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GULF OF SUEZ PETROLEUM COMPANY

(GUPCO)

PROJECTS QA/QC DEPARTMENT

GUIDELINES FOR THE MANAGEMENT OF BOLTED


JOINT INTEGRITY

Origin
Code
GU

Location
0000

Disc
Code
PM

Doc
Type
PRO

Sequential
Number
0047

Rev.
C2

Rev.

Issue Date

Reason for Issue

Prepared By

Checked By

Approved By

A1
C1

18/11/08
10/12/08

REVIEW
Approved for use

H. HELMY

S. WRIGHT

S.TANTAWY

H. HELMY

S. WRIGHT

S.TANTAWY

C2

08/09/09

Revised in Italics to
include Hydratight
Comments

H. HELMY

S. WRIGHT

S.TANTAWY

ORIGINATING COMPANY (GUPCO)

GUPCO PROJECTS QA/QC DEPT.


DOC. NO. GU-0000-PM-PRO-0047 REV. C2
GUIDELINES FOR THE MANAGEMENT OF BOLTED JOINT INTEGRITY

TABLE OF CONTENTS
1.0 INTRODUCTION............................................................................................................ 3
1.1

Scope.............................................................................................................. 3

2.0 CODES, STANDARDS AND REGULATIONS............................................................... 3


2.1

International Standards (Latest edition)........................................................... 3

2.2

Project Specifications ...................................................................................... 3

3.0 Bolting........................................................................................................................... 3
4.0 Quality Records
APPENDIX A

DIMENSIONAL TOLERANCES FOR FINISHED FABRICATED PIPEWORK


.............................................................................................................. 3

APPENDIX B

PROCEDURE FOR APPLICATION OF BOLT TORQUE ON FLANGED JOINTS


.............................................................................................................. 3

APPENDIX C

BOLT TORQUE SEQUENCE ............................................................... 3

APPENDIX D

RECOMMENDED TORQUES FOR BOLTING (LB FT NM )................ 3

APPENDIX E

SUMMARY OF STUD BOLT TIGHTENING APPLICATIONS .............. 3

APPENDIX F

SAMPLE JOINT INTEGRITY CERTIFICATE .11

Page 2 of 12

GUPCO PROJECTS QA/QC DEPT.


DOC. NO. GU-0000-PM-PRO-0047 REV. C2
GUIDELINES FOR THE MANAGEMENT OF BOLTED JOINT INTEGRITY
1.0
1.1

INTRODUCTION
Scope
This Specification defines the minimum requirements for the management of bolted joint
integrity at both Onshore and Offshore facilities operated by GUPCO during the delivery of
GUPCO Projects.
Contractors or Sub-Contractors performing works on behalf of GUPCO Projects shall adhere to
these guidelines. Any deviation by the Contractor or Sub-Contractor is to be approved in writing
by the authorised GUPCO representative prior to performing the work.

2.0
2.1

CODES, STANDARDS AND REGULATIONS


International Standards (Latest edition)
ASME B31.3
ASME B31.4
ASME B.31.8
API RP 14E
APR-RP-520
NACE MR 0175
AWWA C600
AWWA CM23

2.2

Process Piping
Pipeline Transportation Systems for Liquid Hydrocarbons and
Other Liquids
Gas Transportation and Distribution Piping Systems
Design and Installation of Offshore production Platform Piping
Systems
Recommended Practice for Design and Installation of Pressure
Relieving Systems.
Sulphide Stress Cracking Resistant Metallic Materials for
Oilfield Equipment
Installation of Ductile Iron Water Mains and their Appurtances
PVC Design & Installation

Project Specifications
GU-0000-PM-PRO-0031
GU-0000-PM-PRO-0035
GU-0000-PM-PRO-0036
GU-0000-PM-PRO-0038
GU-0000-PM-PRO-0039
GU-0000-PM-PRO-0041
GU-0000-PM-PRO-0043
GU-0000-PM-PRO-0044

3.0

Hydrotest Procedure
Handover and Completion Certificates
As-Built Dossier Index
Dimensional Control Procedure for Piping
Works
Dimensional Control Procedure for Piping
Works
Inspection, measuring & test Equipment
Calibration & Control Procedure
Inspection & Test Plan Control Procedure
Construction Procedure

BOLTING
All flange bolting shall be checked for correct grade and any damage to coatings and threads
prior to fitting.
All flanges bolting shall be free to move through mating flanges holes in a plane at right angles
to the flange face and parallel to the pipe run (misalignment of flange holes resulting in knurling
of nut on the flange will be rejected)
All flange machine bolts shall extend fully through their nuts and shall have bolt heads all one
side of the joint.

Page 3 of 12

GUPCO PROJECTS QA/QC DEPT.


DOC. NO. GU-0000-PM-PRO-0047 REV. C2
GUIDELINES FOR THE MANAGEMENT OF BOLTED JOINT INTEGRITY

Each stud bolt shall be assembled with a minimum of one full thread beyond the nut at each
end but preferably 2 to 3 threads at each end.
Each stud bolt 11/8 diameter and larger shall be assembled as above but with 1 1/2 bolt
diameters beyond the nut at one end but in no case less than a minimum of one bolt diameter
beyond the nut at one end to facilitate installation using a hydraulic bolt tensioning device.
Stud bolts shall not be cut from lengths of studding and grade and manufacturer markings shall
be clearly visible for checking after installation.
All nut bearing faces and threads of bolts and stud bolts shall be lubricated with API 5A2 or
equal lubricant prior to fitting. BP standard bolting lubricant is Dow Corning Molycote 1000
which has a coefficient of friction of 0.11 and is to be used in preference to other bolting
lubricants when available.
Bolt torque/tension shall be applied in three stages using the diametrical sequence, 1st stage
30%, 2nd stage 60%, 3rd stage 100% Refer to appendix B.
Prior to pressure testing all flanged joints shall be tightened in accordance with this procedure
and the Joint Integrity certificate (appendix F) completed by the contractor and witnessed by
GUPCO. This record shall form part of the final documentation handover package
4.0

QUALITY RECORDS
Records of all flanges subjected to Joint Integrity Management shall be maintained.
These records shall form part of the final handover documentation.
A sample Joint Integrity certificate is shown in appendix F.

Page 4 of 12

GUPCO PROJECTS QA/QC DEPT.


DOC. NO. GU-0000-PM-PRO-0047 REV. C2
GUIDELINES FOR THE MANAGEMENT OF BOLTED JOINT INTEGRITY

APPENDIX A DIMENSIONAL TOLERANCES FOR FINISHED FABRICATED PIPEWORK

Page 5 of 12

GUPCO PROJECTS QA/QC DEPT.


DOC. NO. GU-0000-PM-PRO-0047 REV. C2
GUIDELINES FOR THE MANAGEMENT OF BOLTED JOINT INTEGRITY

APPENDIX B Procedure for Application of Bolt Torque on Flanged Joints


1. Align flange or joint component parts ensuring that both vertical and horizontal alignment conforms
to the fabrication tolerances shown in appendix A.
2. Ensure that mating faces of pipe flanges and any valves/in-line equipment to be tightened are
clean of any corrosion product, rust, grease or other contaminant as this will affect the leak
tightness of the joint.
3. Where raised face flanges and spiral wound gaskets are used, ensure proper centering of the
gasket on the raised face surfaces. Failure to do so will result in uneven pinching of the gasket
outer/centering ring and may lead to dishing or cupping of the outer/centring ring. Although some
degree of dishing or cupping of Spiral wound Gasket Outer/centering rings is a common occurance
and will not affect leak tightness of the joint, severe dishing or cupping may indicate a poor
installation technique or flange face misalignment outside of fabrication tolerances. Where this has
been determined to be the case the affected joint is to be rejected and remade using new gaskets.
4. Lubricate stud (or bolt) threads in area of nut (or forged ring) engagement, also lubricate face of
nuts (or bolt head) using Molycote 1000 or equivalent
5. Install all Bolts and nuts finger tight
6. Number bolts so that torquing requirements can be followed.
7. Apply torque in 33 % (1/3) steps of the required final torque, loading all bolts at each step before
proceeding to next step
8. Tighten bolts in sequential order 0-180 , 90 270 , 45225 & 135 315 at each step until
final torque is reached (see appendix C )
9. Use rotational tightening until all bolts are stable at final torque level (then check pass around the
circumference until no further movement of the nuts occour.)

Page 6 of 12

GUPCO PROJECTS QA/QC DEPT.


DOC. NO. GU-0000-PM-PRO-0047 REV. C2
GUIDELINES FOR THE MANAGEMENT OF BOLTED JOINT INTEGRITY
APPENDIX C

Page 7 of 12

GUPCO PROJECTS QA/QC DEPT.


DOC. NO. GU-0000-PM-PRO-0047 REV. C2
GUIDELINES FOR THE MANAGEMENT OF BOLTED JOINT INTEGRITY

APPENDIX D

RECOMMENDED TORQUES FOR BOLTING (LB FT Nm )


BOLT MATERIAL ASTM A193 Grade B7 & L7
NUT MATERIAL ASTM A194-7

Bolt Stress The table below gives torque values required to achieve an average bolt stress equivalent
to 50 % of the bolt yield stress.
(Care should be taken to select the correct coefficient of friction)
Lubricant / (Coefficient of friction )
HTL654
HTL655
Copper
Nickel /
Molycote 1000
(=0.10)
(=0.11)
Torque required lbf.ft(Nm)
79 (107)
85 (115)
139 (188)
151 (205)
223 (302)
242 (328)
333 ( 451)
362 (491)
508 (689)
553 (750)

Bolt
Size
(in)

Bolt
Tension
(lbs)

Min
Yield
(psi)

HTL653
MOLY
(=0.06)

5/8

7/8
1
1
1/8
1
1
3/8
1
1
5/8
1
1
7/8
2
2
2
2
3
3
3

10305
15466
21525
28323
38902

105000
105000
105000
105000
105000

52 (71)
92 (125)
146 (198)
219 (297)
331 (449)

49560
61530

105000
105000

459 (622)
616 (835)

710 (963)
959 (1300)

773 (1048)
1044 (1415)

1338 (1814)
1816 (2462)

74760
89250

105000
105000

804 (1090)
1027 (1392)

1258 (1706)
1614 (2188)

1372 (1860)
1761 (2388)

2393 (3245)
3081 (4177)

105000
122325

105000
105000

1288 (1746)
1592 (2158)

2031 (2754)
2519 (3415)

2216 (3004)
2751 (3730)

3888 (5217)
4836 (6557)

140700
181125
226800
251750
302100
357675
418000

105000
105000
105000
95000
95000
95000
95000

1937 (2626)
2766 (3750)
3805 (5159)
4602 (6239)
5976 (8102)
7613 (10322)
9526 (12915)

3074 (4168)
4411 (5980)
6091 (8258)
7392 (10022)
9627 (13052)
12294 (16668)
15414 (20898)

3358 (4553)
4822 (6538)
6663 (9034)
8089 (10967)
10540 (14290)
13464 (18254)
16887 (22895)

5914 (8018)
8521 (11553)
11806 (16007)
14367 (19479)
18753 (25425)
23995 (32532)
30137 (40860)

Dry
(=0.20)

146 (198)
258 (350)
415 (563)
620 (841)
953 (1292)

NB THESE FIGURES SHOULD BE VERIFIED BY THE


INSTALLATION FABRICATOR

Page 8 of 12

GUPCO PROJECTS QA/QC DEPT.


DOC. NO. GU-0000-PM-PRO-0047 REV. C2
GUIDELINES FOR THE MANAGEMENT OF BOLTED JOINT INTEGRITY

APPENDIX E SUMMARY OF STUD BOLT TIGHTENING APPLICATIONS

BOLT
SIZE
INS

5/8

7/8
1
1 1/8
1
1 3/8
1
Up to &
incl 3

RATING
900# & ABOVE
NA
NA
MW
MW
MW
HT
HT
HT
HT
HT

RATING
600#
MW
MW
MW
MW

OR NM
OR NM
OR NM
OR NM
MW
HT
HT
HT
HT
HT

RATING
150#-300#
MW
MW
MW
MW

OR NM
OR NM
OR NM
OR NM
MW
HT
HT
HT
HT
HT

HT

Hydraulic Tensioning

MW

Manual Torque Wrenching

NM

Non-Mandatory Methods of Tightening

NA

Bolt size not applicable

AT HYDROTEST
BOUNDARIES ALL
RATINGS
MW
MW
MW
MW
MW
HT
HT
HT
HT
HT

Page 9 of 12

GUPCO PROJECTS QA/QC DEPT.


DOC. NO. GU-0000-PM-PRO-0047 REV. C2
GUIDELINES FOR THE MANAGEMENT OF BOLTED JOINT INTEGRITY

Project Title:
Maintenance No:
Work Pack No:

* YES/NO/NA

SIGN:

FORM JI1

Complete Cleaning & Flushing

* YES/NO

SIGN:

SITE:

Complete Piping Completion

* YES/NO

SIGN:

4.1.2

* YES/NO/NA

SIGN:

* YES/NO

SIGN:

Complete Joint Integrity

Complete Witness Joint

MC1 No:

JOINT INTEGRITY CERTIFICATE

Complete Service Test

LOCATION :

SYSTEM :
4.2
Com
missioning

Installation Phase
PRE MC1 ACCEPTANCE
Tag
Number

Location
(P&ID and
Description)

Joint
Assembled by
(Print)
Signature to
Confirm
Compliance
with Assembly
Procedure

1
2
3
4

F4
F6
F9
F8

m.ebrahem
m.ebrahem
m.ebrahem
PMS
riggers

Torque Tightening
Required
Torque
Value+
(Nm or ftlb)

Hydraulic
Tool Model
Required
Hydraulic
Tool
Pressure+
(barg or psig)

Hydraulic Bolt Tensioning

Actual (Hand)
Torque
Value+ (Nm
or ft-lb) or
Hydraulic
Tool
Pressure+
(barg or psig)

1816 ft
(2462)

HTWP3140P-A

1816ft
(2462)

HTWP3140P-A

1816ft
(2462)

HTWP3140P-A

8500psi

N\A

N\A

N\A

N\A

8500psi

8500psi

F7

PMS
riggers

N\A

N\A

Required
Residual Bolt
Stress+
(N/mm2 or
lbs/in2 )

Reqd Tool
Pressure
1st Pass+
(barg or
psig)

Actual Tool
Pressure
1st Pass+
(barg or
psig)

Hydraulic
Tool Model

Reqd Tool
Pressure
2nd Pass+
(barg or
psig)

Actual Tool
Pressure
2nd Pass+
(barg or
psig)

-------

-------

-------

-------

-------

-------

-------

-------

-------

-------

-------

-------

-------

-------

Joint Tightened
by (Print)

Date
Tightened

Signature to
Confirm
Compliance with
Tightening
Procedure

A.omara

05/07/
2010

A.omara

05/07/
2010

-------

A.omara

06/07/
2010

-------

-------

PMS
riggers

24/08/
2010

-------

-------

-------

N\A

-------

-------

-------

PMS
riggers

24/08/
2010

N\A

-------

-------

-------

PMS
riggers

24/08/
2010

-------

-------

-------

-------

-------

-------

PMS
riggers

24/08/
2010

-------

-------

-------

-------

-------

-------

PMS
riggers

24/08/
2010

------N\A
N\A

N\A
5

SHT of

Leak
Tested by

SL1 Leak
Test
Number

Operational Phase
POST SH1 ACCEPTANCE
Service
Test
after
start up

Service
Test
after
warm
up

Service
Test
Period

Service
Test
Period

Service
Test
Period

Service
Test
Period

Temporary
Tag
Removal
Date

N\A
6

F12

PMS
riggers

N\A

N\A
N\A

F10

PMS
riggers

N\A

N\A

N\A

N\A
8

F11-F16

PMS
riggers

N\A

N\A

N\A

N\A
------------------4.4
Parts A & B to be completed before the SH1 can be signed and the equipment safely operated
+
4.5
Please state units
4.6
Bolt Lubricant To Be Used for Torque Tightening:
COMPLETED
APPROVED BY
REMARKS (include any procedural non-compliances);
BY
FLANGES FACE INSPECTED BY - CIC -ONLY
COMPANY
GUPCO.ENG
PMS
ONE BOLT IN F6 WAS SHORT AND2 BOLTS SHORT IN F15
SIGNATURE
INSTALL BOLTS ASTEM193-B8 IN FLANG F4
DATE

Complete Post SH1 acceptance - equipment can be operated safely


without jeopardizing plant, personnel or the environment

GUPCO PROJECTS QA/QC DEPT.


DOC. NO. GU-0000-PM-PRO-0047 REV. C2
GUIDELINES FOR THE MANAGEMENT OF BOLTED JOINT INTEGRITY
PRINT
NAME
* DELETE AS APPLICABLE

GUPCO PROJECTS QA/QC DEPT.


DOC. NO. GU-0000-PM-PRO-0047 REV. C2
GUIDELINES FOR THE MANAGEMENT OF BOLTED JOINT INTEGRITY

JOINT INTEGRITY CERTIFICATE

Form JI1 SHT of


Part A

Tag
Number

Location
(P&ID and
Description)

Joint
Assembled by
(Print)
Signature to
Confirm
Compliance
with Assembly
Procedure

Torque Tightening
Required
Torque
Value+
(Nm or ftlb)

Hydraulic
Tool Model
Reqd Tool
Pressure+
(barg or psig)

Actual (Hand)
Torque Value
(Nm or ft-lb)
or Hydraulic
Tool
Pressure+
(barg or psig)

Part B
Hydraulic Bolt Tensioning
Required
Residual Bolt
Stress+
(N/mm2 or
lbs/in2 )

Reqd Tool
Pressure
1st Pass+
(barg or
psig)

Actual Tool
Pressure
1st Pass+
(barg or
psig)

Hydraulic
Tool Model

Reqd Tool
Pressure
2nd Pass+
(barg or
psig)

Actual Tool
Pressure
2nd Pass+
(barg or
psig)

Joint Tightened
by
(Print)
Signature to
Confirm
Compliance with
Tightening
Procedure

Date
Tightened

Leak
Tested by

SL1 Leak
Test
Number

Part C
Service
Test
after
start up

Service
Test
after
warm
up

Service
Test
Period

Service
Test
Period

Service
Test
Period

Service
Test
Period

Temporary
Tag
Removal
Date