ADDITIONAL AGREEMENT/APPROVAL RECORD

Party Ref Ind Name Sign Date

Revision Philosophy
All revisions for review will be issued at R01, with subsequent R02, R03, etc as required.
All revisions approved for issue or design will be issued at A01, with subsequent A02, A03, etc as required.
Documents approved for Construction will be issued at C01, C02, and C03 respectively.
Documents or drawings revised as “As built” will be issued as Z01, Z02 Z03 etc.
Narrative sections revised from previous approved issues are to be noted in the table below and/or
highlighted in the RH margin (using the appropriate revision status) thus: | A02
Previous revision highlighting to be removed at subsequent issues.
Drawings/diagrams revised from previous approved issues are highlighted by 'clouding' the affected areas
and by the use of a triangle containing the revision status.

Revision History

Revision No. Date of Reason for change

issue

C01
07/08/2016 Issued for Approval

A01
07/03/2015 Issued for Review

R01
03/03/2015 Issued for Internal Review

GBU-NG01016919-GEN-BA6070-00037 BOLT TIGHTENING PROCEDURE

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 CONTENTS

1. PURPOSE 04

2. REFERENCES 04

3. DEFINITIONS 04

4. ABBREVIATIONS 05

5. FLANGES DIMENSIONAL DETAILS 06

6. JOINT PREPARATION 06

7. TORQUING PROCEDURE 09

8. TORQUE VALUES 10

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 1.0 PURPOSE
The purpose of this document is the minimum construction requirements for Safety &
enviromental, general guidelines for Flanges Bolt tightening(Torquing) of new pipeline.

2.0 REFERENCES
DEP 82.00.10.10-Gen - Project Quality Assurance

DEP 31.40.00.10-Gen – Pipeline Engineering

DEP 31.40.40.38-Gen – Hydrostatic Pressure Testing of New Pipelines

DEP 61.40.20.30-Gen - Welding Pipelines & Related Facilities

ISO 13623:2000 Petroleum & Natural Gas Industries-Pipeline

Transportation Systems

ASME B31.8 - Gas Transmission and Distribution System

GBU-NG01016919-GEN-LA6046-00001 - Cleaning and Gauging Procedure.

GBU-NG01016919-GEN-LA6046-00002 – Procedure for Hydro test of New Pipelines.

3.0 DEFINITIONS

Company Shell Petroleum Development Company of Nigeria (SPDC)

Contractor Morpol-Jaihind-Zakhem Association (MJZA)
Assembly An arrangement of pipes/components such as a crossing, pig trap,
block valve station or riser.
Pre-test A hydrostatic pressure test carried out on part or all of an
assembly prior to final installation.
Test equipment All temporary fittings, piping, test heads, pumps, pigs, materials,
equipment and consumables used for the pressure testing
operations.
Test point The primary point of pressure measurement of a test section. This
is normally at the point of pressurisation.

Test pressure The pressure at which the pipeline is tested for strength.

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 Test procedure The Contractor's procedure covering preparation, testing,
rectifying and post- testing activities.
4.0 Abbreviations

MAOP Maximum Allowable Operating Pressure

SMYS Specified Minimum Yield Strength

ISO International Organization for Standardization

ITP Inspection and Test Plan

KPI Key Performance Indicators

MC Mechanical Completion

MOC Management of Change

MTC Material Test Certificate

NCR Non-Conformance Report

NDT Non Destructive Test

PQP Project Quality Plan

RCA Root Cause Analysis

SCE Safety Critical Element

TPI Third Party Inspection

TS Technical Standard

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 5.0 Flanges Dimensional Details

Class 2500
Nominal
Pipe Size
NPS Diameter of No. Diameter of Diameter of Bolt
(inches) Flange of Bolts Bolt Holes Circle
(inches) Bolts (inches) (inches) (inches)

6 19 8 2 2.12 14-1/2

8 21-3/4 12 2 2.12 17-1/4

10 26-1/2 12 2-1/2 2.62 21-1/4

12 30 12 2-3/4 2.88 24-3/8

Note: The specified diameter of the bolt holes will be measured by using A venier caliper

6.0 JOINT PREPARATION

• Thoroughly clean the flange faces and check for scars.
• Check studs and nuts for proper size, piping material specifications and
cleanliness; and any rust, paint or corrosion to be removed by wire brushing
or bead blasting.
• Remove burrs from all threads.
• If one stud is replaced, all must be replaced.
• Gaskets are to be checked for proper size and specifications. Metal gaskets
to be free of grease, rust or burrs.
• Check flange spot face where nut makes contact. This area must be clean
and smooth. Use 1/4" thick hardened steel washers on both ends of studs
when installing new bolts.
• Check flange alignment: alignment of parallelism tolerance shall be limited to
3/32" per foot of pipe diameter measured at any point on the flange
circumference.

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 • Number the studs and nuts for identification and control during bolting
procedure.
• Lubricate the thread area of both stud and nut. Also lubricate the face of the
nut in contact with the flange. Apply lubricant thoroughly to all surfaces.
• Where applicable, the flanges will be pulled together and snugged with hand
wrenches. When working with heavier flanges that have no support, it is
acceptable to use an impact to lightly snug a maximum of 8 bolts beginning
with bolt #1 and following the bolt pattern.

8 Bolt Flanges

• First round - 30% of final torque (flange sequential order)

• Second round- 60% of final torque (flange sequential order)
• Third round - 100% of final torque (flange sequential order)
• One final time - clockwise or counter clockwise sequentially around the flange.

8 Bolt Flanges Tightening Sequence

• Sequential Order: 1-2, 3-4, 5-6, 7-8

• Rotation Order: 1, 5, 3, 7, 2, 6, 4, 8

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 12 Bolt Flanges

• First round - 20% of final torque (flange sequential order)

• Second round - 40% of final torque (flange sequential order)
• Third round - 80% of final torque (flange sequential order)
• Fourth round - 100% of final torque (sequential order)
• One final time - clockwise or counter clockwise sequentially around the flange.

12 Bolt Flanges Tightening Sequence

• Sequential Order: 1-2, 3-4, 5-6, 7-8, 9-10, 11-12

• Rotation Order: 1, 5, 9, 3, 7, 11, 2, 6, 10, 4, 8, 12

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 7.0 TORQUING PROCEDURE
• All torque values to be noted as per 30%, 70% and 100% torque values and
follow as above pattern sequence for the bolt tightening.
• Set the torque wrench to the 30% torque value and apply the torque wrench
in the criss-cross pattern for that particular flange until all bolts have been
tightened once.
• Set the torque wrench to the 70% torque value and repeat step 2.
• Set the torque wrench to the 100% torque value and repeat the criss-cross
pattern a third time. Check all bolts at 100% torque with a circular pattern.
• A final circular pass will be made with the torque wrench set at 100% torque
value 24 hours after the third pass is completed on joints with spiral wound
gaskets.
 Lubricating the bolt was mentioned earlier as one of the variables that would
reduce the K Factor.
 Actually, just lubricating the bolt is not enough. The lubricant must be the correct
one for the bolt material being used. It must also be able to withstand the

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 temperature and pressure to which it will be subjected. A lubricant is not effective
if it breaks down or is pushed out from between the threads of the fastener. It
must remain between the threads, nut faces and washers to be effective.
8.0 TORQUE VALUES

TORQUE VALUES # 2500 FLANGES

Size of
Dia Quantity of Torque Value Torque Value
Sl.No Bolt
(Inches) Bolts (Ft-Lbs) (Nm)
(Inches)

1 6 8 2 3100 4200

2 8 12 2 3100 4200

3 10 12 2.5 5370 7280

4 12 12 2.75 8195 11110

Note : Bolt Lubricant Molycote 1000.

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 Shell Petroleum Development Company
(SPDC)
GBARAN-UBIE INFILL PROJECT
(GBU2A)
DOCUMENT REVIEW OBSERVATIONS & COMMENTS SHEET

GBU-NG01016919-GEN-BA6070-00037 Revision Code A01 Return Code 2 Obinna Agu

Comments:
5 1.00 how do you measure 2.12inches, 2.62 inches and 2.88inches being the specified diameter of the bolt holes.

Contractor's Return Comments:

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