GUIDELINES FOR BOLTED FLANGE JOINT ASSEMBLY

1. Evaluation and Planning

Characteristics and purpose of the flange (Critical/non-critical)
S- size
T - temperature
A- applications
M- media
P- pressure
Assembly/Disassembly limitations
Time, space, corrosion, temperature, reusability, sequence

2. Inspection and preparation
Examine and clean/dress all working surfaces
Gasket or joint contact surfaces
Damage, nicks, scratches, cracks, warping, rotation, etc.
Bolt/nut threads, washer faces, rust, corrosion, burrs, uniformity, etc.
Nut/washer bearing surfaces
Select and procure all necessary tools and parts
Studs, nuts, washers, gasket, lubricant, wrenches, marker, backup
tools, etc.
Verify bolt and nut specifications (size, grade, threads, new/used,
(replace all or none) etc.)
Ensure joint is out of service and empty of hazards before dis-assembly
3. Assembly
Align mating surfaces
Install proper gasket if required
OD, ID, thickness, material, concentric, handling, alignment,
adhesives(?),contamination etc
Lubricate bolt working surfaces (friction, corrosion, avoid galling)
Appropriate lubricant (temp., chemicals, etc.), threads, nut/washer
faces
Install bolts and snug hand tight
Align studs for length
Check nut engagement
Number bolts for assembly sequence depending on number of wrenches
(see suggested patterns)
Select desired torque/load and set hydraulic system

Tighten nuts in sequence
1. 20-30% check alignment
2. 50-70% check alignment
3. 100%
4. Tighten in rotation at 100% until no movement
5. Re-check critical applications or soft gasket flanges after time
Pressurize and check for leaks
For critical flanges Record (date, assembler, procedure, problems,
recommendations, etc.)
4. Dis-assembly
Ensure flange is out of service and free of hazards
Check records for any concerns
Examine for corrosion or damage
Apply solvent or lubricant as appropriate
Choose tools with sufficient capacity (break-out torque is more than
assembly torque)
Set hydraulic pressure on pump to maximum
Determine loosening sequence
(critical flanges will require load control during dis-assembly
remove in reverse of assembly sequence two flats at a time until
unloaded then remove)
Safety considerations (sockets, pinch points, reaction, etc.)
Judicious use of heat and shock
Remove bolts
Inspect and prepare for re-assembly









48 bolt tightening sequence showing groupings




3-2-4 method for numbering bolts for tightening sequence