Flange Joint Bolt Tightening Procedure
December 25, 2016 | Author: Adiguna Dhana | Category: N/A
Short Description
Download Flange Joint Bolt Tightening Procedure...
Description
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
Flange Joint Bolt Tightening Procedure
Revision Log Register
Document Number
Document Title
: PHE-ONWJ-G-PRC-0016
: Flange Joint Bolt Tightening Procedure
Revision
: 0
Page
Date
Revise
PHEONWJ Reviewer
1
2
3 4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
PHEONWJ-G-PRC-0016 Rev. 0.
Page
2
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
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 Do‟s & Don‟ts ........................................................................17
11.2.
Bolt Tensioning
– Do‟s and Don‟ts ......................................................................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
PHEONWJ-G-PRC-0016 Rev. 0.
Page
3
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
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
PHEONWJ-G-PRC-0016 Rev. 0.
Page
4
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
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
PHEONWJ-G-PRC-0016 Rev. 0.
Page
5
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
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
½” square drive. The wrench contains a mechanism that clicks when the required torque
value is achieved.
PHEONWJ-G-PRC-0016 Rev. 0.
Page
6
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
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.
PHEONWJ-G-PRC-0016 Rev. 0.
Page
7
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
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.
PHEONWJ-G-PRC-0016 Rev. 0.
Page
8
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
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:
o
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!
o
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:
PHEONWJ-G-PRC-0016 Rev. 0.
Page
9
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
Flange Joint Bolt Tightening Procedure
o
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
PHEONWJ-G-PRC-0016 Rev. 0.
Page
10
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
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=
σLE / E
Where :
D= Elongation of the stud in inches
σ = Target Bolt stress
L
E= Effective bolt length in inches
E = Modulus of Elasticity
PHEONWJ-G-PRC-0016 Rev. 0.
Page
11
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
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
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
Page
12
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
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 Owner‟s
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 Owner‟s Engineer‟s approval.
7.
Thread lubricants shall be suitable for the operating temperature of the system and
shall require the approval of the Owner‟s Engineer. Thread lubricants for bolting shall
not contain lead. Thread lubricants for austenitic bolting shall not contain chlorides.
Unless otherwise specified by the Owner‟s 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
PHEONWJ-G-PRC-0016 Rev. 0.
Page
“criss-cross”
13
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
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 Ø 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.
PHEONWJ-G-PRC-0016 Rev. 0.
Page
14
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
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.
o
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
1
Number of
Criss-Cross Tightening Sequence Procedure
Bolt Flange
1-3-2-4
4
1-5-3-7-2-6-4-8
2
8
3
12
1-7-4-10-2-8-5-11-3-9-6-12
4
16
1-9-5-13-3-11-7-15-2-10-6-14-4-12-8-16
5
20
1-11-6-16-3-13-8-18-5-15-10-20-2-12-7-17-4-14-9-19
6
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
7
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
8
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
PHEONWJ-G-PRC-0016 Rev. 0.
Page
15
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
Flange Joint Bolt Tightening Procedure
No
Number of
Criss-Cross Tightening Sequence Procedure
Bolt Flange
9
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:
o
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.
Page
16
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
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 Do’s & Don’ts
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. Don’ts
a.
Never tighten damaged or corroded bolts.
PHEONWJ-G-PRC-0016 Rev. 0.
Page
17
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
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
– Do’s and Don’ts
1.
Do’s
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. Don’ts
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.
Page
18
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
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
3
1
4 BOLT
8 Bolts
Sequence Order
1 – 2
3 – 4
5 – 6
7 – 8
PHEONWJ-G-PRC-0016 Rev. 0.
2
4
Rotation Order
1
3
2
4
3
7
1
5
8 BOLT
6
2
Rotation Order
1
7
3
5
2
8
4
6
8
4
Page
19
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
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
3
9
7
5
11
1
12 BOLT
2
12
Rotation Order
1
5
9
3
7
11
2
6
10
4
8
12
6
8
10
4
16 Bolts
13
3
11
5
7
9
15
16 BOLT
1
16
2
10
8
6
12
4
14
Rotation Order
1
5
9
13
3
11
7
15
2
10
6
14
4
12
8
16
PHEONWJ-G-PRC-0016 Rev. 0.
Page
20
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
Flange Joint Bolt Tightening Procedure
Figure 7
Typical “Criss -Cross” Bolting Tightening Sequence for bolts 24 & bolts 28
PHEONWJ-G-PRC-0016 Rev. 0.
Page
21
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
Flange Joint Bolt Tightening Procedure
Figure 8
Typical “Criss -Cross” Bolt Tightening
for bolts 32
PHEONWJ-G-PRC-0016 Rev. 0.
Page
22
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
Flange Joint Bolt Tightening Procedure
Figure 9
Typical “ Criss -Cross” Bolt Tightening Sequence
for bolt 36
PHEONWJ-G-PRC-0016 Rev. 0.
Page
23
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
Flange Joint Bolt Tightening Procedure
Figure 10
Typical “ Criss -Cross” Bolt Tightening Sequence for bolts 40
PHEONWJ-G-PRC-0016 Rev. 0.
Page
24
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
Flange Joint Bolt Tightening Procedure
Figure 11
Typical “ Criss -Cross” Bolt Tightening Sequence for bolts 44
PHEONWJ-G-PRC-0016 Rev. 0.
Page
25
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
Flange Joint Bolt Tightening Procedure
Figure 12
Typical “Criss -Cross” Bolt Tightening Sequence for bolts 48
PHEONWJ-G-PRC-0016 Rev. 0.
Page
26
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
Flange Joint Bolt Tightening Procedure
Figure 13
Typical “ Criss -Cross” Bolt Tightening Sequence for bolts 52
PHEONWJ-G-PRC-0016 Rev. 0.
Page
27
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
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
¾
30
22
59
43
94
69
1
36
26
59
43
94
69
1¼
48
35
94
69
105
78
1½
48
35
165
121
185
137
2
94
69
94
69
105
78
2½
94
69
165
121
165
121
3
117
86
165
121
185
137
4
94
69
165
121
329
243
6
165
121
185
137
441
325
8
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).
PHEONWJ-G-PRC-0016 Rev. 0.
Page
28
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
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
¾
48
35
94
69
94
69
165
121
185
137
206
152
1
48
35
94
69
94
69
263
194
296
218
329
243
1 ¼
48
35
94
69
105
78
296
218
329
243
538
397
1 ½
54
40
165
121
185
137
441
325
489
361
785
579
2
94
69
94
69
105
78
263
194
329
243
538
397
2 ½
105
78
165
121
165
121
392
289
489
361
714
526
3
117
86
165
121
185
137
329
243
714
526
1096
809
4
105
78
185
137
329
243
642
474
997
735
1947
1436
6
185
137
185
137
441
325
714
526
1347
994
4332
3195
8
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.
Page
29
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
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
¾
-
-
94
69
94
69
165
121
185
137
206
152
1
48
35
94
69
94
69
263
194
296
218
362
267
1 ¼
48
35
94
69
105
78
263
194
296
218
538
397
1 ½
48
35
165
121
165
121
392
289
441
325
785
579
2
94
69
94
69
105
78
263
194
329
243
538
397
2 ½
94
69
165
121
165
121
392
289
441
325
785
579
3
94
69
165
121
185
137
296
218
714
526
997
735
4
94
69
165
121
296
218
642
474
997
735
1947
1436
6
165
121
185
137
441
325
642
474
1213
894
4766
3515
8
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.
Page
30
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
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
2
(IN
)
¾ x 10
10
1-1/4”
0.334
7/8 x 9
9
1-7/16”
0.461
1x8
8
1-5/8”
0.605
1-1/8 x 8
8
1-13/16”
1-1/4 x 8
8
1-3/8 x 8
8
1-1/2 x 8
8
1-5/8 x 8
8
1-3/4 x 8
8
1-7/8 x 8
8
2x8
8
2-1/8 x 8
8
2-1/4 x 8
8
2-3/8 x 8
8
2-1/2 x 8
8
2-3/4 x 8
8
3x8
8
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
8
3-1/2 x 8
8
3-3/4 x 8
8
4x8
8
4-1/4 x 8
8
4-1/2 x 8
8
4-3/4 x 8
8
5x8
8
5-1/4 x 8
8
5-1/2 x 8
8
5-3/4 x 8
8
6x8
8
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).
PHEONWJ-G-PRC-0016 Rev. 0.
Page
31
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
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)
2
3
4
6
8
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
PHEONWJ-G-PRC-0016 Rev. 0.
Page
32
of
37
DOCUMENTUM|09/16/13|Paper Copies Are Uncontrolled
PHEONWJ Ltd.
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)
2
3
4
6
8
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
of
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)
3
4
6
8
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)
2
3
4
6
8
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)
2
3
4
6
8
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
2
3
:
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
2
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
View more...
Comments
