SAEP-351 Bolted Flange Joint Assembly

Engineering Procedure SAEP-351

7 November 2006

Bolted Flange Joints Assembly Piping Standards Committee Members Nasri, Nadhir Ibrahim, Chairman Dib, Tony Georges, Vice Chairman Balhareth, Nasser Mohammad Bannai, Nabeel Saad Fadley, Gary Lowell Holland, Brad John Khashab, Jaafar M. Lewis, Trevor Mahmoud, Khalid Ahmed Phan, Howard Cong Rao, Sanyasi Rasheed, Mahmood A. Sharif, Talal Mahmoud Shiha, Saad Mohammed Swar, Ahmad H. (ABQ PLANTS)

Saudi Aramco DeskTop Standards Table of Contents 1 2 3 4 5 6 7 8

Scope............................................................. References..................................................... Responsibilities.............................................. Pre-Assembly Inspection............................... Torquing......................................................... Torquing Tools............................................... Stud Bolt Tightening Procedure..................... Stud Bolt Additional Tightening Procedure where Leaks Occur During Pressure Testing................................

Previous Issue: 30 April 2003 Next Planned Update: 7 November 2011 Revised paragraphs are indicated in the right margin Primary contact: Nasri, Nadhir Ibrahim on 966-3-8734525 Copyright©Saudi Aramco 2006. All rights reserved.

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Document Responsibility: Piping Issue Date: 7 November 2006 Next Planned Update: 7 November 2011

SAEP-351 Bolted Flange Joints Assembly

Table of Contents (Con't) Table-SAEP-351-01 – Friction Factors for Different Lubricants.................................. 7 Table-SAEP-351-02 – Torque Values for Low-Alloy Steel Bolting............................. 8 Table-SAEP-351-03 – Torque Values for Isolating Gaskets (PIKOTEK) on ASME B16.5 and ASME B16.47 Series A & B, Class 150 Through Class 2500 Flanges....................................... 9 Figure SAEP-351-01 – Stud Bolt Tightening Sequence (4 to 32 Bolts).............................. 10 Figure SAEP-351-02 – Stud Bolt Numbering (36 to 68 Bolts)............................................. 11 Table-SAEP-351-04 – Cross-Pattern Tightening Sequence (36 to 68 Bolts) Per (ASME PCC-1)...................................... 12

1

Scope This procedure defines minimum requirements to assemble bolted flanged joints in pressure containing piping systems as defined in SAES-L-100. It is applicable for both new and existing facilities.

2

References 2.1

Saudi Aramco References Saudi Aramco Engineering Standards SAES-L-100

Applicable Codes & Standards for Pressure Piping Systems

SAES-L-109

Selection of Pipe Flanges, Bolts and Gaskets

SAES-L-350

Construction of Plant Piping

SAES-L-450

Construction of Pipelines

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Document Responsibility: Piping Issue Date: 7 November 2006 Next Planned Update: 7 November 2011

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SAEP-351 Bolted Flange Joints Assembly

Industry Codes and Standards American Petroleum Institute API BULL 5A2

Bulletin on Thread Compounds for Casing, Tubing, and Line Pipe

American Society of Mechanical Engineers

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ASME B16.5

Pipe Flanges and Flanged Fittings NPS ½ Through NPS 24

ASME B16.47

Large Diameter Steel Flanges NPS 26 Through NPS 60

ASME B31.3

Process Piping

ASME B31.4

Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids

ASME B31.8

Gas Transmission and Distribution Piping Systems

ASME PCC-1

Guidelines for Pressure Boundary Bolted Flange Joint Assembly

Responsibilities 3.1

3.2

For existing facilities the following shall apply: 3.1.1

It is the responsibility of Operations Superintendent to ensure that this procedure is adhered to during the maintenance activities within the facilities under his jurisdiction.

3.1.2

The maintenance personnel executing the flange assembly activities must be aware of this procedure and ASME PCC-1 Guideline and have the proper training to conduct the work.

For new capital program projects the following shall apply: 3.2.1 The Project Manager is responsible for ensuring that the Construction Contractor is following this procedure or specific procedures that shall be approved by Proponent, SAPMT, Inspection and the Piping Standards Committee Chairman or his representative. 3.2.2

The contractor personnel executing the flange assembly shall adhere to flange assembly procedure. They shall have proper training and skills to conduct the job.

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Document Responsibility: Piping Issue Date: 7 November 2006 Next Planned Update: 7 November 2011

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SAEP-351 Bolted Flange Joints Assembly

Pre-Assembly Inspection 4.1

The gasket shall be verified for correct type, rating, dimension and compatibility with the flange facing. Also, it shall be free from any damage particularly in the seating element. Ensure that spiral wound gaskets are stored flat especially for large sizes, 24 inches and larger.

4.2

Bolts, nuts and washers shall be visually checked for proper size, grade, dimension and for any physical damage to shanks or threads which would affect the bolt assembly or performance. Also, check the suitability of the stud bolts and nuts material for the service temperature and the compatibility with the flange material.

4.3

The flange facing, particularly the seating area, shall be visually examined for cleanliness and ensure that no damage, such as scratches exist. For ring joint type flanges, the ring and the ring groove shall be free of damage and dirt.

4.4

Proper lubricant for bolts and nuts shall be used. Lubricant for bolts and nuts shall be Jet-Lube SS-30 or other acceptable lubricants listed in Table-SAEP351-01.

4.5

Tightening tools shall be checked for adequacy, performance and calibration, if required.

4.6

Lubricant shall not be used in the gasket and the gasket seating area.

4.7

Flange shielding shall be installed/reinstalled when required. Commentary Note: Flange shielding is normally used for personnel protection against possible liquid splash or high temperature during operation.

5

Torquing 5.1

Torque values vary according to flange rating, bolt size, type of gasket, and friction factor of the thread lubricant.

5.2

The torque values are specified in Table-SAEP-351-02 and Table-SAEP-351-03.

5.3

Table-SAEP-351-02 applies to all gaskets listed in SAES-L-109, except for insulating gaskets.

5.4

Table-SAEP-351-03 applies to isolating gaskets (e.g., PIKOTEK), based on a friction factor of 0.16. Page 4 of 12

Document Responsibility: Piping Issue Date: 7 November 2006 Next Planned Update: 7 November 2011

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SAEP-351 Bolted Flange Joints Assembly

Torquing Tools 6.1

There are various types of tools available to achieve the proper torque value. Selection of the proper tool depends on the stud bolt size, physical location of the flanged joint, and criticality of the flange. Identifying the proper tools shall be resolved between Contractor, SAPMT, Proponent and Inspection prior to commencing the erection of the piping.

6.2

The manufacturer's instructions shall be followed for the operation, limitation and maintenance of all torque wrenches used to perform flange bolts tightening.

6.3

Torque wrench calibration shall be performed in accordance with manufacturer's recommendations.

Stud Bolt Tightening Procedure Step 1

Align flanges and gasket. Forced tightening is not allowed to overcome non acceptable alignment tolerances. Clamp securely in place.

Step 2

Apply lubricants to stud threads over length and nut engagement and to face of nut which contacts flange. Ensure that the nuts run freely down the thread of the studs.

Step 3

Install all studs and nuts hand tight, ensure that studs pass freely through the flange holes. Position the nut on one end of the stud such that only the crown of the stud projects beyond the face of the nut. The excess stud length should project beyond the nut on the other side. Commentary Note: By doing this, the nut that is installed nearly flush with the end of the stud can be easily removed since the threads are not coated, and normally have not been subjected to corrosion. The side of the stud with the flush nut should be chosen by taking into consideration factors such as whether one side has better access for maintenance personnel and/or tightening tools, e.g., torque wrench or impact wrench, etc.

Step 4

Number each stud according to its position in the flange as shown on Figure 1: Stud Bolt Tightening Sequence.

Step 5

For insulting gaskets like PIKOTEK, enough gap (½" of gap is recommended) should be available between flange faces to avoid any damage to seals during inserting the gaskets, if due to any reasons, seals are damaged, change the seal before installing PIKOTEK.

Step 6

Matting flange faces and the gaskets should be dry and free from grease, oil or water. Page 5 of 12

Document Responsibility: Piping Issue Date: 7 November 2006 Next Planned Update: 7 November 2011

SAEP-351 Bolted Flange Joints Assembly

Step 7

Tighten studs per the Stud Bolt Tightening Sequence, for 4 to 32 bolts use Figure SAEP-351-01 and for 36 to 68 bolts see Figure SAEP-351-02 for bolts numbering and then follow the tightening sequence of Table SAEP-351-04. An appropriate tool should be used such as an air impact wrench or equivalent.

Step 8

For joints containing RTJ or Spiral Wound Gaskets, repeat step 7.

Step 9

Tighten the stud bolts in stages to obtain the final required torque from the appropriate torque Table-SAEP-351-02. The first stage should not be more than 30% of the final torque. The final torque shall be within ±5% of the required torque value. Apply the torque evenly to each stud following the stud bolt tightening sequence. The final torque must be within ±5% of the required values per Section 7 above.

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Stud Bolt Additional Tightening Procedure where Leaks Occur During Pressure Testing Step 1

Depressurize the piping system and re-torque stud bolts to maximum torque value shown on Table-SAEP-351.

Step 2

If leak does not stop after re-torquing has been performed, disassemble the flange joint and inspect as follows:

Step 3

a.

Inspect stud bolts and nuts for defects or damage to threads or improper cleaning of threads.

b.

Inspect flange faces for damage, misalignment.

c.

Inspect gasket for damage or defects.

After all defective and damaged items have been repaired or replaced, reassemble the flange joint using a new gasket and tighten the bolts using the maximum torque values.

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Document Responsibility: Piping Issue Date: 7 November 2006 Next Planned Update: 7 November 2011

SAEP-351 Bolted Flange Joints Assembly

Table-SAEP-351-01 – Friction Factors for Different Lubricants Friction Factors

Torque Correction Factor

Moly Graphite

.06

0.67

Tool Joint Compound Graphite and Oil (used as the base line for torque values in Table-SAEP-351-02)

.08

0.8

.10

1.0

Aerocote #4

.11

1.1

KOPR-KOTE

.11

1.1

EL-PRO C5A

.11

1.1

FEL-PRO C100 FEL-PRO C102 (commonly called Anti-Seize)

.11

1.1

.11

1.1

Lubricants

Jet Lube SS-30 API BULL 5A2 Thread Compound

.12

1.2

.125

1.3

Light Machine Oil as shipped

.15

1.5

Dry Bolts

.2

2

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Document Responsibility: Piping Issue Date: 7 November 2006 Next Planned Update: 7 November 2011

SAEP-351 Bolted Flange Joints Assembly

Table-SAEP-351-02 – Torque Values for Low-Alloy Steel Bolting Stud Bolt Size inch

Torque Ft-Lb Noncoated Bolts

Coated Bolts

1/2

60

45

5/8

120

90

3/4

210

160

7/8

350

250

1

500

400

1-1/8

750

550

1-1/4

1050

800

1-3/8

1400

1050

1-1/2

1800

1400

1-5/8

2350

1800

1-3/4

2950

2300

1-7/8

3650

2800

2

4500

3400

2-1/4

6500

4900

2-1/2

9000

6800

2-3/4

12000

9100

3

15700

11900

3-1/4

20100

15300

3-1/2

25300

19100

3-3/4

31200

23600

4

38000

28800

Notes: 1) Torque values are based on 50,000 psi prestress on stud bolts and Friction Factor of 0.16 for noncoated surfaces and 0.12 for new coated surfaces. A combination of various elements such as the conditions of the threads, the condition of the flange to the nut bearing surface and the type of lubricant used, makes up the friction factor which can vary from .04 to .20 or as much as 500%. 2) Torque values for stainless steel or other alloy stud bolts can be obtained by multiplying the ratio of the specified minimum yield strength (SMYS) of stainless steel stud bolts to A193 B7 stud bolts, to the torque values in the Table-SAEP-351-02. The SMYS values for all bolting materials are listed in ASME B31.3 code (Note: SMYS depends on grade, class and size).

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Document Responsibility: Piping Issue Date: 7 November 2006 Next Planned Update: 7 November 2011

SAEP-351 Bolted Flange Joints Assembly

Table-SAEP-351-03 – Torque Values for Isolating Gaskets (PIKOTEK) on ASME B16.5 and ASME B16.47 Series A & B, Class 150 Through Class 2500 Flanges

Note:

Stud Bolt Size inch

Torque Value Ft-Lb

1/2

30

9/16

45

5/8

60

3/4

100

7/8

160

1

245

1-1/8

355

1-1/4

500

1-3/8

680

1-1/2

800

1-5/8

1100

1-3/4

1500

1-7/8

2000

2

2200

2-1/4

3180

2-1/2

4400

2-3/4

5920

3

7720

3-1/4

8400

3-1/2

9000

3-3/4

9600

4

10000

Torque values based on 30,000 psi tension load and 0.16 Friction Factor from API BULL 5A2 thread compound. See Table-SAEP-351-02 Note (1) for other factors.

Commentary Notes: a)

For ASME Class 900 through Class 2500, API-6B and API-6BX Class 2000 through Class 15000, and RTJ Flanges, the maximum compressive stresses induced during installation should not exceed 25,000 psi. Design to 12,500 psi when possible.

b)

Calculations for compressive stresses applied during torque-up procedures must account for ring joint grooves, gasket seal grooves, raised face diameters, and gasket inside diameter. (See PIKOTEK Gasket User's manual).

c)

Bolt tensioning equipment such as HYDRATIGHT may be used for class 900 and above resulting in a minimum residual bolt stress of 30000 psi and a maximum of 50,000 psi. Refer to PIKOTEK Gasket User's manual for specific bolting instructions. Page 9 of 12

Document Responsibility: Piping Issue Date: 7 November 2006 Next Planned Update: 7 November 2011

SAEP-351 Bolted Flange Joints Assembly

Figure SAEP-351-01 – Stud Bolt Tightening Sequence (4 to 32 Bolts)

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Document Responsibility: Piping Issue Date: 7 November 2006 Next Planned Update: 7 November 2011

SAEP-351 Bolted Flange Joints Assembly

Figure SAEP-351-02 – Stud Bolt Numbering (36 to 68 Bolts)

1 2 3 4 5 6 7 8 9 14

10 13

12

11

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Document Responsibility: Piping Issue Date: 7 November 2006 Next Planned Update: 7 November 2011

SAEP-351 Bolted Flange Joints Assembly

Table-SAEP-351-04 – Cross-Pattern Tightening Sequence (36 to 68 Bolts) per (ASME PCC-1) No. of bolts 36

Sequence 1-2-3 → 19-20-21 → 10-11-12 → 28-29-30 → 4-5-6 → 22-23-24 → 13-14-15

↵

31-32-33 → 7-8-9 → 25-26-27 → 16-17-18 → 34-35-36 40

1-2-3-4 → 21-22-23-24 → 13-14-15-16 → 33-34-35-36 → 5-6-7-8 → 25-26-27-28

↵

17-18-19-20 → 37-38-39-40 → 9-10-11-12 → 29-30-31-32 44

1-2-3-4 → 25-26-27-28 → 13-14-15-16 → 37-38-39-40 → 5-6-7-8 → 29-30-31-32

↵

17-18-19-20 → 41-42-43-44 → 9-10-11-12 → 33-34-35-36 → 21-22-23-24 48

1-2-3-4 → 25-26-27-28 → 13-14-15-16 → 37-38-39-40 → 5-6-7-8 → 29-30-31-32

↵

17-18-19-20 → 41-42-43-44 → 9-10-11-12 → 33-34-35-36 → 21-22-23-24 → 45-46-47-48 52

1-2-3-4 → 29-30-31-32 → 13-14-15-16 → 41-42-43-44 → 5-6-7-8 → 33-34-35-36 17-18-19-20 → 45-46-47-48 → 21-22-23-24 → 49-50-51-52 → 25-26-27-29

↵

↵

9-10-11-12 → 37-38-39-40 56

1-2-3-4 → 29-30-31-32 → 13-14-15-16 → 41-42-43-44 → 21-22-23-24 → 49-50-51-52 9-10-11-12 → 37-38-39-40 → 25-26-27-28 →

↵

↵

53-54-55-56 → 17-18-19-20

45-46-47-48 → 5-6-7-8 → 33-34-35-36 60

1-2-3-4 → 29-30-31-32 → 45-46-47-48 → 13-14-15-16 → 5-6-7-8 → 37-38-39-40 21-22-23-24 → 53-54-55-56 → 9-10-11-12 → 33-34-35-36 → 49-50-51-52

↵

↵

17-18-19-20 → 41-42-43-44 → 57-58-59-60 → 25-26-27-28 64

1-2-3-4 → 33-34-35-36 → 17-18-19-20 → 49-50-51-52 → 9-10-11-12 → 41-42-43-44 25-26-27-28 → 57-58-59-60 → 5-6-7-8 → 37-38-39-40 → 21-22-23-24

↵

↵

53-54-55-56 → 13-14-15-16 → 45-50-51-52 → 29-30-31-32 → 61-62-63-64 68

1-2-3-4 → 37-38-39-40 → 21-22-23-24 →

53-54-55-56

→ 9-10-11-12 → 45-46-47-49

↵

29-30-31-32 → 61-62-63-64 → 17-18-19-20 → 57-58-59-60 → 33-34-35-36 → 5-6-7-8 41-42-43-44 → 13-14-15-16 → 49-50-51-52 → 25-26-27-28 → 65-66-67-68

7 November 2006

Revision Summary Revised the "Next Planned Update". Reaffirmed the contents of the document, and reissued with minor changes.

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