FOSTERWHEELER WORLEYPARSONS PROJECT SPECIFICATION BOLT TORQUE PROCEDURE

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DOCUMENT REVISION
FWW Rev No 01 02 WPPL Rev No A B Date Issued 16/01/07 06/02/07 Description of Change Issued for Review Issued for Project Specification Prepared By M Watkins M Watkins

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TABLE OF CONTENTS 1. HOW TO USE THIS DOCUMENT 2. BOLT TORQUE VALUES FOR ASME FLANGES 2.1 ASME FLANGES 2.2 Other Flanges 3. BOLT TORQUE TOOLS 4. BOLTING PROCEDURE 4.1 Prior To The Making Up Of Flanges 4.2 Assembly Procedure 5. QA/QC

4 4 4 5 5 6 6 7 8

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1.

HOW TO USE THIS DOCUMENT

The importance of bolting flanges properly is not to be underestimated: Failing flanges can lead to hazardous situations and/or severe and costly process interruptions. It is therefore necessary to formalise practice. Adhering to the given procedure will lead to minimal flange leakages, ensure good workmanship, increase efficiency because of the undisputed tensioning figures and finally will eventually help to make a better judgement on decisions on hot bolting. The document contains: A specification on what bolt tension should be applied. For cases that are beyond the given applications, instructions from Company should be requested. Guidelines on what tools are to be used. Guidelines on proper torqueing, i.e. sequence, allowable misalignments etc. A checklist on flange jointing.

2. 2.1

BOLT TORQUE VALUES FOR ASME FLANGES ASME FLANGES

The bolt torque level is based upon flange parameters, bolt properties and the use of anti-seize lubricant. A very important parameter for getting the right bolt stresses is the friction factor of the applied anti-seize. The table below is based on the use of FELPRO HEAVY DUTY ANTI-SEIZE LUBRICANT which produces a friction factor of 0.15 between steel parts. It should be noted that when using a different anti-seize with a different friction factor the table below should not be used.

BOLT TORQUE LEVEL L7 ANTI-SEIZE/ Friction factor BOLT SIZE 5/8 7/8 1 1 1/8 1 1 3/8 FEL-PRO 51607 Friction factor = 0.15 {Nm} 70 140 240 380 560 820 1150 1550 B8M (Class 2) FEL-PRO 51607 Friction factor = 0.15 {Nm} 40 120 200 300 430 640 860 1000

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1 1 5/8 1 1 7/8 2

2020 2590 3270 4090 4970

1200 1500 1850 2290 2800

NOTES:For conversion of the Nm values into Lb-FT: - Multiply above values by 0.74. If required, above values may be exceeded by some 10%. This should always be logged properly.

2.2

Other Flanges
For bolting flanges of items such as heads and covers, or flanges with bolt sizes > 2, seek advice from Company.

3.

BOLT TORQUE TOOLS

RECOMMENDED BOLT TORQUE EQUIPMENT FOR NORMAL APPLICATIONS

BOLT SIZE
150# 5/8 7/8 1 1 1/8 1 1 3/8 1 1 5/8 1 1 7/8 2 1 1 1 2 2 2 2 2 2 2 3 3 3 300# 1 1 1 2 2 2 2 2 2 2 3 3 3 600# 1 1 1 2 2 2 2 2 2 2 3 3 3

CLASS
800# 1 1 1 2 2 2 2 2 2 2 3 3 3 900# 1 1 1 2 2 2 2 2 2 2 3 3 3 1500# 1 1 1 2 2 2 2 2 2 2 3 3 3 2500# 1 1 1 2 2 2 2 2 2 2 3 3 3

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2 1/8 2 >

3 3 3

3 3 3

3 3 3

3 3 3

3 3 3

3 3 3

3 3 3

LEGEND 1= 2= 3= SPANNERS OR TORQUE WRENCH/GUN TORQUE WRENCH/GUN TORQUE GUN OR HYDRAULIC BOLT TENSIONING (DECISION TO BE BASED ON PRACTICALITY)

4. 4.1

BOLTING PROCEDURE Prior To The Making Up Of Flanges

Note: For several applications as defined in Clause 5.0, the guidelines as outlined below are formalised with a checklist that must be filled in. For vessels and the like this list shall be part of the closure certificate.

4.1.1

For the Flange 1. Ensure flange faces are clean, free of gasket residue, free of damage and the gramophone finish is in a serviceable condition. In particular, check the raised face for: Circumferential scoring deeper than the depth of machining. Radial scoring longer than of the raised face width. Internal corrosion exceeding the raised face width. 2. 3. Check that the flange alignment is within the tolerances specified on the attached chart. Ensure that nut seating area at the back of the flange is clean, smooth and free of paint.

4.1.2

For the Gasket 4. 5. Ensure that the gasket is of the correct size and type for the pipe class and check that SWGF gaskets have stainless steel outer and/or inner rings. Check that the gaskets are free from damage, specifically check for defects in the spiral windings or scouring of the RTJ (Ring Type Joint) surfaces.

4.1.3

For the Bolts and Nuts 6. Ensure that the bolts are the correct size and material type for the pipe class.

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7. 8.

Ensure that the threads are clean and not damaged, the nut runs freely on the thread and that the bolt is in a serviceable condition. Old bolts may be used after randomly checking with a thread gauge.

Any defects outside the above allowable limits should be reported to the supervisor.

4.2

Assembly Procedure
Additional Precautions When Using Hydraulic Equipment 1.

Wear adequate safety gear conforming to JHA for bolt tensioning :Glasses, face shield Thin gloves which do not restrict hand feel or movements

2.

Before using the hydraulic equipment check for any defects:Particularly check the hydraulic hoses for any cracks or damage. Ensure that the hoses have been inspected.

3. 4.

When first applying pressure to the system recheck for any leakage of hydraulic fluid. Ensure protective rubber sleeve is attached to socket when using HYTORC equipment.

Caution: - Be careful not to trap fingers between the flange and tool reaction bar, secure reaction bar in correct direction.

1. 2.

Before torqueing the bolts ensure that the threads are coated with anti-seize. Coat also the nut/flange face with a small amount of anti-seize.

Note :a) Anti-seize should not be applied to the gaskets. b) PTFE coated bolts should also be lubricated with anti-seize. 1. 2. 3. 4. 5. Install bolts and hand tighten. Check for correct positioning of both the bolts and the gasket. Obtain the final bolt torque setting from the tables of Clause 2.0. Torque the bolts to 30% of this setting following a standard star pattern shown below. Repeat step 3 for 60% and then 100% of the torque setting. Finally, starting at bolt number 1 and proceeding according the prescribed sequence, re-torque each bolt to 100% of the setting. Continue until all bolts are even.

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No. of Bolts

BOLT PATTERNS ALL BOLTS ARE TO BE NUMBERED IN A CLOCKWISE DIRECTION

8 12 16 20 24 28 32

1-5-3-7-2-6-4-8 1-7-4-10-2-8-5-11-3-9-6-12 1-9-5-13-3-11-7-15-2-10-6-14-4-12-8-16 1-11-6-16-3-13-8-18-5-15-10-20-2-12-7-17-4-14-9-19 1-13-7-19-4-16-10-22-2-14-8-20-5-17-11-23-6-18-12-24-3-15-9-21 1-15-8-22-4-18-11-25-6-20-13-27-2-16-9-23-5-19-12-26-3-17-10-247-21-14-28 1-17-9-25-5-21-13-29-3-19-11-27-7-23-15-31-2-18-10-26-6-22-14-308-24-16-32-4-20-12-28

5.

QA/QC
Tolerances:
PIPE SIZE Up to 4 6 to 10 10 to 24 MAX. TOLERANCE B {mm} 1 2 3 MAX. PARALLEL TOLERANCE C {mm} 1 2 3

A checklist must be completed by the fitter for all flanges that fall into the category of: Equipment ie. manway, covers, bonnets All flanges within cryogenic service All flanges of 12 and above For these flanges the checklist has to be signed off by the supervisor or QA/QC inspector. The signed off checklist has to be filed with the work-pack as QA/QC check of the performed job. On completion of the work, a sample of these QA/QC sheets should be checked for conformance.