Doc: PRCD.Bolt.

001
Rev.: 01
Bolt-Tension Procedure For Flanges Date:12-Jul-09
Page 1 of 5

Done By Checked By Approved By

Name Eng. Saad Abou-Zeid Mr. Jose Antonio Sipan Mr. Danilo Ceci
Position Mech. Superintendent QA/QC Manager Construction Manager
Signature
Date 12/07/2004 12/07/2004 12/07/2004

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 Doc: PRCD.Bolt.001
Rev.: 01
Bolt-Tension Procedure For Flanges Date:12-Jul-09
Page 2 of 5

Index
1.0 Preliminary Instructions

2.0 Bolt Tensioning Pre-Activities

3.0 Tension Sequence.

4.0 Tension Calculation.

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 Doc: PRCD.Bolt.001
Rev.: 01
Bolt-Tension Procedure For Flanges Date:12-Jul-09
Page 3 of 5

1.0 Preliminary Instructions

¾ This procedure shall be used for bolt sizes 2” and larger in all services with

pressure ratings upto and including class 900 as per SP-2020.

¾ Check the good condition of threads, and surfaces of bolts, nuts and flanges.

¾ Studs and nuts shall be cleaned using wire brush to remove any dirt on the

threads.

¾ Visual examine studs and nuts after cleaning to ensure that they are free

from Burrs.

¾ Ensure that all bolts are installed with an extra length of threaded stud,

above the nut, of at least 1 X Bolt Diameter protrusion through the nuts at

both sides.

2.0 Bolt Tensioning Pre Activities.

¾ “ Hand “ tighten bolts with a short wrench following the “Criss-Cross”

pattern,. Do not tighten the bolts using impact force.

¾ Torque tensioners shall be calibrated and used within the dates of validity for

calibration.

¾ In the event that set-up or seizure of the nut being tensioned is encountered,

back the nut off until seizure is eliminated and torque again.

¾ Apply lubricant if necessary and replace the nut and/ or bolt in case of

seizure again occurs.

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 Doc: PRCD.Bolt.001
Rev.: 01
Bolt-Tension Procedure For Flanges Date:12-Jul-09
Page 4 of 5

3.0 Tensioning Sequence.

All bolts in the joint should be tensioned
simultaneously, 25% simultaneous tensioning
will be carried out, which requires the operator
to make four or five tensioning operations by
moving around the bolts in diametrically
opposed fashion (see Figure 9).

Refer to section 4 for the tension value and

pump settings for the 4 or 5 passes required.

Hydraulic stud bolt tensioners are designed to directly stretch the bolt by
applying a known load to the fastener (see section 4 for values) using a
hydraulic cylinder and threaded puller. The securing nut is then rotated using a
short Tommy bar, whilst the thread is being stretched, until it is firmly tightened
against the joint face. Immediately the hydraulic pressure (load) is released the
bolt tension (residual load) is retained, within the clamp length of the stud bolt,
because it is prevented from returning to its original length by the tightened nut.

To operate hydraulic stud bolt tensioners, on

bolted connections safely and efficently, an
extra length of threaded stud, above the nut, of
at least one x bolt diameter, is required to
facilitate easy fitment of the equipment (see
figure 1). If this cannot be achieved by
attaching all bolt tensioners to one side of the
flange due to lack of space, then alternate the tensioners on opposite side.

Assembly of the tensioners to the stud bolt is quick and easy, provided of
course that the stud bolts and nuts are clean, lubricated and in good condition

Refer to section 2 (see figures 2 -5).

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 Doc: PRCD.Bolt.001
Rev.: 01
Bolt-Tension Procedure For Flanges Date:12-Jul-09
Page 5 of 5

4.0 Tension Calculations

4.1 Doc. No. : 20”-900

4.2 Doc. No. : 24”-900
4.3 Doc. No. : 28”-900
4.4 Doc. No. : 30”-900
4.5 Doc. No. : 32”-900
4.6 Doc. No. : 36”-900
4.7 Doc. No. : 42”-900
4.8 Doc. No. : 48”-900
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