criss -Cross Bolt Tightening for bolts 32 .................................. 22

Figure 9 Typical Criss -Cross Bolt Tightening Sequence for bolt 36 ................. 23

Figure 10 Typical Criss-Cross Bolt Tightening Sequence for bolts 40 ............. 24

Figure 11 Typical Criss -Cross Bolt Tightening Sequence for bolts 44 .............. 25

Figure

12 Typical Criss -Cross Bolt Tightening Sequence for bolts 48 .............. 26

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Flange Joint Bolt Tightening Procedure

Figure 13 Typical Criss -Cross Bolt Tightening Sequence for bolts 52

............. 27

Appendix A .................................................................................................................. 28

Appendix B .................................................................................................................. 29

Appendix C .................................................................................................................. 30

Appendix D .................................................................................................................. 31

Appendix E ................................................................................................................... 32

Appendix F ................................................................................................................... 37

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Flange Joint Bolt Tightening Procedure

1. SCOPE

This Procedure covers flange joint tightening by means of a hydraulic torque wrench, and using

manual torque wrench (click or break back torque wrench), Torque Wrench and Bolt Tension for

Pressure vessel and Piping components for new construction and existing installations

pressurized equipment (up to 2500#).

2. REFERENCE

ANSI / ASME B16.5

: Pipe Flanges and Flanged Fittings

ASME-PCC-1-2000

: Guidelines for Pressure Boundary Bolt Flange Joint

Assembly

ANSI/ASME Sect. VIII

: Rule for Construction of Pressure Vessel

ANSI/ASME B31.3

: Chemical Plant and Petroleum Piping

ANSI/ASME B31.4

: Pipeline Transportation System for Hydrocarbon and

Other Liquid

ANSI/ASME B31.8

: Gas Transmission and Distribution Piping System

PHE ONJW-G-PRC-0148 : Joint Integrity Testing for Pipework and Equipment

3. SAFETY

Hydraulic power tools enable the user to more easily accomplish bolting tasks with increased

force, accuracy and efficiency.

Due to the nature of the tools, with large forces generated, and for hydraulic torque equipment

from high-pressure fluid/air and electricity

strict safety issues are followed through the tools

proper design and documentation. However the user must accept the primary responsibility for

safety when using torque tightening tools by carrying out site related risk assessments, and

reading, understanding and complying with all operating instructions prior to and during

operation.

This procedure is aimed to give proper instruction for use and care of hydraulic & manual tools

and to play a major role in preventing accidents and increasing safety.

Only technicians trained and competent in the use of bolt tightening equipment, who have

completed a recognized competence assessment programmed, shall carry out the controlled

breakout and tightening of bolted joints.

Technician shall be fully conversant with the safe use of the tools and their operating procedures

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Flange Joint Bolt Tightening Procedure

4. GENERAL GUIDELINES

4.1. Flange System

Structurally, the bolts in a flange system can be considered as heavy springs clamping the

rings together in order to maintain a gasket seal. The design for bolted flange connections

considers the proportioning of the bolting, ie. the number and size of bolts, as one of the

most important factors.

In assembling flanged joints, the gasket shall be uniformly

compressed to the proper design loading.

Special care shall be used in assembling

flanged joints in which flanges have widely differing mechanical properties.

The combination of temperatures and thermal expansion coefficients of the flanges and

bolts during service may provide a leaking joint as a result of bolts loosening or creep.

4.2. Flange Elements

The three elements of the system, i.e. gasket, bolting and flange rings, are equally

important as any one can cause a failure i.e. leakage (for example):

a.

Choose the wrong gasket and you may never be able to get a tight joint.

b. Over strength bolts on an incorrect tightening procedure could lead to excessive

flange rotation and thus leakage. The under strength bolts can easily be yielded

without seating the gasket.

c.

An incorrectly proportioned flange ring can give excessive rotation which evens a

change of gasket may not be able to accommodate.

5. METHOD

In general, the selection of the torquing device used to assemble a flanged joint as well as the

method of control. The methods depend either on using torque to produce the bolt end load, or a

stretching technique.

The accuracy of the torquing techniques depend largely upon the

operator's experience and are more susceptible to the quality of the stud and nut surfaces, and

the degree of lubrication. They must be considered a labour saving device the area not enters

reliable as mean of achieving even bolt tension. However, evenness of bolt load can be

considered to be at least as good as that achieved with a spanner and hammer. Therefore only

an experienced and qualified crew should be employed.

5.1. Hand Wrench / Manual Torque Wrench .

Manual torque wrench which is normally rated to a maximum output of 300 Nm and has a

square drive. The wrench contains a mechanism that clicks when the required torque

value is achieved.

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Flange Joint Bolt Tightening Procedure

The manual method bolt tightening using Manual torque wrench or torque wrench will be

applied for bolt nominal diameter below 25mm (1 Inch).

5.2. Hydraulic Torque Wrench / Bolt Tension

The Hydraulic torque wrench or Bolt tension equipment will be used for bolt with nominal

diameter 25 mm (1 Inch) and over.

Hydraulic torque wrench with interchangeable square drive and hexagon cassettes which

are normally powered by an air or electric operated pump unit up to a maximum operating

pressure of 10000 psi.

For flange connections with bolting of nominal diameter 25 mm (1 inch) and over,

tightening shall be using Torque Wrench or Bolt Tension. For sequence bolt tightening

shall have sufficient clearance and access to allow the use of hydraulic torque wrench

equipment.

6. CALIBRATION

The Torque wrench must be in good working order and have a calibration certificate valid for the

date of the task. If the wrench has no valid certificate, it shall be re-calibrated or changed. If the

wrench is dropped or knocked during process then verify the calibration before proceeding, and

for hydraulic Torque Wrenches The pump must have a calibration certificate valid for the date of

the task. If the pump has no valid certificate, it shall be re-calibrated or changed.

7. PERSONNEL

Only technicians trained and competent in the use of bolt tightening equipment, who have

completed a recognized competence assessment programmed, shall carry out the controlled

breakout and tightening of bolted joints.

8. TOOL FITTING OPERATION

8.1.
1.

Manual Torque Wrench

Square drive tools only: check that the correct size impact socket has been selected

and that it has a retaining ring and pin.

2.

Check that the square drive is in the correct position for tightening operations.

3.

Attach the impact socket and secure it with the retaining ring and pin.

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Flange Joint Bolt Tightening Procedure

4.

Spigot drive tools only: check that the correct size of open end or ring attachment has

been selected for the relevant wrench and that it is fitted correctly.

5.

Adjust torque setting for the wrench by turning the handle or nut at the end of the

wrench clockwise to increase the spring tension, which will increase the torque value.

Turning the handle counter clockwise will reduce the spring tension, which will reduce

the torque output.

6.

The torque value selected will be visible either on a graduated scale inside a window of

the handle on smaller click type wrenches or a graduated scale on the end of larger

break back wrenches.

7. Fit the wrench via the socket or spigot fitting to the application .

8.

Position feet apart with one foot in front of the other.

9.

Prepare body for sudden movement in case of ratchet or wrench slippage or back nut

turning.

10. When using larger manual torque wrenches, assistance may be required to pull the

wrench safely. If assistance is not available or the activity cannot be completed safely

then the hydraulic torque tightening method should be used.

11. Pull the wrench clockwise towards the body using both hands, applying a steady force

and constant load.

12. Continue tightening operations by pulling the wrench clockwise until maximum travel or

the torque value is achieved by activating the click or linkage mechanism.

13. Repeat steps 7 to 12 for all bolts/nut to be tightened.

14. After use, reset the torque setting to zero prior to storing the wrench, this helps to

maintain the calibration of the wrench.

Note:

o
o
o

Do not activate the wrench by pulling erratically

Backing spanners must be secured to prevent accidental release by being tied off or

other methods. Backing spanners also introduce pinch points.

When using larger manual torque wrenches assistance may be required to pull the

wrench safely.

8.2. Hydraulic Torque Wrench

1.

Ensure that the power console is full of hydraulic oil and, if an air power console is

being used, that the air lubricator has sufficient oil in it

2.

Make sure that all air and hydraulic couplings are clean and free from dirt.

3.

Square drive tools only: check that the correct size impact socket has been selected

and that it has a retaining ring and pin.

4.

Check that the square drive is in the correct position for tightening operations.

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Flange Joint Bolt Tightening Procedure

5.
Attach
6.

the impact socket and secure it with the retaining O ring and pin.

Position the reaction arm for the best angle and safe operation. Then engage the

retaining device.

7.

Hex head tools only: check that the correct size hex head has been selected for the

relevant power head and that it is fitted correctly.

8.

With the tool removed from the flange and safely positioned on the ground, connect the

hydraulic hoses to the tool and the power console via the quick release fittings

ensuring that all locking collars/thumbscrews are fully tightened.

9.

Connect the pump to an air supply with whip checks and pins at all connections. Switch

on air supply and check system for leaks.

10. The torque wrench is operated via a remote control pendant which is connected to the

pump unit. To extend the actuator depress the actuator extend control button until the

actuator makes a complete stroke then release to allow the actuator to return.

11. Ensure that the torque tool is removed from the flange. Then proceed to set the pump

to the required pressure for tightening by turning the torque control valve clockwise to

increase pressure or counter clockwise to decrease pressure while actuating the tool

until the required pressure is displayed on the pump calibrated pressure gauge.

Note:

Always remove the tool from the flange and place on a surface where reaction will not be

possible when setting/altering the pump pressure or adjusting reaction points!

For two-man operation, ensure the communication procedure is clear and understood before

proceeding.

12. Fit the tool onto the bolt via the nut, ensuring that correct and safe reaction is achieved.

Figure

1 Torque Wrench Equipment

Note:

Pinch points are present around all reaction areas and in tight spaces. Hands and fingers must be kept clear

from pinch points at all times.

13. To tighten the nut, depress the actuator extend control button until the actuator makes

a complete stroke then release to allow the actuator to return. Continue to stroke the

actuator for further strokes until the required torque load and pump pressure is

achieved and the nut is tight.

Note:

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Flange Joint Bolt Tightening Procedure

If the back nut begins to move while tightening a backing spanner must be fitted to

the nut reacting off the next adjacent nut to prevent turning. Backing spanners must

be secured to prevent accidental release by being tied off or other methods.

Backing spanners also introduce pinch points.

8.3. Hydraulic Bolt Tension

1. All flanges and bolts shall be prepared and preassemble prior to tensioning as specified

as section 10.

2. The tension device must engage the threads on the stud bolt for a length equal to a

minimum of 80% of the stud diameter.

3. On the application where several bolts are tensioned simultaneously, all tensioning

equipment shall be connected to the same hydraulic pump.

4. When bolts need to be stressed near their yield point, torquing methods shall be

considered since tensioning requires overtensioning to compensate for short term

relaxation.

5. Stud bolt tensioner shall be used simultaneously in sets of four in the order indicated in

figure 2 through figure 13,(e.g tensioners shall be attached to stud bolts 1 thru 4,

tensioner, then m oved to stud bolts 5 thru 8,etc) Sets of two m ay be used only on

flanges with fours bolts.

6. Bolt tensioning often requires two different pressure settings. The first pass is generally

performed at a pressure designed to overtension the bolts in order to account for bolt

relaxation. Subsequent passes are conducted at a lower pressure, calculated to produce

the required minimum residual bolt stress when the joint is tight. Additional passes

should be performed at this lower pressure until the nuts remain tight when this pressure

is applied to the tensioning equipment.

8.3.1. Tensioner Attachment (Vertical)

a.

Center the stud bolt tensioner on the stud bolt. Lower the tensioner over the

stud and nut assembly. Align the nut socket (on tensioner) with assembly

nut by turning the drive gear. Lower the tensioner until the base rests

squarely on the flange surface.

b.

Thread

the puller bar onto the stud bolt until it bottoms out on the

tensioner piston

c.

Back the puller bar off one quarter (1/4) turn.

d.

Stud bolt tensioners shall not be pressurized until attachment procedure is

complete for tensioners and extensiometer

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Flange Joint Bolt Tightening Procedure

8.3.2. Tensioner Attachment (Horizontal)

a. Align the tensioner axially with the stud and nut assembly to prevent side

stressing of the puller bar and the stud. Align the nut socket (on tensioner)

with the assembly nut by turning the drive gear. Place the tensioner on the

stud and nut assembly until the base rests squarely on the flange surface.

b. Support weight of the tensioner by hand or slings. Do not force wedges for

support.

c.
Thread

the puller bar onto the stud bolt until it bottoms out on the

tensioner piston.

d. Back the puller bar off one quarter (1/4) turn.

e. Stud bolt tensioners shall not be pressurized until the attachment procedure

is complete for both tensioners and the extensiometer

Horizontal

Vertical

Figure 2 Bolt Tension Equipment

9. ELONGATION MEASUREMENT

The amount of elongation of the stud required to achieve the desired tension in the stud is

determined by using of the following formula:

D=

LE / E

Where :

D= Elongation of the stud in inches

= Target Bolt stress

E= Effective bolt length in inches

E = Modulus of Elasticity

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Flange Joint Bolt Tightening Procedure

1.

Determine the lengths L and H as shown in Figure 3

2.

Calculate the effective bolt length, L

E = L + (Ft x H)

Where :

Ft =2/3 when new bolts are used

And

Ft = 1 when old bolts are reused

3.

Elongation is determined by measuring the length of the stud before and againt

after the tensile load is applied to the studs.

4.

A log of the measurements taken for the initial lengths and any subsequent

elongations shall be recorded.

5.

For the second to last torquing / tensioning setting , the elongations shall be

checked to determine if the final torque or tension setting is appropriate.

Adjustments to the final setting may required depending on the elongation

measured.

6.

The acceptance criteria for final elongation measurements shall be 15% of the

targeted elongation, unless otherwise specified by company. If the average

measured value is close to the targeted value but the scatter is not within the

15% limit, additional passes are required at the same load setting.

7.

The project engineer / project coordinator and inspector shall sign of on the report

flange joint records to show acceptance of the joint.

PHEONWJ-G-PRC-0016 Rev. 0.

Figure 3 Bolt Tension Equipment

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Flange Joint Bolt Tightening Procedure

10. FLANGE FIT-UP AND BOLT PREPARATION

10.1. Preparation for Bolt-up

1.

Flange faces shall be thoroughly cleaned using a wire or power brush. All rust and

burrs shall be completely removed. Particular attention shall be paid to the seating

surfaces for metal gaskets such as the grooves in ring joint flanges.

2.

Gasket surfaces on flange faces shall be thoroughly inspected. Any scratches or

indications extending 50% of the width of the seating surface shall be removed by

methods approved by the


Owners

Engineer. Nubbins on flange faces

shall be

inspected and repaired, if necessary. The Inspector or designated representative shall

accept or reject all flange surfaces in accordance with the above criteria

3.

Bolts shall be checked for proper size, length, conformance to specifications,

cleanliness, and absence of burrs. Bolting materials shall be in accordance with

company specification. When using bolts that have been in service, all thread surfaces

shall be cleaned using a wire or power brush. Bolts that are bent or have damaged

threads shall not be re-used

4.

The surface of the flanges where contact is made with the nuts shall be wire or power

brushed.

5.

Gaskets shall be checked for size, conformance to specification, and cleanliness. Metal

gaskets shall have grease, rust, and burrs completely removed. All gaskets shall be

fitted against each flange gasket seating surface to check alignment with the surface.

6.

Spiral wound, metal jacketed or sheet gaskets shall not be reused. Ring Joint type

gaskets shall not be reused without the Owners Engineers approval.

7.

Thread lubricants shall be suitable for the operating temperature of the system and

shall require the approval of the Owners Engineer. Thread lubricants for bolting shall

not contain lead. Thread lubricants for austenitic bolting shall not contain chlorides.

Unless otherwise specified by the Owners Engineer, one of the anti-seize

thread

compounds in shall be used.

8.

Proper thread lubrication shall be applied to every friction surface of the bolt assembly.

This includes the threads, and all bearing surfaces of the nut, washer and bolt head.

Lubrication on the bolt threads shall be applied prior to putting the nuts on.

9.

When ultrasonic elongation control is required, bolting shall have smooth and parallel

ends to assure accurate measurements. In some cases, particularly small diameter

bolting, stud bolt ends will need to be shop machined

10. Never draw up tight on one or two bolt only. This will cause local gasket crushing or

pinching, which will result in leak. Always tighten up gradually, using th e

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Flange Joint Bolt Tightening Procedure

pattern. After each round of tightening, the alignment may be checked by measuring

the distance between the flange faces.

10.2.

Pre-Assembly of Flanges

1.

Only technicians trained and competent in the use of bolt tightening equipment, who

have completed a recognized competence assessment program, shall carry out the

controlled breakout and tightening of bolted joints

2.

Two bolts shall be installed diametrically opposite each other, and one bolt half way

between the previously installed bolts (for flanged joints in horizontal lines, on the

underside) for retaining the gasket (e.g. bolts 2, 3 and 4 in Table 1). The nuts shall

then be engaged.

3.

The gasket shall be inserted, and centered between the flanges. Nuts shall be hand

tightened to hold the gasket in place. When flanged joints are in horizontal lines,

gaskets without centering devices such as ring joint gaskets shall be lowered to the

bolts for retention and then raised into position.

4.
Specially

for Installation of Gasket for flange over 24, ensure

the centered Gasket

between the flanges raise face area shall be match.

5.

Gaskets shall not be held in place with tape during flange alignment. A heavy grease or

gasket cement can be used, if necessary.

6.

Alignment tolerances for flange faces prior to bolt-up shall be in accordance with

company specification. If these tolerances are not met, the Engineer or Inspector shall

be consulted to determine the remedial actions required.

7.

Check flange alignment, pipeworks flanges are often limited to a maximum out-of

alignment of 0.75mm (0.03in).

8.

The use of graphite tape or any other foreign material to hide gasket seating surface

imperfections is strictly prohibited.

9.

All flanged joints shall be snuggled up squarely so that the entire flange face bears

uniformly on the gasket. Four pointing and eight pointing procedures are acceptable for

rd

the initial alignment of joints, provided torque values less than 1/3
(a third) of the final

torque value.

10. Measurements of the gap between flanges shall be taken around the circumference to

assure that the flanges are being brought evenly together.

11. Heavy covers of horizontal equipment shall be provided with external supports and

guides which shall be maintained until the joint is tightened.

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Flange Joint Bolt Tightening Procedure

12. After the initial alignment has been completed, the remaining bolts and nuts shall be

installed and hand tightened. All bolts shall extend completely through their nuts. At

least three complete threads shall be visible from the backside of each nut. With the

approval of Engineer, the three complete thread requirements can be waived but the

bolt must be at least flush with the back side of the nut assuring full thread

engagement. When tensioning will be used for final tightening of the joint, at least one

bolt diameter of thread length shall extend through the nut on the side that the bolt

tension will be used.

Note:

Never draw up tight on one or two bolts only. This will cause local gasket crushing

or pinching, which will result in leaks. Always tighten up gradually, using the "criss-

cross" pattern. After each round of tightening, the alignment may be checked by

measuring the distance between the flange faces.

11. FLANGE BOLT TIGHTENING SEQUENCE

1.

Confirm that Joint Integrity Certificate JI1 has been prepared for the job

2.

Hand tighten the nuts first, ensuring that the correct face of the nut will seat squarely

onto the flange surface

3.

Measure the flange gap at a minimum of four points around the flange (larger flanges

should be at eight points)

4.

The bolt tightening sequence should begin at the point of the largest gap!

5.

Mark the correct tightening sequence on the studs in a clockwise direction with chalk as

per diagram (Reference ASME-PCC-1-2000).

Table No. 1

Criss-Cross Tightening Sequence Examples:

No

Number of

Criss-Cross Tightening Sequence Procedure

Bolt Flange

1-3-2-4

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

12

1-7-4-10-2-8-5-11-3-9-6-12

16

1-9-5-13-3-11-7-15-2-10-6-14-4-12-8-16

20

1-11-6-16-3-13-8-18-5-15-10-20-2-12-7-17-4-14-9-19

24

1-13-7-19-4-16-10-22-2-14-8-20-5-17-11-23-3-15-9-21-6-18-12-24

28

1-15-8-22-4-18-11-25-6-20-13-27-2-16-9-23-5-19-12-26-7-21-14-

28-3-17-10-24

32

1-17-9-25-5-21-13-29-3-19-11-27-7-23-15-31-2-18-10-26-6-22-14-

30-4-20-12-28- 8-24-16-32

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Flange Joint Bolt Tightening Procedure

No

Number of

Criss-Cross Tightening Sequence Procedure

Bolt Flange

36

1-29-13-5-25-17-9-33-21-3-31-15-7-27-19-11-35-23-2-30-14-6-26-

18-10-34-22-4-32-16-8-28-20-12-36-24

10

40

1-17-33-9-25-5-21-13-37-29-3-19-35-11-27-7-23-15-39-31-2-18-

34-10-26-6-22-14-38-30-4-20-36-12-28-8-24-16-40-32

11

44

1-29-13-37-5-21-25-9-33-17-41-3-31-15-39-7-23-27-11-35-19-43-

2-30-14-38-6-22-26-10-34-18-42-4-32-16-40-8-24-28-12-36-20-44

12

48

1-25-41-9-17-33-5-29-45-13-21-37-3-27-43-11-19-35-7-31-47-15-

23-39-2-26-42-10-18-34-6-30-46-14-22-38-4-28-44-12-20-36-8-32-

48-16-24-40

13

52

1-21-37-13-29-45-5-9-25-41-17-33-49-3-23-39-15-31-47-7-11-27-

43-19-35-51-2-22-38-14-30-46-6-10-26-42-18-34-50-4-24-40-16-

32-48-8-12-28-44-20-36-52

Note:

o Correct numbering of bolts should result in all odd numbered bolts around one

side of the flange and all even numbered bolts around the other side.

6.

Second tightening stage should be limited to a maximum of 60% of the final torque

setting.

7.

Third tightening stage should be carried out at the 100% torque setting.

8.

On the Fourth and Final tightening stage, change from criss-cross tightening to adjacent

bolt-to-bolt tightening clockwise using the 100% torque setting and chase around flange

until nuts finally stop rotating.

Note:

First, second and third stages should be tightened using the criss-cross tightening

sequence and the fourth stage should be tightened using the adjacent clockwise bolt to

bolt sequence as shown in the diagrams above

9.

Using a small hammer tap test each bolt to check the sound of the bolt rings true, dull or

vibrating bolts should be retightened to the correct value.

10. Ensure that the work area is left in a safe and tidy condition and that the Permit to Work

has been signed off.

11. Record all tightening information on the Joint Integrity Certificate JI1 part A.

PHEONWJ-G-PRC-0016 Rev. 0.

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Flange Joint Bolt Tightening Procedure

Marked Up 8 Bolt Flange

1st, 2nd, & 3rd Stage

4th & Final Stage

Adjacent Bolt Sequence

Criss Cross Sequence

Figure 4

11.1.

a.

Criss-Cross Sequence

Torque Tightening Dos & Donts

Ensure that you are fully conversant with the safe use of the tools and their operating

procedures.

b.

Check

that

the

torque

values

required

are

applicable

to

the

tools

and

bolt

lubricant/coating being used and to the flanges, gasket and bolt material being

tightened

c.

Number the studs as an aid for applying the correct criss-cross tightening sequence.

d.

M ake sure that the full thread engagem ent of the nut on the bolt has been

achieved

e.

Hand-tighten the nuts first, ensuring that the correct face of the nut will seat squarely

onto the flange surface.

f.

Ensure that the manual torque wrench being used is adequately engaged before

pulling.

g.

Wear suitable PPE as stated within the Permit to Work.

h.

Ensure that the backing spanner, if being used, is correctly engaged and secured.

i.

Ensure that there is sufficient room around the joint being tightened to pull the wrench

safely.

j.

Reset manual torque wrenches to zero prior to storage.

k.

Always remove the tool from the clamp connector and place on a surface where

reaction will not be possible when setting or altering the pump pressure!

2.
Donts

a.

Never tighten damaged or corroded bolts.

PHEONWJ-G-PRC-0016 Rev. 0.

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Flange Joint Bolt Tightening Procedure

b.

D o not draw the joint up tight on one or tw o bolts, as this w ill cause local gasket

crushing or pinching of the gasket.

c.

Do not over tighten bolts; take particular

care with small bolts, i.e. less than 1

diameter.

d.

Never pull the manual torque wrench any further once the click or linkage has

activated.

e.

Never use a wrench that has been dropped or knocked without checking the

calibration.

f.

Never pressurize unconnected hydraulic couplings.

g.

Never stand in line with the bolt axis when tools are pressurized.

h.

Never hold hydraulic wrenches at their pinch/reaction points when energizing.

i.

Do not draw the flange up tight on one or two bolts, as this will cause local gasket

crushing or pinching of the gasket

11.2.

Bolt Tensioning

Dos and Donts

1.

Dos

a.

Ensure that you are fully conversant with the safe use of the tools and their operating

procedures.

b.

Check that the pressures stated are applicable for the tools being used and for the

flange being tightened.

c.

Make sure that the full thread engagement of puller has been achieved.

d.

Hand-tighten the nuts first, ensuring that the correct face of the nut will seat squarely

onto the flange surface.

e.

Wear suitable PPE as stated within the Permit to Work.

2.
Donts

a.

Never pressurize unconnected hydraulic couplings.

b.

Never tension damaged or corroded bolts.

c.

Never stand in line with the bolt axis.

PHEONWJ-G-PRC-0016 Rev. 0.

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Flange Joint Bolt Tightening Procedure

Figure 5

Typical Criss -Cross Bolt Tightening Sequence for 4 bolts & 8 bolts

4 Bolts

Sequence Order

1 2

3 - 4

4 BOLT

8
Bolts

Sequence Order

1 2

3 4

5 6

7 8

PHEONWJ-G-PRC-0016 Rev. 0.

Rotation Order

8 BOLT

Rotation Order

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Flange Joint Bolt Tightening Procedure

Figure 6

Typical Criss -Cross Bolt Tightening Sequence for bolts 12 & 16 bolts

Sequence Order

1 2

3 4

5 6

7 8

9 10

11 12

Sequence Order

1 2

3 4

5 6

7 8

9 10

11 12

13 14

15 16

12 Bolts

11

12 BOLT

12

Rotation Order

11

10

12

10

16 Bolts

13

11

15

16 BOLT

16

10

12

14

Rotation Order

13

11

15

10

14

12

16

PHEONWJ-G-PRC-0016 Rev. 0.

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Flange Joint Bolt Tightening Procedure

Figure 7

Typical Criss -Cross Bolting Tightening Sequence for bolts 24 & bolts 28

PHEONWJ-G-PRC-0016 Rev. 0.

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Flange Joint Bolt Tightening Procedure

Figure 8

Typical Criss -Cross Bolt Tightening

for bolts 32

PHEONWJ-G-PRC-0016 Rev. 0.

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Flange Joint Bolt Tightening Procedure

Figure 9

Typical Criss -Cross Bolt Tightening Sequence

for bolt 36

PHEONWJ-G-PRC-0016 Rev. 0.

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Flange Joint Bolt Tightening Procedure

Figure 10

Typical Criss -Cross Bolt Tightening Sequence for bolts 40

PHEONWJ-G-PRC-0016 Rev. 0.

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Flange Joint Bolt Tightening Procedure

Figure 11

Typical Criss -Cross Bolt Tightening Sequence for bolts 44

PHEONWJ-G-PRC-0016 Rev. 0.

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Flange Joint Bolt Tightening Procedure

Figure 12

Typical Criss -Cross Bolt Tightening Sequence for bolts 48

PHEONWJ-G-PRC-0016 Rev. 0.

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Flange Joint Bolt Tightening Procedure

Figure 13

Typical Criss -Cross Bolt Tightening Sequence for bolts 52

PHEONWJ-G-PRC-0016 Rev. 0.

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Flange Joint Bolt Tightening Procedure

Appendix A

Torque Tables

The following tables contain recommended torque values for a range of standard ASME

B16.5or MSS SP44 flanges (made from materials with a minimum yield strength greater than

30,000lbf/in2), various gasket types Molykote 1000 lubricant (co-efficient of friction of 0.11)

and the following bolt materials: ASTM A193 B7, B7M and B16, ASTM A320 L7, L7M and

L43.

Table 2

Sheet Gaskets

Nitrile Rubber-based Reinforced eg Klingersil

Class 150

Nominal

Bore

Class 300

Class 600

Minimum Bolt

Torque

Minimum Bolt

Torque

Minimum Bolt

Torque

Nm

Ft-lbs

Nm

Ft-lbs

Nm

Ft-lbs

1/2

30

22

30

22

48

35

30

22

59

43

94

69

36

26

59

43

94

69

48

35

94

69

105

78

48

35

165

121

185

137

94

69

94

69

105

78

94

69

165

121

165

121

117

86

165

121

185

137

94

69

165

121

329

243

165

121

185

137

441

325

185

137

296

218

714

526

10

263

194

441

325

897

662

12

263

194

642

474

897

662

14

392

289

571

421

1213

894

16

392

289

897

662

1593

1175

18

571

421

897

662

2044

1507

20

571

421

897

662

2044

1507

24

797

588

1593

1175

3194

2356

Note : All value are for lubricated bolt(co-efficient of friction = 0.11).

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Flange Joint Bolt Tightening Procedure

Appendix B

Table Torque

Table 3

Spiral-wound Gasket with Graphite Filler

Class 150
Class 300
Class 600
Class 900
Nominal
Minimum

Minimum

Minimum

Minimum

Bore

Bolt Torque
Bolt Torque
Bolt Torque
Bolt Torque

Class 1500

Class 2500

Minimum

Bolt Torque

Minimum

Bolt Torque

Nm

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

1/2

48

35

48

35

48

35

165

121

165

121

185

137

48

35

94

69

94

69

165

121

185

137

206

152

48

35

94

69

94

69

263

194

296

218

329

243

48

35

94

69

105

78

296

218

329

243

538

397

54

40

165

121

185

137

441

325

489

361

785

579

94

69

94

69

105

78

263

194

329

243

538

397

105

78

165

121

165

121

392

289

489

361

714

526

117

86

165

121

185

137

329

243

714

526

1096

809

105

78

185

137

329

243

642

474

997

735

1947

1436

185

137

185

137

441

325

714

526

1347

994

4332

3195

206

152

296

218

714

526

1213

894

2271

1675

4332

3195

10

263

194

441

325

897

662

1347

994

3549

2618

8598

6341

12

296

218

642

474

897

662

1347

994

4332

3195

11536

8509

14

441

325

642

474

1213

864

1770

1306

5599

4129

16

392

289

897

662

1593

1175

2271

1675

7738

5707

18

571

421

897

662

2044

1507

3549

2618

10383

7658

20

571

421

897

662

2044

1507

4332

3195

13530

9979

24

797

588

1593

1175

3194

2356

7738

5707

21675

15987

Note : All value are for lubricated bolt(co-efficient of friction = 0.11).

PHEONWJ-G-PRC-0016 Rev. 0.

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Flange Joint Bolt Tightening Procedure

Appendix C

Table Torque

Table 4

Ring Type Joint Gasket

Class 150
Class 300
Class 600
Class 900
Nominal
Minimum

Minimum

Minimum

Minimum

Bore

Bolt Torque
Bolt Torque
Bolt Torque
Bolt Torque

Class 1500

Class 2500

Minimum

Bolt Torque

Minimum

Bolt Torque

Nm

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

1/2

48

35

48

35

165

121

165

121

206

152

94

69

94

69

165

121

185

137

206

152

48

35

94

69

94

69

263

194

296

218

362

267

48

35

94

69

105

78

263

194

296

218

538

397

48

35

165

121

165

121

392

289

441

325

785

579

94

69

94

69

105

78

263

194

329

243

538

397

94

69

165

121

165

121

392

289

441

325

785

579

94

69

165

121

185

137

296

218

714

526

997

735

94

69

165

121

296

218

642

474

997

735

1947

1436

165

121

185

137

441

325

642

474

1213

894

4766

3515

165

121

296

218

642

474

1213

893

2271

1675

4766

3515

10

263

194

392

289

897

662

1213

893

3549

2618

8598

6341

12

263

194

571

421

897

662

1213

893

4332

3195

12690

9360

14

392

289

571

421

1213

894

1770

1306

6221

4588

16

392

289

797

588

1593

1175

2271

1675

8598

6341

18

571

421

797

588

2044

1507

3549

2618

11536

8509

20

571

421

897

662

2044

1507

4332

3195

15034

1108

24

797

588

1593

1175

3194

2356

7738

5707

24083

17763

Note : All value are for lubricated bolt(co-efficient of friction = 0.11).

PHEONWJ-G-PRC-0016 Rev. 0.

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Flange Joint Bolt Tightening Procedure

Appendix D

Table 5

Torque Guide for ASTM A 193 Grade B7 Stud

Bolt Tension Based On


65 Percent Yield

Imperial

B7

BOLT SIZE

DIA X TPI

THREAD

PER INCH

HEX NUT

STRESS

AREA

(IN

x 10

10

1-1/4

0.334

7/8 x 9

1-7/16

0.461

1x8

1-5/8

0.605

1-1/8 x 8

1-13/16

1-1/4 x 8

1-3/8 x 8

1-1/2 x 8

1-5/8 x 8

1-3/4 x 8

1-7/8 x 8

2x8

2-1/8 x 8

2-1/4 x 8

2-3/8 x 8

2-1/2 x 8

2-3/4 x 8

3x8

2
2-3/16
2-3/8
2-9/16
2-3/4
2-15/16
3-1/8
3-5/16
3-1/2
3-11/16
3-7/8
4-1/4
4-5/8
5
5-3/8
5-3/4
6-1/8
6-1/2
6-7/8
7-1/4
7-5/8
8
8-3/8
8-3/4
9-1/8

3-1/4 x 8

3-1/2 x 8

3-3/4 x 8

4x8

4-1/4 x 8

4-1/2 x 8

4-3/4 x 8

5x8

5-1/4 x 8

5-1/2 x 8

5-3/4 x 8

6x8

MIN

YEILD

105,000

BOLT

TENSION

(LBS)

Toque

(ft.lbs)

COEF OF

FRICTION

(0.12)

Pressure pump (Psi)

W200

W400

W8000

W1500

22,815

171

31,497

276

1,378

105,000

41,321

413

2,066

0.790

105,000

53,921

607

3,033

1,517

0.999

105,000

68,195

852

4,262

2,131

1.233

105,000

84,144

1,157

5,785

2,892

1,446

1.491

105,000

101,766

1,526

7,632

3,816

1,908

1.774

105,000

121,063

1,967

9,836

4,918

2,459

2.08

105,000

142,035

2,486

6,214

3,107

1,658

2.413

105,000

164,680

3,088

7,719

3,860

2,060

2.769

105,000

189,000

3,780

9,450

4,725

2,521

3.150

105,000

214,994

4,569

5,711

3,047

3.555

105,000

242,662

5,460

6,825

3,642

3.985

105,000

272,005

6,460

8,075

4,309

4.440

105,000

303,022

7,576

9,469

5,058

5.422

95,000

334,832

9,208

6,142

6.503

95,000

401,562

12,047

8,035

7.682

95,000

474,350

15,416

8.959

95,000

553,198

19,362

10.334

95,000

638,105

23,929

11.807

95,000

729,071

29,163

13.378

75,000

652,181

27,718

15.047

75,000

733,564

33,010

16.815

75,000

819,730

38,937

18.681

75,000

910,680

45,534

20.644

75,000

1,006,413

52,837

22.706

75,000

1,106,930

60,881

24.688

75,000

1,212,231

69,703

27.124

75,000

1,322,315

79,399

Note : All value are for lubricated bolt(co-efficient of friction = 0.12).

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Flange Joint Bolt Tightening Procedure

Appendix E

Table 6

Target Bolt Stress For Gasket Seating and Operation ASME/ANSI B16.5 Class

150# with Spiral Wound Gaskets

Hydrotest

Pressure

(Psig)

0 - 290

Target Bolt Stress (Ksi) (1)

Nominal Pipe Size (NPS-Inches)

2
23.3

3
39.9

4
28.9

6
32.4

8
43.5

10

14

16

18

20

24

25.4

32.4

26.8

25.0

24.2

21.3

Table 7

Target Bolt Stress For Gasket Seating and Operation ASME/ANSI B16.5 Class

300# with Spiral Wound Gaskets

Hydrotest

Pressure

(Psig)

Target Bolt Stress (Ksi) (1)

Nominal Pipe Size (NPS-Inches)

10

12

14

16

18

20

24

0 - 400

11.6

13.3

19.3

21.6

20.9

14.5

14.0

12.2

11.9

12.7

13.9

11.5

450

11.6

13.3

19.3

21.6

20.9

14.5

14.0

12.2

11.9

12.7

13.9

12.1

500

11.6

13.3

19.3

21.6

20.9

14.5

14.0

12.2

11.9

12.7

14.9

13.5

550

11.6

13.3

19.3

21.6

20.9

14.5

14.0

12.8

12.9

13.9

16.4

14.8

600

11.6

13.3

19.3

21.6

20.9

14.5

15.2

14.0

14.1

15.2

17.8

16.2

650

11.6

13.3

19.3

21.6

20.9

16.0

16.4

15.2

15.3

16.4

19.3

17.5

700

11.6

13.3

19.3

21.6

22.0

17.2

17.7

16.3

16.5

17.7

20.8

18.9

750

11.6

13.3

19.3

21.6

23.6

18.5

19.0

17.5

17.6

19.0

22.3

20.2

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Flange Joint Bolt Tightening Procedure

Table 8

Target Bolt Stress For Gasket Seating and Operation ASME/ANSI B16.5 Class

600# with Spiral Wound Gaskets

Hydrotest

Pressure

(Psig)

Target Bolt Stress (Ksi) (1)

Nominal Pipe Size (NPS-Inches)

10

12

14

16

18

20

24

100

11.6

13.3

16.6

13.3

13.4

10.2

10.2

8.6

8.7

8.8

8.0

7.0

200

11.6

13.3

16.6

13.3

13.4

10.2

10.2

8.6

8.7

8.8

8.0

7.0

300

11.6

13.3

16.6

13.3

13.4

10.2

10.2

8.6

8.7

8.8

8.0

7.0

400

11.6

13.3

16.6

13.3

13.4

10.2

10.2

8.6

8.7

8.8

8.0

7.0

500

11.6

13.3

16.6

13.3

13.4

10.2

10.2

8.6

8.7

8.8

8.3

8.2

600

11.6

13.3

16.6

13.3

13.4

10.2

10.2

9.1

9.6

10.2

10.0

9.9

700

11.6

13.3

16.6

13.3

13.4

10.8

11.6

10.6

11.2

11.9

11.6

11.5

800

11.6

13.3

16.6

13.4

15.0

12.3

13.2

12.1

12.8

13.6

13.3

13.1

900

11.6

14.2

16.6

15.1

16.9

13.8

14.9

13.7

14.4

15.3

14.9

14.8

1000

12.7

15.8

18.3

16.7

18.8

15.4

16.6

15.2

16.0

16.9

16.6

16.4

1100

13.9

17.4

20.2

18.4

20.7

16.9

18.2

16.7

17.5

18.6

18.3

18.1

1200

15.2

18.9

22.0

20.1

22.5

18.5

19.9

18.2

19.1

20.3

19.9

19.7

1300

16.5

20.5

23.8

21.7

24.4

20.0

21.5

19.7

20.7

22.0

21.6

21.4

1400

17.7

22.1

25.7

23.4

26.3

21.5

23.2

21.2

22.3

23.7

23.2

23.0

1500

19.0

23.7

27.5

25.1

28.2

23.1

24.8

22.8

23.9

25.4

24.9

24.6

PHEONWJ-G-PRC-0016 Rev. 0.

Page

33

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37

DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled

PHEONWJ Ltd.

Flange Joint Bolt Tightening Procedure

Table 9

Target Bolt Stress For Gasket Seating and Operation ASME/ANSI B16.5 Class

900# with Spiral Wound Gaskets

Hydrotest

Pressure

(Psig)

Target Bolt Stress (Ksi) (1)

Nominal Pipe Size (NPS-Inches)

10

0 - 400

12.4

9.6

10.1

0.0

7.3

500

12.4

9.6

10.1

7.9

7.3

600

12.4

9.6

10.1

7.9

700

12.4

9.6

10.1

7.9

800

12.4

9.6

10.1

900

12.4

9.6

1000

12.8

1100

14.0

1200

12

14

16

18

20

24

7.8

7.0

6.7

6.3

5.7

4.2

7.8

7.0

6.7

6.3

6.1

5.1

7.3

7.8

7.3

7.7

7.3

7.3

6.2

8.1

9.0

8.5

9.0

8.5

8.5

7.2

9.0

9.3

10.2

9.7

10.2

9.7

9.8

8.2

11.4

10.1

10.4

11.5

10.9

11.5

10.9

11.0

9.3

10.5

12.7

11.2

11.6

12.8

12.1

12.8

12.1

12.2

10.3

11.6

13.9

12.3

12.7

14.1

13.4

14.1

13.3

13.4

11.3

15.3

12.7

15.2

13.4

13.9

15.4

14.6

15.4

14.5

14.7

12.3

1300

16.6

13.7

16.5

14.6

15.1

16.6

15.8

16.6

15.7

15.9

13.4

1400

17.9

14.8

17.7

15.7

16.2

17.9

17.0

17.9

16.9

17.1

14.4

1500

19.1

15.8

19.0

16.8

17.4

19.2

18.2

19.2

18.1

18.3

15.4

1600

20.4

16.9

20.3

17.9

18.5

20.5

19.4

20.5

19.4

19.5

16.5

1700

21.7

17.9

21.5

19.0

19.7

21.8

20.6

21.8

20.6

20.8

17.5

1800

23.0

19.0

22.8

20.2

20.9

23.1

21.8

23.0

21.8

22.0

18.5

1900

24.2

20.0

24.1

21.3

22.0

24.3

23.1

24.3

23.0

23.2

19.5

2000

25.5

21.1

25.3

22.4

23.2

25.6

24.3

25.6

24.2

24.4

20.6

2100

26.8

22.2

26.6

23.5

24.3

26.9

25.5

26.9

25.4

25.6

21.6

2200

28.1

23.2

27.9

24.6

25.5

28.2

26.7

28.2

26.6

26.9

22.6

PHEONWJ-G-PRC-0016 Rev. 0.

Page

34

of

37

DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled

PHEONWJ Ltd.

Flange Joint Bolt Tightening Procedure

Table 10

Target Bolt Stress For Gasket Seating and Operation ASME/ANSI B16.5 Class

1500# with Spiral Wound Gaskets

Hydrotest

Pressure

(Psig)

Target Bolt Stress (Ksi) (1)

Nominal Pipe Size (NPS-Inches)

10

12

14

16

18

20

24

200

8.6

7.5

7.9

6.6

5.9

5.4

4.2

3.3

3.5

3.5

3.2

2.9

300

8.6

7.5

7.9

6.6

5.9

5.4

4.2

3.3

3.5

3.5

3.2

2.9

400

8.6

7.5

7.9

6.6

5.9

5.4

4.2

3.3

3.5

3.5

3.2

2.9

500

8.6

7.5

7.9

6.6

5.9

5.4

4.2

3.3

3.5

3.5

3.2

3.2

600

8.6

7.5

7.9

6.6

5.9

5.4

4.2

3.7

3.8

4.0

3.9

3.9

700

8.6

7.5

7.9

6.6

5.9

5.6

4.9

4.3

4.5

4.6

4.5

4.5

800

8.6

7.5

7.9

6.6

6.3

6.4

5.6

4.9

5.1

5.3

5.2

5.2

900

8.6

7.5

7.9

7.3

7.1

7.2

6.3

5.5

5.7

6.0

5.8

5.8

1000

8.6

7.5

8.4

8.1

7.9

8.0

7.0

6.1

6.4

6.6

6.5

6.5

1100

8.6

8.3

9.3

8.9

8.7

8.8

7.7

6.7

7.0

7.3

7.1

7.1

1200

9.1

9.0

10.1

9.7

9.5

9.6

8.4

7.3

7.6

7.9

7.8

7.7

1300

9.8

9.8

11.0

10.5

10.3

10.4

9.1

7.9

8.3

8.6

8.4

8.4

1400

106

10.5

11.8

11.4

11.1

11.2

9.8

8.5

8.9

9.3

9.1

9.0

1500

11.4

11.3

12.7

12.2

11.9

12.1

10.5

9.2

9.6

9.9

9.7

9.7

1600

12.1

12.0

13.5

13.0

12.7

12.9

11.2

9.8

10.2

10.6

10.4

10.3

1700

12.9

12.8

14.4

13.8

13.5

13.7

11.9

10.4

10.8

11.3

11.0

11.0

1800

13.6

13.6

15.2

14.6

14.3

14.5

12.6

11.0

11.5

11.9

11.7

11.6

1900

14.4

14.3

16.0

15.4

15.0

15.3

13.2

11.6

12.1

12.6

12.3

12.3

2000

15.1

15.1

16.9

16.2

15.8

16.1

13.9

12.2

12.7

13.2

13.0

12.9

2100

15.9

15.8

17.7

17.0

16.6

16.9

14.6

12.8

13.4

13.9

13.6

13.6

2200

16.7

16.6

18.6

17.8

17.4

17.7

15.3

13.4

14.0

14.6

14.3

14.2

2300

17.4

17.3

19.4

18.6

18.2

18.5

16.0

14.0

14.7

15.2

14.9

14.8

2400

18.2

18.1

20.3

19.5

19.0

19.3

16.7

14.6

15.3

15.9

15.6

15.5

2500

18.9

18.8

21.1

20.3

19.8

20.1

17.4

15.3

15.9

16.6

16.2

16.1

2600

19.7

19.6

22.0

21.1

20.6

20.9

18.1

15.9

16.6

17.2

16.9

16.8

2700

20.5

20.3

22.8

21.9

21.4

21.7

18.8

16.5

17.2

17.9

17.5

17.4

2800

21.2

21.1

23.6

22.7

22.2

22.5

19.5

17.1

17.8

18.5

18.2

18.1

2900

22.0

20.2

17.7

18.5

19.2

18.8

18.7

3000

22.7

22.6

25.3

24.3

23.8

24.1

20.9

18.3

19.1

19.9

19.5

19.4

3100

23.5

23.3

26.2

25.1

24.5

24.9

21.6

18.9

19.8

20.5

20.1

20.0

3200

24.2

24.1

27.0

25.9

25.3

25.7

22.3

19.5

20.4

21.2

20.8

20.7

3300

25.0

24.8

27.9

26.8

26.1

26.5

23.0

20.1

21.0

21.9

21.4

21.3

3400

25.8

25.6

28.7

27.6

26.9

27.3

23.7

20.7

21.7

22.5

22.1

21.9

3500

26.5

26.3

29.6

28.4

27.7

28.1

24.4

21.4

22.3

23.2

22.7

22.6

3600

27.3

27.1

30.4

29.2

28.5

28.9

25.1

22.0

22.9

23.8

23.4

23.2

3700

28.0

27.9

31.2

30.0

29.3

29.7

25.8

22.6

23.6

24.5

24.0

23.9

21.8

24.5

23.5

23.0

23.3

PHEONWJ-G-PRC-0016 Rev. 0.

Page

35

of

37

DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled

PHEONWJ Ltd.

Flange Joint Bolt Tightening Procedure

Table 11

Target Bolt Stress For Gasket Seating and Operation ASME/ANSI B16.5 Class

2500# with Spiral Wound Gaskets

Hydrotest

Pressure

(Psig)

Target Bolt Stress (Ksi) (1)

Nominal Pipe Size (NPS-Inches)

10

12

200

6.6

5.9

5.2

4.3

3.7

2.8

3.0

300

6.6

5.9

5.2

4.3

3.7

2.8

3.0

400

6.6

5.9

5.2

4.3

3.7

2.8

3.0

500

6.6

5.9

5.2

4.3

3.7

2.8

3.0

600

6.6

5.9

5.2

4.3

3.7

2.8

3.0

700

6.6

5.9

5.2

4.3

3.7

3.0

3.3

800

6.6

5.9

5.2

4.3

4.0

3.4

3.8

900

6.6

5.9

5.2

4.8

4.5

3.8

4.3

1000

6.6

5.9

5.6

5.3

5.0

4.3

4.8

1100

6.6

6.5

6.1

5.8

5.5

4.7

5.3

1200

6.9

7.1

6.7

6.4

6.0

5.1

5.7

1400

8.1

8.3

7.8

7.4

7.0

6.0

6.7

1600

9.2

9.4

8.9

8.5

8.0

6.8

7.6

1800

10.4

106

10.0

9.5

9.0

7.7

8.6

2000

11.5

11.8

11.2

10.6

10.0

8.5

9.6

2200

12.7

13.0

12.3

11.7

11.0

9.4

10.5

2400

13.8

14.2

13.4

12.7

12.0

10.2

11.5

2600

15.0

15.3

14.5

13.8

13.0

11.1

12.4

2800

16.1

16.5

15.6

14.8

14.0

11.9

13.4

3000

17.3

17.7

16.7

15.9

15.0

12.8

14.3

3200

18.4

18.9

17.9

16.9

16.0

13.6

15.3

3400

19.6

20.1

19.0

18.0

17.1

14.5

16.3

3600

20.7

21.2

20.1

19.1

18.1

15.3

17.2

3800

21.9

22.4

21.2

20.1

19.1

16.2

18.2

4000

23.0

23.6

22.3

21.2

20.1

17.1

19.1

4200

24.2

24.8

23.4

22.2

21.1

17.9

20.1

4400

25.3

26.0

24.6

23.3

22.1

18.8

21.0

4600

26.5

27.1

25.7

24.4

23.1

19.6

22.0

4800

27.6

28.3

26.8

25.4

24.1

20.5

22.9

5000

28.8

29.5

27.9

26.5

25.1

21.3

23.9

5200

30.0

30.7

29.0

27.5

26.1

22.2

24.9

5400

31.1

31.9

30.1

28.6

27.1

23.0

25.8

5600

32.3

33.0

31.3

29.7

28.1

23.9

26.8

5800

33.4

34.2

32.4

30.7

29.1

24.7

27.7

6000

34.6

35.4

33.5

31.8

30.1

25.6

28.7

6200

35.7

36.6

34.6

32.8

31.1

26.4

29.6

PHEONWJ-G-PRC-0016 Rev. 0.

Page

36

of

37

DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled

PHEONWJ Ltd.

Flange Joint Bolt Tightening Procedure

Appendix F

Form Flange Joint Records

Project
Customer
Area
Scope / Job No.

FLANGE JOINT
RECORDS

:
:
:
:

Technician

Date of Tightening

: 1

Flange Identification

Line No.
P & ID No.
Location

:
:
:

Flange No.
SH1 No.
MC1 No.

Flange Data

Size & Class

Flange Material

Gasket Type

Bolt Material

Bolt Diameter
Nuts A/F Size
No. of Bots
Hydrostatic Test Press (lbs/inch)

:
:
:
:

Visual Check

Bold Condition

Good

Fair

Poor

Flange Face Condition

Good

Poor

Flange Preparation by
Min Thread Protrusion
Thread Form
Joint Configuration

Not Visible

Tension Method Use

Torque Wrench
Model :

Manufacture
:

Serial No.
:

Bolt Tension Model :


Manufacture
:
Serial No.
:

Residual Bolt Load


Coef of Friction

Specified Loads

:
:

Tonf

Residual Bolt Stress


Torque

:
:

Bolt Tensioner Record

No. of Tensioner
Percentage Tool Coverage
Bolt Tensioner Type
Pump Serial No.

:
:
:
:

Lb/ln2

Ft Lbs

Tensioner Pressure (lbs ln


)

st

-1
Pass Pressure
:

nd

-2
Pass Pressure :

-Checking Pressure :

Torque Record

Torque Wrench Type


Pump Serial No.
Torque Value

st

-1
Pass 30% of Torque
nd

-2
Pass 60% of Torque

:
:
:
:

Lubricant Used
Lubricant appllied by
Ft Lbs

rd

-3
Pass 100% of Torque
th

-4
Pass 100% (Final)
(For Check of Torque)

Review and Acceptance Signature

Technician of Torque Wrench


Name & Sign

Review by TAR Job Officer


Name & Sign

Date :

Date :

PHEONWJ-G-PRC-0016 Rev. 0.

Witnessed by QC Inspector

Name & Sign

Date :

Page

37

of

37