Rp Flng Tightening

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Ltd, India

Best Practices For Flange Tightening Please send your comments and suggestions to the author. This document is intended for guidance purpose and may be adopted with minor modifications by any functional department within RIL group of companies. Reproduction of this document or parts thereof in not allowed unless written permission is obtained from the approving authority.

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 1 of 31 Date: 21-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Ltd, India

INDEX 1 2 3 4 5 5.1 5.2 5.3 5.4 5.5 5.6 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 7.0 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 8.0 8.1 8.2 9 10 11 12 13 14

Introduction

03

Scope Objective Applicable codes Design calculation Gasket seating Bearing stress on flanges Pressure thrust Dead load bending moment Thermal bending moment Thermal gradient at the bolts General requirement Material identification Flanges Hardware Lubricants Gaskets Flange fit up Manual tightening Manual torque Hydraulic torque Tensioning Disassembly and retightening Installation procedure Pre bolting inspection Flange and gasket assembly Stud bolt torquing Bolt tensioning Tightening Manual tightening Manual torque Hydraulic torque Quality assurance Tool calibration Compliance with installation procedure Annexure I – Tolerance flange alignment Annexure II- Tensioning torque details Annexure III- Tightening/torquing/tensioning record Annexure IV- Flange Fit up/Tightening check list Annexure V- Bolt tightening sequence References

03 03 03 03 03 03 03 03 04 04 04 04 04 05 05 05 05 06 06 06 06 06 06 06 06 08 08 08 09 09 09 09 09 10 11 12 24 25 26 31

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 2 of 31 Date: 21-Mar-07 Revision no.: 0.0

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Reliance Industries Limited

Copyright: Reliance Industries Ltd, India

1.0 INTRODUCTION Tightening of the flanges is a common and important maintenance activity in a continuous process industry. Maintenance crew must be highly skilled & the supervisor handling the job should be well conversant with the details & procedures. Since the failure of the flange joint can lead to hazardous situation as well revenue loss to the organization in the form of direct cost as well as in the form of opportunity cost, enough importance should be given to this maintenance activity. 2.0 SCOPE In summary, this will consist of pipe to pipe, pipe to equipment, instrument to pipe, flanged connections, their associated component parts, and preparation i.e. gaskets, studs, bolts, nuts, cleaning, lubrication, alignment, manual tightening, manual torquing, hydraulic torquing, and associated documentation. Then procedure is based on standard ANSI 16.5 and B16.74 3.0 OBJECTIVE Objective of this document is to lay down the best practices & procedures to be adopted in Reliance Industries Ltd for tightening the flanges. 4.0 APPLICABLE CODES ƒ ƒ ƒ

ANSI B 1.1 - Unified Inch Screw Threads ASME Section VIII - Boiler and Pressure Vessel Code, Pressure Vessels Division 1 Code for Pressure Piping • B31.1 - Power Piping • B31.3 - Chemical Plant and Petroleum Refinery Piping • B16.5 - Steel Pipe Flanges and Fittings • B16.47 -Large Diameter Steel Flanges

5.0 DESIGN CALCULATIONS The design calculations used to arrive at the minimum bolt loading include the following criteria. 5.1 Gasket Seating. The minimum load on the gasket which will seat the gasket on the flange faces. This load is equal to the optimum gasket seating stress specified by the gasket manufacturer at the operating temperature. 5.2 Maximum Bearing Stress on Flanges 1. Austenitic stainless steel flanges

350N/mm2

2. Ferritic steel flanges

450N/mm2

5.3 Pressure Thrust The hydrostatic end thrust that tends to separate the flanges. 5.4 Dead Load Bending Moment The maximum moment occurring at the flange joint when dead weight loading is considered independently of all other loadings.

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

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Copyright: Reliance Industries Ltd, India

5.5 Thermal Bending Moment The maximum moment occurring at the flanged joint when thermal loading is considered independently of all other loadings. 5.6 Thermal Gradient at the Bolts For un-insulated flanged joints, the bolts are assumed to be a different temperature from the flanges, causing differential thermal expansion across the bolted joint. For systems operating above installation temperatures, this differential will tend to tighten the joint. For systems operating below the installation temperature this differential will tend to open the joints. Additionally if the flange joint will be subjected to high temperatures, the initial calculated bolt load shall be increased by the amount necessary to ensure an adequate working life for the joint, considering loss of bolt load due to the effect of "creep and relaxation" on the bolts. Gasket relaxation should be incorporated as well. The hydrostatic test condition shall be also considered. For mechanical equipment stresses are compared against the lowest minimum yield stress determined for bolting materials found in the ASME VIII, Div. I.

6.0

GENERAL REQUIREMENTS

6.1

Material Identification

The operating process temperature to which a piping system is designed is a critical factor. Temperature affects and dictates the materials specified in the design of flanged joints. Specifically, bolts and studs stretch easier at higher temperatures. If a bolt or stud graded for a lower temperature is used in a high temperature system, it may stretch, lose its memory, and at the very least leak. At worst, it can catastrophically fail, and cause great loss of life. 6.2 Flanges Flange surfaces shall be finished in accordance with the flange finish description referred to by the Piping Class. Gasket surfaces shall be inspected by the fit up crew, and shall not show evidence of damage, or contaminants. The bolt or nut seating surface shall be flat and provide a low friction, full contact area for bolt head or nut. Discrepancies shall be addressed to Field Engineering for evaluation. Note: Cast firewater valves / flanges are an exception to this rule. In extreme case, the flange may require re-machining. Should this situation arise, Field Engineering shall contact procurement and project controls for evaluation of potential back charges. 1. Gasket surface areas shall be cleaned in accordance with the gasket manufacturer’s installation instructions. Typically previous gasket materials and contaminants such as dirt, oil, and grease. Thin, uniform preservative coatings are generally acceptable. Provided they do not fill seating finish or show evidence of build up or runs. When using a wire brush for cleaning, ensure the wire brush is compatible with the flange material i.e. do not use carbon steel bristles on stainless steel flanges. The direction of brushing shall also follow the seating surface grooves or finish. Take care not to over smooth the finish, and use only Hand brushes. Depending on gasket type, minimum profiles are required for optimum gasket performance. Power brushes shall only be used, if approved by Field Engineering.

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 4 of 31 Date: 21-Mar-07 Revision no.: 0.0

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Copyright: Reliance Industries Ltd, India

2. Flange gasket seating surfaces shall be inspected for scratches, dents, scoring, and other damage. Depending on the gasket type, pipe size, and extent of imperfections, some deviation can be accommodated, without flanged joint degradation. Contact Field Engineering if further interpretation is required. 3. Flange seating surfaces shall also be monitored for flatness, around their circumference. 6.3

Hardware

The fit up crew shall verify all studs, nuts, and bolting hardware against the respective ISO’s and MTO’s to ensure the correct components are used when assembling flange joints, and piping system’s in general. Studs shall be of sufficient length to achieve full thread engagement plus a minimum of two threads beyond the nut, or threaded flange. Studs greater than 1-1/8" diameter shall have one full stud diameter beyond the nut to allow tensioning. Any discrepancies or questions shall be addressed to Field Engineering for resolution. Studs, nuts, and bolting hardware shall be inspected, and deemed free of damage, corrosion, and contaminants. Studs, nuts, and bolting hardware threads shall be coated with an approved lubricant. 6.4

Lubricants

Shall be used only the approved lubricants: Loctite Anti Seize Paste # 771 6.5 Gaskets Design engineering selects gaskets as a joint system to provide optimum performance through out the range of expected operating pressures and temperatures. The fit up crew shall follow the procedure below, when installing gaskets. Regardless of gasket type: 1. Prior to installing gasket, ensure all flange and gasket surfaces are cleaned and dry. 2. Until ready for installation, the gasket shall remain horizontal. And attached to its accompanying packaging. 3. For gasket centering or vertical applications, check with the Field Engineer for approved spray contact adhesive. 6.6

Flange Fit up. 1. All above preparations and verifications must have been performed prior to flange fit up. Special attention shall be paid to appropriate material selection, identification, and cleanliness. 2. Flanged piping shall be properly supported. It is preferable that pipe be in its final position with permanent supports installed. 3. Flanged equipment shall be properly supported, leveled, aligned, and locked in its final position. It is preferable that final grouting and curing be complete. 4. The pipe itself shall be inspected, and any dirt, tools, or construction debris removed. The Fit up crew foreman shall indicate the pipe is clean on Annexure IV, the Flange Fit up / Tightening / Torquing Checklist. For un-tested joints this activity shall also be noted on Annexure III, the Tightening/Torquing/Tensioning Record. Any problems shall be addressed to Field Engineering. 5. Flange face alignment shall be within 1 mm per 10 inch pipe diameter. On pipe to pipe flanges, loosen adjacent pipe supports and adjust to achieve proper alignment. When performing pipe to equipment fit up, only the pipe shall be adjusted. 6. In no case, shall the equipment be adjusted to achieve alignment. 7. Contact Field Engineering should there be any problem.

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

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Copyright: Reliance Industries Ltd, India

8. Flange face stud, or bolt, hole alignment shall be within 1.5 mm. When performing pipe to equipment fit up, only the pipe shall be adjusted. In no case, shall the equipment be adjusted to achieve alignment. Contact Field Engineering should there be any problem. 9. Stud/bolt, holes shall be clean, and free of any foreign debris. This debris will contaminate flange and gasket surfaces. 10. Install sufficient studs to locate the gasket. 11. Install the gasket. Do not use force or use seating compounds. Contact Field Engineering if problems arise. 12. Install the remaining studs, bolts, and /or nuts, finger tight. 13. Using Annexure IV, the Flanged Joint / Tightening Checklist. The fit up crew foreman shall assure all tested flanged joints have been properly assembled with the correct components. And are ready for the appropriate tightening, torquing, or tensioning procedure. 14. If the flanged joint will not be hydro-tested, Annexure IV the fit up crew foreman shall sign, date and note his badge number on the Flange Fit up / Tightening/Torquing Completion Record shall also be completed. This input sheet shall than be turned into Field Engineering. It will be entered into the database to ensure the flanged joint will receive additional quality control surveillance during hydro-test restoration, and prior to mechanical completion, and turnover to client. 6.7

Manual Tightening Flange bolts may be tightened by non-calibrated hand combination and hammer wrenches on 150 lb. rated utility piping systems only.

6.8

Manual Torque Flange bolts shall be tightened with calibrated torque wrenches / tools on all hydrocarbon systems for all rated pressures up to 1” and on all utility systems rated 300 and greater. Hammer tightening of bolts or studs in any hydrocarbon system are not permitted. Torque tightening of flanged joints, uses the pitch of a threaded bolt or stud to transform rotational movement (relative to the nut or threaded flange), to provide stress or tension in the bolt or stud. Properly designed, this stress is adequate to maintain the integrity of flanged joint, without a permanent stretch or change in length. For any given material type and diameter of bolt or stud, there is maximum stress allowed. Exceeding this may cause a bolt or stud to stretch and “lose its memory” of its original length. At this point, all we have is a “longer” bolt or stud with less corresponding stress. Over torque of flanged joints is not allowed. Specifically, bolts and studs may stretch or break, gaskets, or flange faces may be damaged, and continue the very least leak. At worst, it can catastrophically fail, either during torquing or operation, and cause injury or lose of life.

6.9

Hydraulic Torque When specified, requested by Field Engineering, or when the flanged joint requires a torque value of greater than 500 Ibf.ft (678 Nm) to be applied, calibrated hydraulic torquing will be utilized. Instructions accompanying the torquing equipment shall be strictly followed.

6.10

Tensioning

Stud and bolt sizes 1-1/8 inches and greater, and specified critical flanged joints, require tensioning, regardless of service or rating. Tensioning requires one stud diameter extending beyond the nut, on the most accessible side of the flange.

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

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For Internal Circulation Only 6.11 • • • •

Reliance Industries Limited

Copyright: Reliance Industries Ltd, India

Disassembly and re-tightening of previously tightened flanged joints Studs, nuts, and bolting hardware shall be loosened in the sequence show in Figures 1 thru 5, as applicable. Using Figures 1 thru 5 loosen each nut by l/2 in sequence. Every nut or bolt shall backed off at 1/2 turn before completely loosening any nut or bolt. Prior to re-tightening, all inspections and verifications shall be performed as shown in above paragraphs. Studs, nuts, and bolting hardware shall be re-tightened in accordance with the procedures

7.0

INSTALLATION PROCEDURE

7.1

Pre-Bolting Inspection •

Inspect the gasket material for possible defects such as bends or creases.

•

Inspect the mating flanges for dirt, mechanical damage and corrosion. Use a suitable solvent to clean the surfaces. The contact area of the flanges should be free from excessive pitting, radial tool marks and scratches.

•

Inspect the studs and nuts. They should be free of dirt and corrosion. The studs should be straight and the threads free from nicks, burrs and chips. Molykote. P 37 shall be used as lubricant / anti seize compound, except for oxygen lines. Before application the studs shall be degreased.

7.2

Flange and Gasket Assembly •

Ensure gasket of correct dimension and of specified material is used.

•

Gasket shall be located correctly to ensure full sealing as indicated in drawing. For example gasket on tube sheet of exchanger needs to be located so that outer periphery of gasket matches with OD of tube sheet at all points.

•

Before inserting the gasket in between the pipe flanges, check the flanges are parallel and co-axial (When none of the bolts is installed in the flange).

•

As per ANSI B 31.3 clause no. 335-C, permitted tolerances are as follows: Flange faces shall be aligned to the design plane within 1mm in 200mm (1/16 in. /ft) measured across any diameter; flange bolts holes shall be aligned within 3mm (1/8 inch) maximum offset.

•

If pipe flanges are not meeting the ANSI B31.3 requirement, piping shall be rectified.

•

All gaskets seating area shall be cleaned properly before gasket insertion. If serration is damaged, reserration must be done. • Finger tightens all studs and nuts. Center studs between nuts so an equal number of threads project at each end. When tensioning is required a threaded length of one times bolt diameter should protrude at the end where the bolt tensioners are to be placed. The stud end away from the tensioned side shall be flush or maximum protrude two thread windings. • For tolerances on flange joints see Annexure I

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Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 7 of 31 Date: 21-Mar-07 Revision no.: 0.0

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7.3

Reliance Industries Limited

Copyright: Reliance Industries Ltd, India

Stud Bolt Torquing •

Ensure that material of all bolts and nuts is as specified.

•

Bolts & nuts shall be cleaned with suitable solvents like Diesel using wire brush, especially in threaded portion.

•

The bolt shall be lubricated with molybdenum di-sulfide and it is essential especially in all bolts of size 7/8” and above to check the application as the bolt load developed by torque is dependent on the lubrication of threads.

•

It is recommended to avoid use of short bolts on the flange joints.

•

Bolt torquing shall be applied for bolt sizes 1 inch and smaller, a manual torque wrench may be used. For larger bolts (> 1 inch), a suitable hydraulic torque wrench should be used at all times. Using torque loadings given in Annexure II. Make the first pass. Follow the tightening sequence from Annexure II. Make the second pass. Make the final pass. Bring the nuts up to the final torque value. Be sure to follow the same sequence.

• • • •

7.4

Bolt Tensioning Bolt tensioning shall be applied in accordance with Annexure II. The application of bolt-tensioning equipment shall be in strict accordance with the manufacturer's instruction manual and safety procedures. • The personnel using the equipment shall be adequately trained in its application. • To facilitate loosening of the nuts when required at some later date, it will be necessary to treat the thread of the bolts with an acceptable anti-seize compound before fitting the nuts. • Lubricant shall not be applied on bolts used in oxygen systems. • •

7.4.1

7.4.2

After the tightening procedure is completed the extended thread lengths of uninsulated connections (including H2 lines) shall be protected against the effects of corrosion to allow the nuts to be subsequently unscrewed. Protection shall be done using suitable (aluminum) screwed endcaps covering the full extended thread length. Upon completion of bolt tensioning each flange connection shall be provided with a wire seal 1) Materials to be used for wire seal: 2) Wire: stainless steel 3) Seal: stainless steel or aluminimum.

The use of "low melting" metals such as zinc or lead is prohibited. 7.5 TIGHTENING •

It is important that all bolted joints are tightened uniformly and in a diametrically staggered

•

In case of pipe flanges 8"NB & up to 12"NB and having a pipe with spacer piece and minimum of two gaskets (which are getting compressed simultaneously during tightening) the distance between two

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

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flanges should be measured at four locations like 12’o clock, 3’o clock’ 6’o clock and 9’on clock positions and maintained equal for even tightening. The tightening shall be gradual and uniform. In case of flanges above 12” NB distance between the flanges shall be measured in 8 locations for uniform tightening. •

All stud bolts of 7/8" and above shall be tightened using torque wrench. While tightening the bolt with torque wrenches (for pipe / Manway flanges) ensure that tightening load to each bolt is applied as uniformly as possible. The tightening shall be carried out in three or four stages in steps of 30, 50 & 70 percent of the final torque value. At fourth stage again use 70 percentage of the final torque value.

•

For heat exchangers flanges torque values to be 30, 70,100 and 100 percent of the final torque value. Where recommended to use hydraulic tensioner for bolt tightening follow the manufacturer recommendations.Some tightening Methods are

7.5.1 • • • 7.5.2 • •

Manual Tightening Verify that the general requirements above have been completed. Tightening shall be accomplished utilizing non-calibrated hand tools. The tightening sequence shown in Figures 1 thru 5 shall be adhered to regardless of the tightening technique. To ensure even tightening of the flanged joint. At the request of Field Engineering, torquing may substitute manual tightening. Manual Torque Verify that the general requirements above have been completed. Including verification of tool calibration and range. Tools shall also be inspected for any indication of damage. Any discrepancies shall be noted for resolution and / or replacement. Torque shall be applied in stages of 30%, 60% and 100% of the specified torque values. The tightening sequence shown in Figures 1 thru 5 shall be adhered to regardless of tightening technique. To ensure even tightening of the flanged joint.

•

At the request of Field Engineering, hydraulic torquing or tensioning may substitute manual torquing.

7.5.2

Hydraulic Torque

With the exception, of the type of tool, all procedures that apply to manual torquing. Also apply to hydraulic torquing. 8

QUALITY ASSURANCE

8.1 Tool Calibration •

Acceptable makes of bolt tensioning equipment.

•

The calibration of torque wrenches and tensioners shall be checked against the manufacturer’s specifications upon receipt. Any tools that are out of calibration shall be rejected.

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

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DOC. No: GMS/RP/30

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•

A recheck of the calibration shall be made as per tool manufacturer standard. Any tool found to be out of calibration shall immediately be taken out of service for repair.

•

All flanged joints secured with tools found to be defective shall be rechecked with a properly functioning tool.

8.2

Compliance with Installation Procedures

Contractor shall provide a bolt tensioning and bolt torquing procedure for approval. The procedure shall show all required information amongst others: • • • • • •

Type of bolt torquing tensioning equipment Pre-installation measurements Precautions to be taken Record preparation instructions Establishment of the "break loose" torque based on minimum 4 tensioners 24 hours recheck procedure.

Contractor shall prepare a bolt torquing/tensioning record per flange joint. Those records shall be issued as part to the turnover packages. Records for flange joints requiring bolt torquing using bolts with bolt diameter < 1 inch are not required. Subject non documented flange connections shall be checked and signed after torquing in the field The numbering system for flanged joints in piping systems shall be as follows: Starting with the flow direction of each line number within one unit the flange sets shall be identified as Fl, F2, F3, etc. and line number. The flange numbering shall be added to the isometric line over by erection contractor. The numbering system for flanged joints of equipment not part of a piping system, ie manholes etc. shall be as follows. Each equipment flange set shall be identified with the nozzle number as shown on the equipment drawing followed by the equipment number.

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

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Copyright: Reliance Industries Ltd, India

Reliance Industries Limited ANNEXURE - I

1.0

TOLERANCE FLANGE ALIGNMENT FLANGE SIZE/RAT' G 1" 2”

600LB 600LB

FLG 0/D

Recommended tol. (2.5mm/m)

FLG FLANGE SIZE/RAT' G O/D C

Recommen ded tol. (2.5mm/m)

124mm

0 , 3 1mm

1" 900LB

14 9mm

0 , 37mm

165

0,41

2"

216

0, 54

4”

600LB

273

0,68

4"

292

0, 73

6”

600LB

356

0,69

6"

381

0, 93

10"

600LB

508

1, 27

10"

546

1, 37

12”

600LB

559

1,40

12"

610

1, 53

16”

600LB

686

1 , 72

16"

705

1,76

20"

600LB

813

2, 03

20"

857

2, 14

24"

600LB

940

2 , 35

24"

1041

2, 60

1"

1500LB

149mm

0 , 3 7mm

1" 2500LB

15 9mm

0, 40

2"

1500LB

216

0, 54

2"

235

0, 59

4”

1500LB

311

0, 78

4"

356

0, B9

6"

1500LB

394

0, 99

6"

483

1, 21

10"

1500LB

584

1, 46

10"

673

1,68

12"

1500LB

673

1, 68

12"

762

1, 91

16"

1500LB

826

2, 07

20"

1500LB

984

2, 46

24"

1500LB

1168

2, 92

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"

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Reliance Industries Limited ANNEXURE II TORQUE /TENSIONING DETAILS

1.0 TENSIONING Hydraulic tensioning shall be required on all hydrocarbon line classes flanged connections with studs sizes 28 mm (1 1/8”) and greater. Hydraulic tensioning shall also be required on all utility systems with flange ratings 300# ANSI and greater. 2.0 TORQUING All hydrocarbon line classes with flange studs 16 mm (5/8”) up to 25 mm (1”) inclusive shall have flanged connections tightened with the use of torque control. Manual torque tightening is acceptable up to torque values greater than 500 ft-lbs. This generally means manual torquing can be used for stud sizes up to 38mm (1 1/8”) diameter and hydraulic torque tightening is required for larger studs. The following table summarizes the studs, which require torque control during tightening. SERVICE CLASS

16mm 5/8”

25mm 1‘

28mm 1 1/8 “

31mm 1¼“

34mm 1 3/8 “

38mm 1½“

44mm 1¾“

50mm 2“ plus

Tightening Method Torquing

Tensioning

All Hydrocarbon All Utilities 300# Notes: (1)(2) NOTES: 1. Utilities 150 # ANSI class is exempted from tensioning or torquing. 2. Utilities means line classes: low pressure steam, instrument air, nitrogen 3.0

BOLT TENSIONING/TORQUING TABLE 600 LBS

flange size

150/300 LBS

900 LBS

DN

B

A

B

15

-

1/2

to

20

-

5/8

25

-

40

2500 LBS

1500 LBS B

A

B

A

B

3/4

to

3/4

to

3/4

to

to

3/4

to

3/4

to

3/4

to

5/8

to

7/8

to

7/8

to

7/8

to

-

3/4

to

1

to

1

to

1 1/8

to*

50

_

5/8

to

7/8

to

7/8

to

1

to

80

-

3/4

to

7/8

to

1 1/8

to*

1 1/4

to*

100

-

7/8

to

1 1/8

to*

1 1/4

to*

1 1/2

te

150

-

1

to*

1 1/8

to*

1 3/8

to*

2

te

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A

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Reliance Industries Limited

200

-

1 1/8

to*

1 3/8

to*

1 5/8

te

2

te

250

-

1 1/4

to*

1 3/8

to*

1 7/8

te

2 1/2

te

300

-

1 1/4

to*

1 3/8

to*

2

te

2 3/4

te

350

_

1 3/8

to*

1 1/2

te

2 1/4

te

>

te

400

-

1 1/2

te

1 5/8

te

2 1/2

te

>

te

450

-

1 5/8

te

1 7/8

te

2 3/4

te

>

te

500

-

1 5/8

te

2

te

3

te

>

te

600

-

1 7/8

te

2 1/2

te

3 1/2

te

>

te

650-700

-

>

te

>

te

>

te

>

te

800-1000

-

>

te

>

te

>

te

>

te

1050

-

>

te

>

te

>

te

>

te

A - Bolt size diameter (inch) - = Manual wrench tightening (no torquing/tensioning required) To = Torquing and no documentation required (bolt size < 1") To* = Torquing with Hydraulic torque wrench and complete documentation required (bolt size > 1") t.e = tensioning and documentation required.

1.4

Calculations for Bolt Torquing.

Calculations of bolt torquing result in required torque figures are as shown in the below table.

Stainless steel stud bolts (b8 & b8m) bolt stress: (25,000 psi) 172375 kpa Torque (Nm) Bolt Size

1st Pass

2nd Pass

Final Pass

½”

10

20

35

5/8”

25

50

75

3/4"

30

60

100

7/8"

50

110

160

1"

80

170

250

1-1/8"

120

240

360

1-1/4"

170

340

510

1-3/8"

230

460

690

1-1/2"

270.

550

820

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 13 of 31 Date: 21-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Copyright: Reliance Industries Ltd, India

Reliance Industries Limited

TORQUE VALUES FOR STANDARD ANSI / MSS FLANGES

150lb

MIN.

RES.

SUGGESTED APPLIED TORQUE VALUES (NM) BASED ON

NOMIN

BOLTING

BOLT

BOLT

RESIDUAL BOLT STRESS & PUMP PRESSURE

AL SIZE

NO. / SIZE

STRE

STRE

PUM

(INCH)

(INCH)

S TO

S(PSI

SEAL

)

*0.1

P Psi

*0.1

PUM

3

P Psi

*0.15

PUM P Psi

*0.2

PUMP Psi

12

12 X 7/8

25,338

48000

277

2039

365

2688

380

2801

515

3789

14

12 X 1

21,012

45000

388

2858

509

3748

532

3921

721

5317

16

16 X 1

19575

45000

388

2858

509

3748

532

3921

721

5317

18

16 X 1 1/8

18777

41160

404

2978

682

5027

747

5505

1013

7465

20

20 X 1 ¼

16321

42195

568

4187

700

5157

766

5645

1013

7465

24

20 X 1 ¼

13234

43250

785

3855

993

4874

1091

5357

1479

7264

28

28 X 1 ¼

14928

43790

793

3895

1004

4930

1144

5617

1495

7340

30

28 X 1 1/4

14928

43790

803

3942

1016

4987

1158

5686

1513

7430

32

28 X 1 ½

11238

38980

1267

2815

1610

3578

1812

4027

2410

5357

34

32 X 1 1/2

10941

36880

1199

2665

1523

3385

1738

3864

2279

5067

36

32 X 1 ½

12395

37797

1242

2761

1561

3470

1782

3961

2336

5194

38

32 X 1 1/2

13634

37460

1218

2707

1547

3439

1767

3928

2316

5149

40

36 X 1 1/2

14933

37797

1229

2731

1561

3470

1782

3961

2336

5194

42

36 X 1 1/2

14624

38441

1249

2776

1588

3530

1813

4030

2376

5281

44

40 X 1 1/2

14433

38882

1264

2809

1606

3569

1833

4075

2403

5341

46

40 X 1 1/2

15625

39013

1268

2818

1611

3581

1840

4091

2411

5360

48

44 X 1 1/2

15329

39408

1280

2846

1627

3617

1858

4130

2435

5414

50

44 X 1 7/8

11842

38285

2133

4742

3178

7066

3117

6930

4099

9112

52

44 X 1 7/8

12707

38708

2518

3231

3212

4121

3676

4716

4834

6202

54

44 X 1 7/8

13603

39124

2545

3266

3248

4167

3715

4767

4886

6268

56

48 X 1 7/8

13318

39398

2563

3288

3269

4195

3741

4800

4920

6312

58

48 X 1 7/8

14195

39742

2586

3318

3299

4233

3775

4843

4963

6367

60

52 X 1 7/8

13938

39982

2601

3337

3318

4257

3797

4871

4993

6406

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 14 of 31 Date: 21-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Copyright: Reliance Industries Ltd, India

Reliance Industries Limited

TORQUE VALUES FOR STANDARD ANSI / MSS FLANGES

300 lb

NOMINA

BOLTING

MIN.

RES.

SUGGESTED APPLIED TORQUE VALUES (NM) BASED ON

L SIZE

NO. / SIZE

BOLT

BOLT

RESIDUAL BOLT STRESS & PUMP PRESSURE

(INCH)

(INCH)

STRE

STRE

S TO

*0.1

PUM

*0.1

PUM

S(PSI

P

3

P Psi

SEAL

)

Psi

*0.15

PUM

*0.2

P Psi

PUMP Psi

3 1/2

8 X 3/4

17846

53599

193

1419

254

1869

275

2029

358

2638

4

8 X 3/4

21871

47117

170

1249

224

1649

241

1779

315

2319

5

8 X 3/4

29311

48843

175

1289

232

1709

248

1829

325

2398

6

12 X 3/4

26247

49546

178

1309

235

1729

255

1879

331

2438

8

12 X 7/8

28034

47426

274

2019

359

2648

391

2878

509

3748

10

16 X 1

21792

45626

393

2898

515

3798

561

4137

731

5387

12

16 X 11/8

22379

41818

549

4047

693

5107

789

5816

1029

7585

14

20 X 11/8

20608

42457

557

4107

704

5187

801

5906

1044

7695

16

20 X 11/4

20722

42791

785

5786

993

7315

1132

8345

1479

10903

18

24 X 1 1/4

22117

41104

727

3569

953

4681

1088

5340

1421

6978

20

24 X 1 1/4

26007

41442

759

3728

961

4720

1096

5380

1432

7031

24

24 X 1 1/2

23523

39429

1279

2843

1629

3620

1859

4133

2437

5417

28

28 X 1 5/8

21321

39707

1656

2124

2106

2702

2407

3088

3159

4054

30

28 X 1 3/4

20598

36098

1893

2429

2412

3095

2758

3539

3625

4650

32

28 X 1 7/8

19940

39121

2545

3266

3248

4167

3715

4766

4885

6267

34

28 X 1 7/8

22061

39466

2567

3293

3275

4201

3748

4809

4929

6324

36

32 X 2

18694

37615

2986

2974

3814

3799

4366

4349

5745

5722

38

32 X 1 1/2

34901

44064

1405

1802

1820

2335

2077

2665

2724

3495

40

32 X 1 5/8

32680

44952

1801

2310

2385

3060

2726

3497

3577

4589

42

32 X 1 5/8

35637

45276

1888

2422

2401

3081

2745

3521

3603

4623

44

32 X 1 3/4

33553

41682

2186

2804

2785

3573

3185

4087

4185

5369

46

28 X 1 7/8

35446

44509

2895

3714

3695

4741

4227

5423

5558

7131

48

32 X 1 7/8

33781

44850

2918

3744

3726

4781

4259

5465

5602

7187

50

32 X 2

32018

40422

3208

3195

4360

4342

4990

4970

6567

6541

52

32 X2

34336

42993

3142

3129

4360

4342

4990

4970

6567

6541

54

28 X 2 1/4

32884

40016

4559

3054

5838

3911

6682

4477

8807

5901

56

28 X 2 1/4

35094

42337

4823

3232

6171

4135

7070

4737

9318

6243

58

32 X 2 1/4

32958

40413

4604

3084

5890

3947

6749

4522

8894

5959

60

32 X 2 1/4

35025

42920

4890

3276

6257

4192

7168

4802

9446

6329

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 15 of 31 Date: 21-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Copyright: Reliance Industries Ltd, India

Reliance Industries Limited

TORQUE VALUS FOR STANDARD ANSI / MSS FLANGES

400 lb

NOMINA

BOLTING

MIN.

RES.

SUGGESTED APPLIED TORQUE VALUES (NM) BASED ON

L SIZE

NO. / SIZE

BOLT

BOLT

RESIDUAL BOLT STRESS & PUMP PRESSURE

(INCH)

(INCH)

STRES

STRE

TO

S(PSI

P

P

SEAL

)

Psi

Psi

*0.1

PUM

*0.13

PUM

*0.15

PUM

*0.2

PUMP

P Psi

Psi

4

8 X 7/8

20765

45681

263

1939

347

2558

377

2778

490

3608

8

12 X 7/8

24920

45487

262

1929

346

2548

376

2768

488

3598

10

16 X 11/8

21826

42753

561

4137

708

5217

807

5946

1051

7745

12

16 X 11/4

21324

43965

805

3955

1020

5007

1162

5706

1520

7464

14

20 X 1 3/8

22002

40070

991

4867

1258

6179

1436

7051

1879

9228

16

20 X 1 3/8

22002

40070

991

4867

1258

6179

1436

7051

1879

9228

18

24 X 1 1/2

22726

39689

1290

2867

1639

3644

1871

4160

2453

5453

20

24 X 1 1/2

22726

39689

1290

2867

1639

3644

1871

4160

2453

5453

22

24 X 1 5/8

21830

40724

1698

3774

2160

4802

2469

5489

3241

7204

24

24 X 1 3/4

22077

38207

2004

2571

2553

3276

2919

3746

3836

4922

26

28 X 1 3/4

21161

40258

2111

2709

2690

3452

3077

3947

4042

5186

28

28 X 1 7/8

20506

38725

2519

3232

3215

4125

3677

4718

4837

6206

30

28 X 2

20263

39572

3142

3129

4012

3996

4593

4574

6045

6021

32

28 X 2

22852

40227

3193

3181

4079

4063

4669

4650

6145

6120

34

28 X 2

25282

42821

3399

3386

4342

4325

4970

4950

6541

6515

36

32 X 2

24641

43097

3421

3408

4370

4353

5002

4982

6583

6557

38

32 X 1 3/4

33794

43972

2307

2297

2938

2927

3360

3347

4415

4397

40

32 X 1 7/8

31919

44619

2903

3725

3703

4751

4238

5437

5573

7150

42

32 X 1 7/8

34785

44850

2918

3744

3724

4777

4259

5465

5602

7187

44

32 X 2

33006

42702

3390

4349

4330

5555

4956

6359

6524

8370

46

36 X 2

321365

43081

3420

3406

4368

4350

5001

4981

6581

6554

48

28 X 2 1/4

34850

44463

5065

5044

6482

6456

7425

7396

9786

9747

50

32 X 2 1/4

32758

42544

4846

3247

6208

4159

7105

4761

9366

6275

52

32 X 2 1/4

35159

45055

5132

3439

6567

4400

7524

5041

9916

6644

54

28 X 2 1/2

34618

44887

7062

3460

9050

4434

10375

5084

13687

6707

56

32 X 2 1/2

32326

45133

7092

3475

9099

4458

10432

5112

13763

6744

58

32 X 2 1/2

24428

45282

7123

3490

9129

4473

10466

5128

13808

6766

60

32 X 2 3/4

30279

39832

8404

4118

10784

5284

12371

6062

16336

8005

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 16 of 31 Date: 21-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Copyright: Reliance Industries Ltd, India

Reliance Industries Limited

TORQUE VALUES FOR STANDARD ANSI / MSS FLANGES

600lb

NOMI

BOLTING

MIN.

RES.

SUGGESTED APPLIED TORQUE VALUES (NM) BASED ON

NAL

NO. / SIZE

BOLT

BOLT

RESIDUAL BOLT STRESS & PUMP PRESSURE

SIZE

(INCH)

STRES

STRES(

TO SEAL

PSI)

(INCH

*0.1

PUM

*0.13

P Psi

)

PUM

*0.15

PUM

P

P

Psi

Psi

*0.2

PUM P Psi

4

8 X 7/8

31148

44436

188

1389

338

2488

366

2698

476

3508

5

8X1

31809

45158

389

2868

510

3758

556

4097

721

5317

6

12 X 1

28484

46004

393

2898

519

3828

567

4177

727

5357

8

12 X 11/8

32092

45464

597

4397

754

5557

856

6306

1119

8245

10

16 X 11/4

25698

44626

818

6026

1036

7635

1182

8715

1549

11413

12

20 X 1 1/4

27787

45237

830

4075

1050

5153

1196

5872

1563

7677

14

20 X 1 1/2

25763

41257

1021

2270

1295

2879

1478

3286

1935

4302

16

20 X 1 1/2

27162

40678

1322

2939

1680

3735

1919

4265

2515

5592

20

24 X 1 5/8

28554

42743

1782

3961

2267

5040

2591

5760

3401

7560

22

24 X1 3/4

27833

36526

1916

2458

2441

3132

2792

3582

3668

4706

24

24 X 1 7/8

28425

39467

2567

3293

3276

4203

3748

489

4929

6324

26

28 X 1 7/8

27246

40132

2610

3349

3332

4275

3812

4890

3656

4690

28

28 X 2

26741

38261

3037

3025

3880

3864

4441

4423

5844

5821

30

28 X 2

30394

40818

3119

3106

4139

4122

4738

4719

6232

6207

32

28 X 2 1/4

26628

34936

3980

2667

5092

3411

5835

3909

7689

5151

38

28 X2 1/4

34756

44463

5065

3393

6482

4343

7425

4975

9786

6557

40

32 X 2 1/4

38389

47083

5363

3593

6863

4598

7863

5269

10363

6943

42

28 X 2 1/2

33703

44793

7047

4722

9031

6051

10353

6937

13659

9152

44

32 X 2 1/2

32279

40471

6366

3120

8159

3998

9354

4583

12341

6047

46

32 X 2 1/2

34864

43068

6776

3320

8682

4254

9954

4878

13133

6435

48

32 X 3 1/4

30883

39974

8434

4133

10822

5303

12414

6083

16394

8033

50

28 X 3

31582

41061

11285

5529

14494

7102

16634

8151

21982

10771

52

32 X 3

29599

39114

10749

3827

13807

4915

15845

5641

20939

7932

54

32 X 3

31890

41617

11437

4071

14690

5229

16859

6002

22280

7932

56

32 X 3 1/4

28716

39965

14026

4993

18031

6419

20701

7369

27376

9746

58

32 X 3 1/4

30787

40145

14089

3452

18112

4437

20794

5095

27500

6737

60

28 X 3 1/2

32202

39246

17256

2537

22218

3266

25517

3751

33764

4963

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 17 of 31 Date: 21-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Copyright: Reliance Industries Ltd, India

Reliance Industries Limited

TORQUE VALUES FOR STANDARD ANSI FLANGES

900lb

NOMINA

BOLTING

MIN.

RES.

SUGGESTED APPLIED TORQUE VALUES (NM) BASED ON

L SIZE

NO. / SIZE

BOLT

BOLT

RESIDUAL BOLT STRESS & PUMP PRESSURE

(INCH)

(INCH)

STRE

STRE

S TO

S(PSI

SEAL

)

*0.1

PUM

*0.13

P Psi

PUM

*0.15

PUM

P

P

Psi

Psi

*0.2

PUMP Psi

3

8X 7/8

32399

49331

285

2099

374

2758

407

2998

529

3898

4

8 X 1 1/8

26946

43039

564

4157

446

3288

811

5976

1058

7795

5

8 X 1 1/4

28347

44293

690

3389

658

3229

1172

5752

1531

7517

6

12 X 1 1/8

32338

45462

597

4397

536

3948

854

6296

1116

8225

8

12 X 1 3/8

30318

40071

991

2204

952

2116

1436

3192

1879

4178

10

16 X 1 3/8

30929

41257

1024

2276

971

2158

1478

3286

1935

4302

12

20 X 1 1/2

33443

42707

1060

2357

1050

2333

1535

3412

2003

4452

14

20 X 1 1/2

31684

41940

1363

3029

1309

2909

1977

4395

2593

5764

16

20 X1 7 /8

33998

45436

1889

4199

1803

4009

2750

6113

3614

8033

18

20 X 2 1/2

27490

38441

6048

2963

5542

2716

8885

4353

11723

5744

20

20 X 2

32478

42507

3374

3360

3292

3279

4934

4915

6494

6468

24

20 X 2 1/2

27490

38441

6048

2963

5542

2716

8885

4353

11723

5744

26

20 X 2 3/4

25057

34928

7370

3611

6784

3324

10848

5316

14325

7019

30

20 X 3

26793

36031

9902

3525

9457

3367

14596

5196

19589

6867

32

20 X 3 1/4

25521

34782

12207

2991

11514

2821

18016

4414

23826

5837

34

20 X 3 1/2

24161

34277

15083

2217

13678

2011

22252

3312

29808

4382

7 36

20 X 3 1/2

26912

34648

15247

2241

15235

2239

22527

3312

29808

4382

38

20 X 3 1/2

30809

37550

16523

2429

17441

2564

24415

3589

32305

4749

40

24 X 3 3/4

28547

35927

15810

2324

16161

2376

23358

3434

30909

4544

42

24 X 3 3/4

30954

36326

15985

2350

17524

2576

23619

3472

31252

4594

44

24 X 3 3/4

29256

34989

19038

2799

20435

3004

28076

4127

37168

5464

46

24 X 4

28064

37421

22081

3246

23883

3511

32685

4805

43289

6363

48

24 X 4

30134

35440

23414

3442

25646

3770

34659

5095

45905

6748

TORQUE VALUES FOR STANDARD ANSI FLANGES

1500lb

NOMINA

BOLTING

MIN.

RES.

SUGGESTED APPLIED TORQUE VALUES (NM) BASED ON

L SIZE

NO. / SIZE

BOLT

BOLT

RESIDUAL BOLT STRESS & PUMP PRESSURE

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 18 of 31 Date: 21-Mar-07 Revision no.: 0.0

For Internal Circulation Only (INCH)

(INCH)

Copyright: Reliance Industries Ltd, India

Reliance Industries Limited STRE

STRE

*0.1

PUM

*0.13

PUM

*0.15

PUM

S TO

S(PSI

P

P

P

SEAL

)

Psi

Psi

Psi

*0.2

PUMP Psi

3

8 X 1 1/8

31167

46236

607

4477

766

5646

872

6426

1138

8385

4

8 X 11/4

35144

45175

829

4068

1048

5147

1195

5866

1561

7663

5

8 X 1 1/4

31223

42550

1383

3075

1757

3907

2007

4461

2631

5848

6

12 X 1 3/8

33971

43148

1069

2375

1355

3011

1546

3436

2023

4497

8

12 X 1 5/8

34729

45758

1907

4238

2427

5396

2774

6167

3641

8094

10

12 X 1 7/8

34466

45377

2952

3787

3767

4833

4309

5529

5667

7270

12

16 X 2

30375

39334

3123

3110

3988

3972

4566

4547

6008

5984

14

16 X 2 1/4

27161

36409

4148

2779

5307

3556

6080

4074

8013

5368

16

16 X 2 3/4

27787

38891

6118

2998

7840

3842

8989

4405

11860

5811

18

16 X 2 3/4

29008

38670

8160

3999

10470

5130

12010

5885

15860

7771

20

16 X3

28424

37864

10406

3705

13365

4758

15338

5460

20271

7216

24

16 3 1/2

28029

34282

15086

2218

19407

2853

22290

3277

29493

4335

TORQUE VALUES FOR STANDARD ANSI FLANGES

2500lb

NOMINA

BOLTING

MIN.

RES.

SUGGESTED APPLIED TORQUE VALUES (NM) BASED ON

L SIZE

NO. /

BOLT

BOLT

RESIDUAL BOLT STRESS & PUMP PRESSURE

SIZE

STRES

STRE

(INCH)

TO

S(PSI

SEAL

)

(INCH)

*0.1

PUM

*0.13

P

PUMP

*0.15

Psi

PUM

*0.2

P Psi

PUMP Psi

Psi

3

8 X 1/4

41801

51000

936

4594

1184

5812

1349

6625

1763

8655

4

8 X 1 1/2

39662

45300

1473

3274

1871

4160

2136

4748

2800

6225

5

8 X 1 1/2

38108

45250

2373

3045

3024

3880

3458

4436

4544

5830

6

8X2

37736

44750

3553

3539

4537

4519

5195

5174

6836

6808

8

12 X 2

38138

46400

3683

3668

4705

4686

5386

5364

7088

7059

10

12 X 2 /2

32272

40050

6300

3087

8074

3956

9256

4535

12213

5985

12

12 X 2 3/4

35161

42100

8883

4353

11399

5585

13075

6407

17266

8460

* CO-EFFICINT OF FICTION DEPENDS ON LUBRICATION DONE ON BOLTS. ASSUMED BOLT MATERIAL

ASTM 193-B7 ; B16

ASSUMED GASKET :

SWJ or RTJ soft iron / Carbon steel / Stainless steel

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 19 of 31 Date: 21-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Copyright: Reliance Industries Ltd, India

Reliance Industries Limited

TENSIONING VALUES FOR STANDARD ANSI / MSS FLANGES

150 lb

NOMINAL

BOLTING

MIN. BOLT

RES. BOLT

PUMP

PUMP

TOOL

TOMMY

TOM

PIPE SIZE

NO./SIZE

STRESS

STRESS

PRESSURE

PRESSURE

NO.

BAR

MY

TO SEAL

(Psi)

A

B

SIZE

BAR

SOCKET

SIZE

(mm)

PUL

(inch)

LER (mm ) 32

28 x 11/2

11238

38980

14000

11000

2

10

12

34

32 x / 1/2

10941

36880

13500

10500

2

10

12

36

32 x 1 1/2

12395

37797

13500

10500

2

10

12

38

32 x 1 1/2

13634

37460

13500

10500

2

10

12

40

36 x 1 1/2

14933

37797

13500

10500

2

10

12

42

36 x 1 1/2

14624

38441

13500

10500

2

10

12

44

40 x 1 1/2

14433

38882

13500

10500

2

10

12

46

40 x 1 1/2

15625

39013

13500

10500

2

10

12

48

44 x 1 7/8

15329

39408

13500

10500

2

10

12

52

44 x 1 7/8

127070

38708

14000

11000

4

10

12

54

44 x 1 7/8

13603

39124

14000

11000

4

10

12

56

48 x 1 7/8

13318

39392

14000

11000

4

10

12

58

48 x 1 7/8

14195

39742

14000

11000

4

10

12

60

52 x 1 7/8

13938

39982

14000

11000

4

10

12

Assumed standard test pressure of

: 425 Psi

TENSIONING VALUES FOR STANDARD ANSI / MSS FLANGES

300LB

NOMINAL

BOLTING

MIN. BOLT

RES. BOLT

PUMP

PUMP

TOOL

TOMMY

TOM

PIPE SIZE

NO./SIZE

STRESS

STRESS

PRESSURE

PRESSURE

NO.

BAR

MY

TO SEAL

(Psi)

A

B

SIZE

BAR

SOCKET

SIZE

(mm)

PUL

(INCH)

LER (mm ) 24

24 X 1 1/2

23523

39429

14500

11500

2

10

12

28

28 X 1 5/8

21321

39707

12500

9500

3

10

12

30

28 X 1 3/4

20598

36098

14000

11000

3

10

12

32

28 X 1 7/8

19940

39121

13000

10000

4

10

12

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 20 of 31 Date: 21-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Copyright: Reliance Industries Ltd, India

Reliance Industries Limited

34

28 X 1 7/8

22061

39466

13000

10000

4

10

12

36

32 X 2

18694

37615

14000

11000

4

10

12

38

32 X 1 1/2

34901

44064

14500

11500

3

10

12

40

32 X 1 5/8

32680

44952

13000

10000

3

10

12

42

32 X 1 5/8

35637

45276

13000

10000

3

10

12

44

32 X 1 3/4

33553

41682

14500

11500

3

10

12

46

28 X 1 7/8

35446

44509

13500

10500

4

10

12

48

32 X 1 7/8

33781

44850

13500

10500

4

10

12

50

32 X 2

32018

40422

14000

11500

4

10

12

52

32 X 2

34336

42993

14500

11500

4

10

12

54

28 X 2 1/4

32884

40016

11000

8000

6

12

14

56

28 X 2 1/4

35094

42337

11500

8500

6

12

14

58

32 X 2 1/4

32958

40413

11000

8000

6

12

14

60

32 X 2 1/4

35025

42920

11500

8500

6

12

14

TENSIONING VALUES FOR STANDARD ANSI / MSS FLANGE

600 LB

NOMINAL

BOLTING

MIN. BOLT

RES. BOLT

PUMP

PUMP

TOOL

TOMMY

TOM

PIPE SIZE

NO./SIZE

STRESS

STRESS

PRESSURE

PRESSURE

NO.

BAR

MY

TO SEAL

(Psi)

A

B

SIZE

BAR

SOCKET

SIZE

(mm)

PUL

(INCH)

LER (mm ) 16

20 X 1 1/2

27162

40678

14500

11500

2

10

12

18

20 X 1 5/8

29141

42008

13000

10000

3

10

12

20

24 X 1 5/8

28554

42743

13000

10000

3

10

12

22

24 X 1 3/4

27833

36526

14000

11000

3

10

12

24

24 X 1 7/8

28425

39467

13000

10000

4

10

12

26

28 X 1 7/8

27246

40132

13000

10000

4

10

12

28

28 X 2

26741

38261

14000

11000

4

10

12

30

28 X 2

30394

40818

14500

11500

6

10

12

32

28 X 2 1/4

26628

34936

11000

8000

6

12

14

34

28 X 2 1/4

29459

37490

11000

8000

6

12

14

36

28 X 2 1/2

26206

37155

11000

8000

6

12

14

38

28 X 2 1/4

34756

44463

12000

9000

6

12

14

40

32 X2 1/4

38389

47083

15500

12500

6

12

16

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 21 of 31 Date: 21-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Copyright: Reliance Industries Ltd, India

Reliance Industries Limited

42

28 X 2 1/2

33703

44793

15000

12000

6

12

16

44

32 X 21/2

32279

40471

14000

11000

6

12

16

46

32 X 21/2

34864

43068

14500

11500

6

12

16

48

32 X 2 3/4

30883

39974

13500

10500

7

14

16

50

28 X 3

31582

41061

12000

9000

8.5

14

16

52

32 X 3

29599

39114

12000

9000

8.5

14

16

54

32 X3

31890

41617

12000

9000

8.5

14

16

56

32 X 3 1/4

28716

39965

14000

11000

8.5

14

16

58

32 X 3 1/4

30787

40145

14000

11000

8.5

14

16

60

28 X 3 1/2

32202

39246

15500

12500

8.5

14

16

TENSIONING VALUES FOR STANDARD ANSI / MSS FLANGES

900LB

NOMINAL

BOLTING

MIN. BOLT

RES. BOLT

PUMP

PUMP

TOOL

TOMMY

TOM

PIPE SIZE

NO./SIZE

STRESS

STRESS

PRESSURE

PRESSURE

NO.

BAR

MY

TO SEAL

(Psi)

A

B

SIZE

BAR

SOCKET

SIZE

(mm)

PUL

(INCH)

LER (mm ) 14

20 X 1 1/2

31684

41940

14500

11500

2

10

12

16

20 X 1 5/8

33998

45436

13500

10500

3

10

12

18

20 X 1 7/8

31770

42089

13500

10500

3

10

12

20

20 X 2

32478

42507

15000

12000

4

10

12

24

20 X 2 1/2

27490

38441

14000

11000

6

12

16

26

20 X 2 3/4

25057

34928

13000

10000

7

12

16

28

20 X3

23573

33284

11500

8500

8.5

14

16

30

20 X3

26793

36031

12000

9000

8.5

14

16

32

20 X 3 1/4

25521

34782

13500

10500

8.5

16

16

34

20 X 3 1/2

24161

34277

15000

12000

8.5

14

16

36

20 X 3 1/2

26912

34648

15000

12000

8.5

14

16

38

20 X 3 1

30809

37550

15500

12500

8.5

14

16

40

24 X 3 1/2

28547

35927

15000

12000

8.5

14

16

42

24 X 3 1/2

30594

36326

15000

12000

8.5

14

16

44

24 X 3 1/2

29256

34989

14000

11000

10

16

16

46

24 X 4

28064

37421

15000

12000

10

16

16

48

24 X 4

30134

35440

15500

12500

10

16

16

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 22 of 31 Date: 21-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Copyright: Reliance Industries Ltd, India

Reliance Industries Limited

TENSION VALUES FOR STANDARD ANSI / MAA FLANGES

1500LB

NOMINAL

BOLTING

MIN. BOLT

RES. BOLT

PUMP

PUMP

TOOL

TOMMY

TOM

PIPE SIZE

NO./SIZE

STRESS

STRESS

PRESSURE

PRESSURE

NO.

BAR

MY

TO SEAL

(Psi)

A

B

SIZE

BAR

SOCKET

SIZE

(mm)

PUL

(INCH)

LER (mm ) 5

8 X 1 1/2

31223

42550

15000

12000

2

10

12

8

12 X 1 5/8

34729

45758

13500

10500

3

10

12

10

12 X 1 7/8

34466

45377

14000

11000

4

10

12

12

16 X 2

30375

39334

14000

11000

4

10

12

14

16 X 2 1/4

27161

36409

11000

8000

6

12

14

16

16 X 2 1/2

27787

38891

14000

11000

6

12

16

18

16 X 2 3/4

29008

38670

13500

10500

7

12

16

20

16 X3

28424

37864

12000

9000

8.5

14

16

24

16 X 3 1/2

28029

34282

14500

11500

8.5

14

16

TENSION VAULES FOR STANDARD ANSI / MSS FLANGE

2500 LB

NOMINAL

BOLTING

MIN. BOLT

RES. BOLT

PUMP

PUMP

TOOL

TOMMY

TOM

PIPE SIZE

NO./SIZE

STRESS

STRESS

PRESSURE

PRESSURE

NO.

BAR

MY

TO SEAL

(Psi)

A

B

SIZE

BAR

SOCKET

SIZE

(mm)

PUL

(INCH)

LER (mm ) 4

8 X 1 1/2

39662

45300

15500

12500

2

10

12

5

8 X 1 3/4

38108

45250

15500

12500

3

10

12

6

8X2

37736

44750

15500

12500

4

10

12

8

12 X 2

38138

46400

15500

12500

4

10

12

10

12 X 2 1/2

32272

40050

14000

11000

6

12

14

12

12 X 2 3/4

35161

42100

14000

11000

7

12

16

ASSUMED BOLT MATERIAL ASSUMED GASKET:

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

ASTM 193-B7; B16 SWJ or RTJ soft iron / Carbon steel / Stainless steel

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 23 of 31 Date: 21-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Ltd, India

ANNEXURE III

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 24 of 31 Date: 21-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Copyright: Reliance Industries Ltd, India

Reliance Industries Limited

ANNEXURE - IV FLANGE FIT UP / TIGHTENING / CHECKLIST ISO No. P&ID No. Instrument Tag No. Manual Tighten

FLANGE SIZE (No. of Bolts) STUD / BOLT SIZE: TIGHTENING METHOD Manual Torque Hydr-Torque

Tool Serial No.

Tool Calibration Due Date:

Tensioning Torque Value:

Flange Fit Up Check List:

Ye s

Engineer Initial

Correct Studs / Bolts / Nuts Correct Gasket Pipe(s) properly supported Equipment Anchored / Leveled / Aligned Pipe Clean Flange Clean Flange Face Aligned Flange Holes Aligned Studs / Bolts / Nuts / Threaded holes Clean & Lubricated Flanged Joint Properly Tightened Work Completed Satisfactory

Date:

Maintenance manager:

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 25 of 31 Date: 21-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Ltd, India

ANNEXURE V TORQUING SEQUENCE

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 26 of 31 Date: 21-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Ltd, India

Figure 1

Figure 2

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 27 of 31 Date: 21-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Ltd, India

Figure 3

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 28 of 31 Date: 21-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Ltd, India

Figure 4

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 29 of 31 Date: 21-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Ltd, India

Figure 5

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 30 of 31 Date: 21-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Ltd, India

REFERENCE 1. Shell DEP 2. E&M Documents, JG 3. Literatures from internet

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services Engineering Services Dept

DOC. No: GMS/RP/30

Page: 31 of 31 Date: 21-Mar-07 Revision no.: 0.0