Bolt Tensioning Procedure

Document Number
Rev. Page
Project Package Originator Discipline Doc. Type Unit nº Serial nº
C 1 / 18
RAPID P0003 TRSA CON PRC 0001 0529
PETRONAS RAPID
(Package 3)
BOLT TENSIONING & TIGHTENING

PROCEDURE
This document replaces the document RAPID-P0003-TRSA-CON-PRC-0001-0530
OWNER Approval:
Name:
Date (DD-MMM-YY):
Signature:
Document Class: X
Pages modified under this revision:
Juan Manuel Tovar

2017.04.21 Alberto Rojas Espinosa
2017.04.22 07:51:58
2017.04.21 18:31:57 +08'00'
17:23:54 +08'00' +08'00'
C 22-Apr-2017 IFR- Issued For Review G.D. Carra A. Rojas J.M. Tovar
DATE WRITTEN BY CHECKED BY APPROVED BY
REV. STATUS-REVISION MEMO
DD-MMM-YY (name & signature) (name & signature) (name & signature)
Sections changed in last revision are identified by a vertical line in the right margin
Electronic filename: RAPID-P0003-TRSA-CON-PRC-0001-0529_C.pdf

Document Number
Rev. Page
C 2 / 17
BOLT TENSIONING & TIGHTENING PROCEDURE

(Package 3)
HOLD´s
HOLD No. REF § DESCRIPTION ACTIONS

Document Number
Rev. Page
C 3 / 18

(Package 3)
Table of Contents
1. INTRODUCTION ............................................................................................................................................ 4
2. SCOPE ........................................................................................................................................................... 4
3. GLOSSARY..................................................................................................................................................... 4
4. GENERAL SAFETY NOTES .............................................................................................................................. 5
5. GENERAL REQUIREMENT ............................................................................................................................. 5
5.1 METHOD ............................................................................................................................................... 5
5.2 JOINT PREPARATION BEFORE TIGHTENING ......................................................................................... 6
5.3 REQUIRED TORQUE VALUE .................................................................................................................. 8
6. BOLT TORQUEING ........................................................................................................................................ 8
6.1 GENERAL REQUIREMENTS ................................................................................................................... 8
6.2 TORQUEING PROCEDURE..................................................................................................................... 9
7. BOLT TENSIONING........................................................................................................................................ 9
7.1 GENERAL REQUIREMENTS ................................................................................................................... 9
7.2 TENSIONING PROCEDURE .................................................................................................................. 10
8. THREAD LUBRICANTS AND PRESERVATION FLUIDS ................................................................................... 11
9. EXECUTION ................................................................................................................................................. 11
9.1 RESPONSIBILITIES ............................................................................................................................... 12
9.2 FLANGED JOINTS TAGGING ................................................................................................................ 12
9.2.1 TAGGING PROCEDURE ............................................................................................................... 12
9.3 FLANGE TIGHTENING REPORTS .......................................................................................................... 13
10. REFERENCE DOCUMENTATION .............................................................................................................. 13
11. ATTACHMENT......................................................................................................................................... 13
Attachment 01 – Recommended torque values for non-coated and coated bolts – (02 PAGES) ..................... 14
Attachment 02 – Flanged Joint Tightening Report – (01 PAGES) ...................................................................... 15
Attachment 03 – GASKETS Colour codes – (01 PAGES) ..................................................................................... 16
Attachment 04 – Multipart Tag Example – (01 PAGES) ..................................................................................... 17
Attachment 05 – List of applicable lubricants (01 PAGES)................................................................................. 18

Document Number
Rev. Page
C 4 / 18

(Package 3)
1. INTRODUCTION
The purpose of this procedure is to specify requirements and methodologies for the tightening of flanges
bolting using spanners, wrenches, torque wrenches (manual and hydraulic), and hydraulic bolt tensioning
equipment where appropriate.
The correct placement of gasket and proper tightening of bolts in a flanged joint will ensure a leak free joint.
The following procedure describes how to achieve the same.
2. SCOPE
This procedure is for use by TR and its nominated subcontractors and shall be applied to all piping flange
bolting and bolting of connecting piping to flanged equipment, in all piping systems belonging to ISBL and
OSBL units at PETRONAS refinery in Pengerang - Malaysia.
3. GLOSSARY
Within the context of this procedure, the following words have the meanings stated:
“shall" indicates a mandatory requirement
"should" indicates a preferred course of action
"may" indicates an acceptable course of action
Client PETRONAS
Contractor Tecnicas Reunidas
Tightening the making tight of a flanged joint by torqueing or tensioning the

flange bolts
Torquing the loading/stressing of flange bolts using manual or hydraulic

torque wrenches
Tensioning the loading/stressing of flange bolts using hydraulic jacking tools
Controlled a method where the loading/stressing of flange bolts is measured

to achieve a pre-determined value.

Document Number
Rev. Page
C 5 / 18

(Package 3)
4. GENERAL SAFETY NOTES

The following notes apply to general safe joint assembly and bolting practices. They can only be considered
as guidelines, since it is still essential that the operator remain alert for potential hazards and conduct the
field operations in a manner that will prevent injury of personnel, or damage to equipment. Where specific
precautions are advised with the relation to individual items of equipment, such safety notes are included in
the text:
A. Proper Eye protection must be worn when operating hydraulic or pneumatic bolting equipment.
B. It is recommended that gloves be worn when operating or handling hydraulic equipment. Special
precautions must be taken to avoid placing hands or fingers in pinch points, especially around the
torque arms of the wrenches and is reaction points.
C. Before operating any hydraulic bolting equipment, verify the maximum operating pressure for each
equipment item and do not exceed the specified maximum levels in operation.
D. Do not handle hydraulic tools by their hoses or hydraulic connections.
E. Always remain alert to the positions and avoid standing in the line of any component that would
become a projectile if a part were to break.
F. Avoid kinking or running equipment over hoses to prevent damage. Inspect spray shields regularly
and insure they are in place and in good condition before operating equipment.
G. Tensioning: Do not exceed the maximum allowable stroke of the Hydraulic rams. Always insure that
the rams are fully returned to the retracted position prior to pressurizing. Observe ram position
often while pressurizing.
H. Verify that all quick connect coupling are connected and fully engaged before pressurizing.
5. GENERAL REQUIREMENT
5.1 METHOD
The method of flange tightening is dependent upon bolt size, system pressure rating and system service, and
shall be as follows:
Conventional Spanner/Wrenches:
Flange bolts may be tightened by conventional manual spanners/wrenches on class 150 utility piping (bolts
size 1” diameter and smaller) systems only, but not on GRP flanges, or steel flanges on GRP lap joints.

Document Number
Rev. Page
C 6 / 18

(Package 3)
Torque Wrenches:
Flange bolts shall be tightened by torque wrenches on all hydrocarbon systems in all pressure ratings, and
utility systems class 300 and above. The flogging of bolts in hydrocarbon systems is not permitted. Bolt
torque values for flanges in GRP systems are not contained in this standard, and shall be obtained from the
GRP system manufacturer.
Hydraulic Jack Bolt Tensioning Equipment:
Where more stringent control of joint stresses is required flange bolting should, whenever practical, be
tightened using hydraulic jack tensioning equipment and is strongly recommended for the following services
and pressure ratings:
1) Bolt sizes 2 inches and larger in all services with pressure ratings up to and including class 900.
2) Bolt sizes 1½ inches and larger in all services with pressure ratings class 1500 and above.
3) Bolt sizes larger than 1 inch in critical applications. Critical applications are considered joints exposed
to cyclic stress i.e. frequent changes of pressure and/or temperature.
4) For Hydrogen service with bolt size 1½ inches and larger and flange rating class 600 and larger.
5.2 JOINT PREPARATION BEFORE TIGHTENING

Apart from the bolt tightening procedure there are several interdependent factors, which are essential to
obtain good performance from a bolted flange connection. These are:
Flanges
 Always visually inspect the surface finish of the flange, which should be clean, degreased and free of
any defects, nicks or burrs. This is important for the back face of the flange where the nuts have to
seat as well as the critical gasket face. Flanges should also be checked for flatness with a
straightedge.
 Check the phonographic or concentric groove on the face of RF flanges. For example, any radial
defects will be virtually impossible to seal against. (For acceptance criteria, refer to ASME B16.5 or
ASME b16.47 as applicable).
 RTJ grooves must be kept scrupulously clean, corrosion free and undamaged.
 When cleaning a flange face, never use a tool that may damage the surface finish. A soft wire brush
is recommended.

Document Number
Rev. Page
C 7 / 18

(Package 3)
 Do not use unnecessary force to bring together flanges which are clearly misaligned as this may over
stress adjacent pipe work and make sealing of the flanged joint difficult and unreliable. Instead, this
situation must be reported and rectified.
The measured lateral misalignment shall not exceed the following values:
DN Maximum Misalignment
≤ 100 2 mm
> 100 3 mm
Bolt holes shall straddle the natural centerline unless specified otherwise. The maximum deviation
from the required theoretical bolt hole position, as measured along the bolt circle, shall be 1.5 mm.
 Do not mate flanges manufactured to different standards unless specified in an approved design.
Bolts
 Ensure that the correct size and material of bolting is used (refer to the piping class).
 Allow for at least two threads to be exposed outside the nut once tightened, this is good practice.
The only exception to this is when a flange requires Hydraulic Bolt Tensioning.
 Only use clean, rust free nuts and stud bolts.
 Coat the stud, the nut thread, the nut and the flange bearing surfaces with Molykote 1000
 Ensure that the nut is free running ideally along the full length of the bolt, but especially around the
area where the nut will be tightened.
 Ensure that the flange area on which the nut will seat is clean and undamaged as unanticipated
friction or compressible debris will adversely affect the Residual Bolt Load.
 Do not use damaged or corroded stud bolts or nuts.
 Do not use nuts or bolts that do not fit correctly together.
 Does not use stud bolts or nuts that are not clearly marked with the correct material grade as a
wrong assumption could have serious consequences. (e.g., stud bolts marked with B7 and nuts with
2H in sweet services and studs marked with B7M and nuts with 2HM in sour services in line with the
pipe class).
 Nuts should not be assembled with the identification marking against the flange. The identification
marking should always point outwards.

Document Number
Rev. Page
C 8 / 18

(Package 3)
Gaskets
 Check the type, class, size and material specification of the gasket before using it. Check with the
piping class to confirm that it is correct. (Applicable gaskets colour code is given in attachment
03)
 Check the gasket for damage, nicks, etc. Ensure that it is clean and free from any contaminants
before use.
 Ensure the gasket fits correctly
 Spiral Wound, and Ring Joint gaskets can only be used ones and shall not be re-used.
 Do not use Spiral Wound, and Ring Joint gasket that have no identification. It may appear to fit
the flange, but this is not a guarantee.
 Do not cut or deform a gasket to fit a flange. If the gasket does not fit, the wrong one has been
chosen.
5.3 REQUIRED TORQUE VALUE

Recommended torque values for non-coated and coated bolts, both on SI and U.S. customary units are given
in Attachment 01.
These torque values will generate the bolt stresses necessary for gasket seating, design pressure and
hydrostatic test pressures, differences in the coefficient of thermal expansion and bolt relaxation, but will
not overstress the flange or crush the gasket.
6. BOLT TORQUEING
6.1 GENERAL REQUIREMENTS
For all flange bolting on class 150 utility piping (bolts size 1” diameter and smaller) except flanges in GRP
systems, tightening may be carried out by conventional spanners/wrenches. Bolt torques for flanges in GRP
systems shall be obtained from the GRP system manufacturer.
Controlled torque wrenching shall be carried out using either manual or hydraulic torque wrenches. The
method chosen is dependent upon bolt loading, access, clearance and tooling availability, which can be
determined by the site personnel. When the bolt loading requires a torque figure of more than 500 Lbf.ft
(678 Nm) to be applied, hydraulic torqueing is recommended, using hydraulic torque wrenches.
(Note: calibration of torque wrenches remains critical, check certificate validity prior to use).
Controlled torqueing shall be carried out on the following flanged connections:

Document Number
Rev. Page
C 9 / 18

(Package 3)
1) Bolt sizes less than 2 inches diameter for all service ratings up to and including class 900, except class
150 utility services (see above).
2) Bolt sizes less than 1½ inches diameter for all service ratings class 1500 and above.
3) Bolt diameters in excess of those stated in (1) and (2) when hydraulic jack tensioning is not practical.
6.2 TORQUEING PROCEDURE

To achieve joint tightness it is important that the following procedure is adhered to:
 Check and ensure that the general requirements of Section 5 have been satisfied.
 To achieve uniform joint load/stress distribution the bolts shall be tightened in three stages,
representing 30%, 60% and 100% of the torque values stated in Appendix 1. At each stage of
tightening, bolts shall be tightened in a controlled sequence as follows (bolts numbered clockwise
around the flange):
4 bolts flange 1,3,2,4.

8 bolts flange 1, 5, 3, 7, 2, 6, 4, 8.
12 bolts flange 1, 7, 4, 10, 2, 8, 5, 11, 3, 9, 6, 12.
16 bolts flange 1, 9, 5, 13, 3, 11, 7, 15, 2, 10, 6, 14, 4, 12, 8, 16.
20 bolts flange 1, 11, 6, 16, 3, 13, 8, 18, 5, 15, 10, 20, 2, 12, 7, 17, 4, 14, 9, 19.
24 bolts flange 1, 13, 7, 19, 4, 16, 10, 22, 2, 14, 8, 20, 5, 17, 11, 23, 6, 18, 12, 24, 3, 15, 9, 21.
28 bolts flange 1, 15, 8, 22, 4, 18, 11, 25, 6, 20, 13, 27, 2, 16, 9, 23, 5, 19, 12, 26, 3, 17, 10, 24, 7,
21, 14, 28.
32 bolts flange 1, 17, 9, 25, 5, 21, 13, 29, 3, 19, 11, 27, 7, 23, 15, 31, 2, 18, 10, 26, 6, 22, 14, 30,
8, 24, 16, 32, 4, 20, 12, 28.
 Finally, the bolts shall be chased round using the 100% torque value stated in Appendix 1, until no
nut movement occurs.
7. BOLT TENSIONING
7.1 GENERAL REQUIREMENTS
Controlled hydraulic jack bolt tensioning enables high integrity jointing to be achieved by uniformly
stretching the bolt shanks in the cold condition by means of hydraulic oil pressure. The elongation produced
in the bolts corresponds to the calculated load required to make the flanged joint.

Document Number
Rev. Page
C 10 / 18

(Package 3)
Whilst the bolts are elongated, the nuts can easily be run down the thread by hand, until they bear against
the flange. When the hydraulic pressure is released virtually all of the bolt extension is retained over its
active length between the nuts, and the required bolt load is obtained.
A jacking tool screws onto one end of the bolt, therefore the bolt needs an additional length of thread
protruding out of the hexagonal nut at one end by about 1 to 1.5 times the bolt diameter. After the
tightening procedure is complete the extended thread lengths shall be protected against corrosion and
damage to allow the nuts to be subsequently unscrewed. Grease filled rubber, plastic caps, or denso tape
are recommended for this purpose. In the loosening procedure the bolts are stretched again and the nuts
unscrewed easily, providing the threads has been protected.
The hydraulic pressure is supplied by a high-pressure oil pump via a distribution ring main to a number of
jacking tools.
Controlled hydraulic jack bolt tensioning shall be carried out on the following flanged connections (where
inadequate space or availability of tooling restricts the use of tensioning, then controlled torqueing shall be
used):
1) Bolt sizes 2 inches and larger in all services with ratings up to and including class 900.
2) Bolt sizes 1.5 inches and larger in all services with ratings class 1500 and above.
3) Bolt sizes larger than 1 inch in critical applications.
4) For Hydrogen service with bolt size 1½ inches and larger and flange rating class 600 and larger.
7.2 TENSIONING PROCEDURE

To achieve joint tightness it is important that the following procedure is adhered to:
 Check and ensure that the general requirements of Section 5 have been satisfied.
 Before starting work, check that the tensioning tool is not too large to fit on the nuts and flange.
 The application of hydraulic jack bolt tensioning equipment shall be in strict accordance with the
manufacturer's instructions and safety procedures.
 Personnel using the equipment shall be properly trained in its application.

Document Number
Rev. Page
C 11 / 18

(Package 3)
8. THREAD LUBRICANTS AND PRESERVATION FLUIDS

All bolts shall be treated with a preservative lubricant as per grade below, or equivalent:
Molykote 1000 (combined friction coefficient for application nut face and threads = 0.11)
Applicable list of lubricants is given in attachment 05.
The use of lubricants with a lower coefficient of friction than that shown can lead to excessive bolt stress
being applied by wrenches or torque wrenches, and yielding or failure of flanges or bolting may result.
Molybdenum Disulphide greases shall not be used under any circumstances as this can result in stress
corrosion cracking.
Note that Molykote 1000 does not contain Molybdenum Disulphide.
When the bolt tightening procedure is completed, to prevent corrosion a liberal coating of grease should be
applied to the nuts up to the back of the flange, and to the stud ends protruding from the nuts. This is
particularly important where low alloy bolts are used on unpainted stainless steel flanges.
9. EXECUTION
Control of the competence of the people working with joints is the most important factor in preventing
leaks.
Only competent and qualified staffs are allowed to execute and supervise flange-fitting activities on all
piping. The contractor shall keep training and competence records of the fitters and supervisors working
under his responsibility. As a minimum fitters and supervisors, staff shall have knowledge/skills of:
 The behavior of nuts and bolts when tightened
 Gasket/seal rings Types application and installation
 Flange surface finish/join sealing face
 Correct assembly of flange components
 Flange alignment measurement and acceptance criteria.
 Safe range of bolt loads and the importance of residual bolt load
 Methods of tightening
 Correct use of tools
 Procedures and reporting.

Document Number
Rev. Page
C 12 / 18

(Package 3)
In addition, the operation of hydraulic bolt tensioning and torque equipment needs dedicated skills and
training.
9.1 RESPONSIBILITIES
It is the responsibility of TR area Supervisor and the executing subcontractor to ensure bolts are tightened in
accordance with this Specification.
It is the responsibility of the executing subcontractor to ensure that only qualified fitters are working on
flange connections.
9.2 FLANGED JOINTS TAGGING

All joints for which controlled tightening is to be applied (manually and hydraulic torque wrench and
hydraulic jack bolt tensioning) shall be uniquely identified, tagged and details recorded.
This requires all joints to be physically tagged so that their identity is clear and visible at the joints location,
including unique joint ID number in order that it can be recognized in a joint database.
A multi part tag will be used for this purpose. In the multipart tags, the status of the joint is indicated by the
colour of the portion remaining of the tag.
Joint status/conditions will be as follows:
- Joint to be broken out/Joint broken out,
- Joint to be assembled/Joint assembled,
- Joint to be controlled tightened/Joint tightened,
- Joint to be tested/Joint tested.
An example of applicable colour multipart tag ID is given in Attachment 04.
9.2.1 TAGGING PROCEDURE

 All joints that are to be made or disturbed during construction, Precommissioning and
commissioning phase, shall be identified, recorded and tagged on a joint register.
 The tags shall be made of waterproof resistant material suitable for outdoor conditions.
 The tags shall be fitted using a suitable tie and in a position adjacent to or on the joint.
 The person who breaks the joint(s) will mark up the tag identification number on a copy of the
relevant Isometric or P&ID and its correspondent register.

Document Number
Rev. Page
C 13 / 18

(Package 3)
 At the completion of each stage of the job (inspection, assembly, tightening and testing), the
responsible person or the supervisor shall record its name against the stage.
 Once the testing has been satisfactorily completed, the removable insert of the tag shall be returned
to the TR area supervisor. The task completion shall be recorded in the relevant test pack when all
joint tag bodies are returned, indicating that all works have been completed.
 The relevant test pack and/or system final pressurization (start-up) shall be prevented until all the
tag inserts are signed off and returned to allow sign-off of the job.
9.3 FLANGE TIGHTENING REPORTS

A copy of the applicable flange tightening report is provided in Attachment 02.
10. REFERENCE DOCUMENTATION

Doc. Number Description
PTS 31.38.01.11 Piping – General Requirements
PTS 31.38.01.31 Shop and Field Fabrication of Piping
ASME-PCC-1-2013 Guidelines for Pressure Boundary Bolted Flange Joint Assembly
ASME B16.20-2012 Metallic Gaskets for Pipe Flanges
ASME B31.3-2014 Process Piping
ASME B16.5-2013 Pipe Flanges and flanged fittings NPS 1/2 Through NPS 24
ASME B16.47 Large Diameter Steel Flanges NPS 26 Through NPS 60 (series B)
RAPID-P0003-TRSA-HSE-PLN-0001-0115 Precommissioning & Commissioning HSE Plan
11. ATTACHMENT

Document Number
Rev. Page
C 14 / 18

(Package 3)
Attachments
Attachment 01 – Recommended torque values for non-coated and coated bolts – (02 PAGES)

ATTACHMENT 01 – RECOMMENDED TORQUE VALUES FOR NON-COATED AND COATED BOLTS
U.S. UNITS
Electronic filename: RAPID-P0003-TRSA-CON-PRC-0001-0529_C-01.pdf

ATTACHMENT 01 – RECOMMENDED TORQUE VALUES FOR NON-COATED AND COATED BOLTS
SI UNITS

Document Number
Rev. Page
C 15 / 18

(Package 3)
Attachment 02 – Flanged Joint Tightening Report – (01 PAGES)

No: 02260-CON-PIP-27
Rev.: 0
TIGHTNESS REPORT FOR BOLTING (PIPING) Date: 14/04/2016
Page: 1 of 1
PROJECT: SUBCONTRACTOR:
SYSTEM/SUBSYSTEM: DRAWING:
TAG NUMBER: DESCRIPTION:
INCLUDED IN FOLDER: REPORT NUMBER:
BAR CODE:
This certificate does not exempt the Subcontractor from the Terms of the Contract, Project Specifications or Quality Procedures but confirms that all these Tests have been performed according to them.
TYPE OF BOLTS 1 TYPE OF BOLTS 2 TYPE OF BOLTS 3

DIAMETER: DIAMETER: DIAMETER:
QUALITY: QUALITY: QUALITY:
QUANTITY: QUANTITY: QUANTITY:
FIRST TORQUING: FIRST TORQUING: FIRST TORQUING:
SECOND TORQUING: SECOND TORQUING: SECOND TORQUING:
TORQUE WRENCH Nº: RANGE: CALIBRATION CERTIFICATE:
FIRST TORQUING SECOND TORQUING

ISOMETRIC JOINT No GASKET ACCORDING TO REMARK
TYPE OF BOLTS
ISOMETRIC DRAWING
DATE ACCEPTED REJECTED DATE ACCEPTED REJECTED
REMARKS:
WITNESSED/REVIEWED BY: SUBCONTRACTOR TR QUALITY SUPERVISOR CLIENT (If required)
SIGNATURE:
PRINT NAME:
DATE:

Document Number
Rev. Page
C 16 / 18

(Package 3)
Attachment 03 – GASKETS Colour codes – (01 PAGES)

ATTACHMENT 03 - GASKETS COLOUR CODE
In addition to the above, permanent Gaskets shall be marked for rating according to the instructions
below:

Document Number
Rev. Page
C 17 / 18

(Package 3)
Attachment 04 – Multipart Tag Example – (01 PAGES)

FRONT REAR
JOINT TESTING
Joint No.
Test Pack No.
Joint Joint
Size Rating
JOINT Tech 1 Tech 2 Date
TIGHTENED
JOINT TIGHTENED
Joint No.
JOINT
Test Pack No.
TO BE Torque Tension
TIGHTENED
Tech 1 Tech 2 Date
JOINT ASSEMBLED
Joint No.
Test Pack No.
JOINT
Lubricant:
Joint Joint
TO BE
Size Rating
Tech 1 Tech 2 Date
ASSEMBLED
JOINT BREAK DATA
Joint No.
Test Pack No.
JOINT Joint Joint
TO BE
Size Rating
Tech 1 Tech 2 Date
BROKEN
Example of a multi part tag

Document Number
Rev. Page
C 18 / 18

(Package 3)
Attachment 05 – List of applicable lubricants (01 PAGES)

ATTACHMENT 05 – LIST OF APPLICABLE LUBRICANTS

Bolt Tensioning Procedure

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BOLT TENSIONING & TIGHTENING

This document replaces the document RAPID-P0003-TRSA-CON-PRC-0001-0530

Pages modified under this revision:

Juan Manuel Tovar

Electronic filename: RAPID-P0003-TRSA-CON-PRC-0001-0529_C.pdf

BOLT TENSIONING & TIGHTENING PROCEDURE

Electronic filename: RAPID-P0003-TRSA-CON-PRC-0001-0529_C.pdf

BOLT TENSIONING & TIGHTENING PROCEDURE

Electronic filename: RAPID-P0003-TRSA-CON-PRC-0001-0529_C.pdf

BOLT TENSIONING & TIGHTENING PROCEDURE

“shall" indicates a mandatory requirement

"should" indicates a preferred course of action

"may" indicates an acceptable course of action

Contractor Tecnicas Reunidas

Tightening the making tight of a flanged joint by torqueing or tensioning the

Torquing the loading/stressing of flange bolts using manual or hydraulic

Tensioning the loading/stressing of flange bolts using hydraulic jacking tools

Controlled a method where the loading/stressing of flange bolts is measured

Electronic filename: RAPID-P0003-TRSA-CON-PRC-0001-0529_C.pdf

BOLT TENSIONING & TIGHTENING PROCEDURE

4. GENERAL SAFETY NOTES

D. Do not handle hydraulic tools by their hoses or hydraulic connections.

Electronic filename: RAPID-P0003-TRSA-CON-PRC-0001-0529_C.pdf

BOLT TENSIONING & TIGHTENING PROCEDURE

Hydraulic Jack Bolt Tensioning Equipment:

5.2 JOINT PREPARATION BEFORE TIGHTENING

Electronic filename: RAPID-P0003-TRSA-CON-PRC-0001-0529_C.pdf

BOLT TENSIONING & TIGHTENING PROCEDURE

 Only use clean, rust free nuts and stud bolts.

 Do not use damaged or corroded stud bolts or nuts.

 Do not use nuts or bolts that do not fit correctly together.

Electronic filename: RAPID-P0003-TRSA-CON-PRC-0001-0529_C.pdf

BOLT TENSIONING & TIGHTENING PROCEDURE

 Ensure the gasket fits correctly

5.3 REQUIRED TORQUE VALUE

Controlled torqueing shall be carried out on the following flanged connections:

Electronic filename: RAPID-P0003-TRSA-CON-PRC-0001-0529_C.pdf

BOLT TENSIONING & TIGHTENING PROCEDURE

6.2 TORQUEING PROCEDURE

4 bolts flange 1,3,2,4.

Electronic filename: RAPID-P0003-TRSA-CON-PRC-0001-0529_C.pdf

BOLT TENSIONING & TIGHTENING PROCEDURE

3) Bolt sizes larger than 1 inch in critical applications.

7.2 TENSIONING PROCEDURE

 Personnel using the equipment shall be properly trained in its application.

Electronic filename: RAPID-P0003-TRSA-CON-PRC-0001-0529_C.pdf

BOLT TENSIONING & TIGHTENING PROCEDURE

8. THREAD LUBRICANTS AND PRESERVATION FLUIDS

Applicable list of lubricants is given in attachment 05.

Note that Molykote 1000 does not contain Molybdenum Disulphide.

 The behavior of nuts and bolts when tightened

 Gasket/seal rings Types application and installation

 Flange surface finish/join sealing face

 Correct assembly of flange components

 Flange alignment measurement and acceptance criteria.

 Correct use of tools

 Procedures and reporting.

Electronic filename: RAPID-P0003-TRSA-CON-PRC-0001-0529_C.pdf

BOLT TENSIONING & TIGHTENING PROCEDURE

9.2 FLANGED JOINTS TAGGING

Joint status/conditions will be as follows:

- Joint to be broken out/Joint broken out,