Professional Documents
Culture Documents
PHEONWJ Ltd.
Document Number
Document Title
: PHE-ONWJ-G-PRC-0016
Revision
: 0
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Table of Contents
CONTENTS ..................................................................................................................... 3
1.
SCOPE ................................................................................................................. 5
2.
REFERENCE ........................................................................................................ 5
3.
SAFETY ............................................................................................................... 5
4.
4.1.
4.2.
5.
METHOD .............................................................................................................. 6
5.1.
5.2.
6.
CALIBRATION ..................................................................................................... 7
7.
PERSONNEL ....................................................................................................... 7
8.
8.1.
8.2.
8.3.
9.
10.
10.1.
10.2.
11.
11.1.
11.2.
Bolt Tensioning
Figure 5 ........................................................................................................................ 19
Figure 6 ........................................................................................................................ 20
Figure 7 Typical Criss -Cross Bolting Tightening Sequence for bolts 24 & bolts
28 .................................................................................................................................. 21
Figure 9 Typical Criss -Cross Bolt Tightening Sequence for bolt 36 ................. 23
Figure 11 Typical Criss -Cross Bolt Tightening Sequence for bolts 44 .............. 25
Figure
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............. 27
Appendix A .................................................................................................................. 28
Appendix B .................................................................................................................. 29
Appendix C .................................................................................................................. 30
Appendix D .................................................................................................................. 31
Appendix E ................................................................................................................... 32
Appendix F ................................................................................................................... 37
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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
2. REFERENCE
ASME-PCC-1-2000
Assembly
ANSI/ASME B31.3
ANSI/ASME B31.4
Other Liquid
ANSI/ASME B31.8
3. SAFETY
Hydraulic power tools enable the user to more easily accomplish bolting tasks with increased
Due to the nature of the tools, with large forces generated, and for hydraulic torque equipment
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
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
Technician shall be fully conversant with the safe use of the tools and their operating procedures
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4. GENERAL GUIDELINES
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
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.
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.
flange rotation and thus leakage. The under strength bolts can easily be yielded
c.
An incorrectly proportioned flange ring can give excessive rotation which evens a
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.
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
Manual torque wrench which is normally rated to a maximum output of 300 Nm and has a
square drive. The wrench contains a mechanism that clicks when the required torque
value is achieved.
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The manual method bolt tightening using Manual torque wrench or torque wrench will be
The Hydraulic torque wrench or Bolt tension equipment will be used for bolt with nominal
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
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
8.1.
1.
Square drive tools only: check that the correct size impact socket has been selected
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.
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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
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
7. Fit the wrench via the socket or spigot fitting to the application .
8.
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
11. Pull the wrench clockwise towards the body using both hands, applying a steady force
12. Continue tightening operations by pulling the wrench clockwise until maximum travel or
14. After use, reset the torque setting to zero prior to storing the wrench, this helps to
Note:
o
o
o
Backing spanners must be secured to prevent accidental release by being tied off or
When using larger manual torque wrenches assistance may be required to pull the
wrench safely.
1.
Ensure that the power console is full of hydraulic oil and, if an air power console is
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
4.
Check that the square drive is in the correct position for tightening operations.
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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
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
9.
Connect the pump to an air supply with whip checks and pins at all connections. Switch
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:
Always remove the tool from the flange and place on a surface where reaction will not be
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
Note:
Pinch points are present around all reaction areas and in tight spaces. Hands and fingers must be kept clear
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
Note:
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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
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
3. On the application where several bolts are tensioned simultaneously, all tensioning
4. When bolts need to be stressed near their yield point, torquing methods shall be
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
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
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
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
b.
Thread
the puller bar onto the stud bolt until it bottoms out on the
tensioner piston
c.
d.
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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.
e. Stud bolt tensioners shall not be pressurized until the attachment procedure
Horizontal
Vertical
9. ELONGATION MEASUREMENT
The amount of elongation of the stud required to achieve the desired tension in the stud is
D=
LE / E
Where :
E = Modulus of Elasticity
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1.
2.
E = L + (Ft x H)
Where :
And
3.
Elongation is determined by measuring the length of the stud before and againt
4.
A log of the measurements taken for the initial lengths and any subsequent
5.
For the second to last torquing / tensioning setting , the elongations shall be
measured.
6.
The acceptance criteria for final elongation measurements shall be 15% of the
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
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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.
indications extending 50% of the width of the seating surface shall be removed by
shall be
accept or reject all flange surfaces in accordance with the above criteria
3.
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
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
7.
Thread lubricants shall be suitable for the operating temperature of the system and
shall require the approval of the Owners Engineer. Thread lubricants for bolting shall
not contain lead. Thread lubricants for austenitic bolting shall not contain chlorides.
thread
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
10. Never draw up tight on one or two bolt only. This will cause local gasket crushing or
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pattern. After each round of tightening, the alignment may be checked by measuring
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
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
4.
Specially
5.
Gaskets shall not be held in place with tape during flange alignment. A heavy grease or
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
7.
Check flange alignment, pipeworks flanges are often limited to a maximum out-of
8.
The use of graphite tape or any other foreign material to hide gasket seating surface
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
11. Heavy covers of horizontal equipment shall be provided with external supports and
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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
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
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
3.
Measure the flange gap at a minimum of four points around the flange (larger flanges
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
Table No. 1
No
Number of
Bolt Flange
1-3-2-4
1-5-3-7-2-6-4-8
12
1-7-4-10-2-8-5-11-3-9-6-12
16
1-9-5-13-3-11-7-15-2-10-6-14-4-12-8-16
20
1-11-6-16-3-13-8-18-5-15-10-20-2-12-7-17-4-14-9-19
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
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
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
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No
Number of
Bolt Flange
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
Note:
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
9.
Using a small hammer tap test each bolt to check the sound of the bolt rings true, dull or
10. Ensure that the work area is left in a safe and tidy condition and that the Permit to Work
11. Record all tightening information on the Joint Integrity Certificate JI1 part A.
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Figure 4
11.1.
a.
Criss-Cross Sequence
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
f.
Ensure that the manual torque wrench being used is adequately engaged before
pulling.
g.
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.
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.
Donts
a.
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b.
D o not draw the joint up tight on one or tw o bolts, as this w ill cause local gasket
c.
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.
g.
Never stand in line with the bolt axis when tools are pressurized.
h.
i.
Do not draw the flange up tight on one or two bolts, as this will cause local gasket
11.2.
Bolt Tensioning
1.
Dos
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
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
e.
2.
Donts
a.
b.
c.
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Figure 5
Typical Criss -Cross Bolt Tightening Sequence for 4 bolts & 8 bolts
4 Bolts
Sequence Order
1 2
3 - 4
4 BOLT
8
Bolts
Sequence Order
1 2
3 4
5 6
7 8
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8 BOLT
Rotation Order
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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
11
12 BOLT
12
Rotation Order
11
10
12
10
16 Bolts
13
11
15
16 BOLT
16
10
12
14
Rotation Order
13
11
15
10
14
12
16
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Figure 7
Typical Criss -Cross Bolting Tightening Sequence for bolts 24 & bolts 28
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Figure 8
for bolts 32
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Figure 9
for bolt 36
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Figure 10
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Figure 11
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Figure 12
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Figure 13
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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
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
30
22
59
43
94
69
36
26
59
43
94
69
48
35
94
69
105
78
48
35
165
121
185
137
94
69
94
69
105
78
94
69
165
121
165
121
117
86
165
121
185
137
94
69
165
121
329
243
165
121
185
137
441
325
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
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Appendix B
Table Torque
Table 3
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
48
35
94
69
94
69
165
121
185
137
206
152
48
35
94
69
94
69
263
194
296
218
329
243
48
35
94
69
105
78
296
218
329
243
538
397
54
40
165
121
185
137
441
325
489
361
785
579
94
69
94
69
105
78
263
194
329
243
538
397
105
78
165
121
165
121
392
289
489
361
714
526
117
86
165
121
185
137
329
243
714
526
1096
809
105
78
185
137
329
243
642
474
997
735
1947
1436
185
137
185
137
441
325
714
526
1347
994
4332
3195
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
PHEONWJ-G-PRC-0016 Rev. 0.
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Appendix C
Table Torque
Table 4
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
94
69
94
69
165
121
185
137
206
152
48
35
94
69
94
69
263
194
296
218
362
267
48
35
94
69
105
78
263
194
296
218
538
397
48
35
165
121
165
121
392
289
441
325
785
579
94
69
94
69
105
78
263
194
329
243
538
397
94
69
165
121
165
121
392
289
441
325
785
579
94
69
165
121
185
137
296
218
714
526
997
735
94
69
165
121
296
218
642
474
997
735
1947
1436
165
121
185
137
441
325
642
474
1213
894
4766
3515
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
PHEONWJ-G-PRC-0016 Rev. 0.
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PHEONWJ Ltd.
Appendix D
Table 5
Imperial
B7
BOLT SIZE
DIA X TPI
THREAD
PER INCH
HEX NUT
STRESS
AREA
(IN
x 10
10
1-1/4
0.334
7/8 x 9
1-7/16
0.461
1x8
1-5/8
0.605
1-1/8 x 8
1-13/16
1-1/4 x 8
1-3/8 x 8
1-1/2 x 8
1-5/8 x 8
1-3/4 x 8
1-7/8 x 8
2x8
2-1/8 x 8
2-1/4 x 8
2-3/8 x 8
2-1/2 x 8
2-3/4 x 8
3x8
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
3-1/2 x 8
3-3/4 x 8
4x8
4-1/4 x 8
4-1/2 x 8
4-3/4 x 8
5x8
5-1/4 x 8
5-1/2 x 8
5-3/4 x 8
6x8
MIN
YEILD
105,000
BOLT
TENSION
(LBS)
Toque
(ft.lbs)
COEF OF
FRICTION
(0.12)
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
PHEONWJ-G-PRC-0016 Rev. 0.
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Appendix E
Table 6
Target Bolt Stress For Gasket Seating and Operation ASME/ANSI B16.5 Class
Hydrotest
Pressure
(Psig)
0 - 290
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
Hydrotest
Pressure
(Psig)
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.
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Table 8
Target Bolt Stress For Gasket Seating and Operation ASME/ANSI B16.5 Class
Hydrotest
Pressure
(Psig)
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.
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Table 9
Target Bolt Stress For Gasket Seating and Operation ASME/ANSI B16.5 Class
Hydrotest
Pressure
(Psig)
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.
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Table 10
Target Bolt Stress For Gasket Seating and Operation ASME/ANSI B16.5 Class
Hydrotest
Pressure
(Psig)
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.
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PHEONWJ Ltd.
Table 11
Target Bolt Stress For Gasket Seating and Operation ASME/ANSI B16.5 Class
Hydrotest
Pressure
(Psig)
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.
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PHEONWJ Ltd.
Appendix F
Project
Customer
Area
Scope / Job No.
FLANGE JOINT
RECORDS
:
:
:
:
Technician
Date of Tightening
: 1
Flange Identification
Line No.
P & ID No.
Location
:
:
:
Flange No.
SH1 No.
MC1 No.
Flange Data
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
Good
Poor
Flange Preparation by
Min Thread Protrusion
Thread Form
Joint Configuration
Not Visible
Torque Wrench
Model :
Manufacture
:
Serial No.
:
Specified Loads
:
:
Tonf
:
:
No. of Tensioner
Percentage Tool Coverage
Bolt Tensioner Type
Pump Serial No.
:
:
:
:
Lb/ln2
Ft Lbs
st
-1
Pass Pressure
:
nd
-2
Pass Pressure :
-Checking Pressure :
Torque Record
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)
Date :
Date :
PHEONWJ-G-PRC-0016 Rev. 0.
Witnessed by QC Inspector
Date :
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