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Title: Flange Bolting Standard
PREFACE
Woodside Energy Ltd. (WEL) has developed a suite of Engineering and Technical Standards
and Guidelines. It is intended that these reflect the most suitable engineering practices for
use on all new WEL facilities as well as the modification of existing facilities. The application
of the Standards is mandatory. The applications of Guidelines are to support the
implementation of the Standards, and are considered best practice, but are not mandatory.
The Standards are based on the experience acquired by WEL personnel and contractors
during WEL’s involvement with the design, construction, operation and maintenance of WEL
processing units and facilities. Where appropriate, the Standards are based on or make
reference to national and international standards and codes of practice.
The objective of this publication is to ensure the overall integrity of engineering design and to
achieve maximum technical and economic benefits through the standardisation of
engineering and technical practices.
Where the standards to be used for a certain application are not provided for in this
publication, WEL expects that the standards that are used will achieve the same level of
integrity as reflected in this publication. If WEL contractors or manufacturers/suppliers have
any doubt as to the relevant standard to use, then they must consult WEL, however they will
remain responsible at all times for the use of the most appropriate standard. Specific
requirements may be added as an addendum to these Standards and Guidelines for various
projects. Project specific requirements must not depart from the requirements of the
Engineering and Technical Standards contained in this publication. Where changes or
additions to these Standards are required, they must be raised as a deviation and presented
to the WEL Technical Authority for consideration.
WEL grants the right to use these Standards and Guidelines to WEL’s consultants,
contractors and suppliers who are contractually authorised to do so and to any tier of
contractor to its consultants, contractors and suppliers who are contractually required to
comply with them.
DISCLAIMER
WEL and its joint venture partners disclaim any liability of whatsoever nature for any damage
(including injury or death) suffered by any company or person whomsoever as a result of or
in connection with the use, application or implementation of any standard, combination of
standards or any part thereof contained in this publication.
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Title: Flange Bolting Standard
TABLE OF CONTENTS
1 INTRODUCTION ............................................................................................ 6
1.1 Scope ............................................................................................................. 6
1.2 Summary ........................................................................................................ 6
1.3 Aims of this Standard ..................................................................................... 6
2 BOLT STRESS LEVELS FOR ASME FLANGES.......................................... 7
2.1 Criteria for Selection of Bolt Stress for ASME Flanges................................... 7
2.2 Stipulated Bolt Stress Levels for ASME Flanges ............................................ 7
3 INSTRUCTIONS FOR FLANGE & CLAMP MAKE UP.................................. 8
3.1 ASME Flange Assemblies .............................................................................. 8
3.2 Gasket Selection ............................................................................................ 8
3.3 Bolt Tensioning Equipment............................................................................. 8
3.4 Bolt Torquing Equipment ................................................................................ 9
3.5 Sequence of Bolting ....................................................................................... 9
3.6 Making Up Clamp Connectors........................................................................ 9
3.7 The Use of Flange & Clamp Connector Checklists....................................... 10
3.8 Accuracy, Calibration and Care of Equipment .............................................. 10
3.9 Re-use of Stud Bolts and Nuts ..................................................................... 10
3.10 Re-use of Ring Tight Joints (RTJ) ................................................................ 11
3.11 Use of Threaded inserts ............................................................................... 11
3.12 Sight Glass Refurbishment ........................................................................... 11
4 GUIDANCE ON MAKE UP OF SPECIAL FLANGE TYPES........................ 12
4.1 Ameron GRE Flange Assemblies ................................................................. 12
4.2 DIN Flange Assemblies ................................................................................ 12
4.3 Non-steel flanges.......................................................................................... 12
5 PROCEDURE FOR HOT BOLTING ............................................................ 13
5.1 Hot Bolting to Replace Corroded Bolts ......................................................... 13
5.2 Hot Bolting to Replace Non-Corroded Bolts ................................................. 14
6 TIGHTENING OF LEAKING JOINTS UNDER PRESSURE ........................ 15
6.1 Instructions for Tightening Leaking Joints Under Pressure........................... 15
7 INSULATING FLANGES.............................................................................. 16
8 REFERENCES ............................................................................................. 18
APPENDIX A ............................................................................................................ 19
APPENDIX B ............................................................................................................ 20
APPENDIX C ............................................................................................................ 25
APPENDIX D ............................................................................................................ 28
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Title: Flange Bolting Standard
APPENDIX E ........................................................................................................... 30
APPENDIX F............................................................................................................ 33
APPENDIX G ............................................................................................................ 34
APPENDIX H ............................................................................................................ 35
APPENDIX I.............................................................................................................. 36
APPENDIX J............................................................................................................. 37
APPENDIX K ............................................................................................................ 48
APPENDIX L............................................................................................................. 51
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Title: Flange Bolting Standard
1 INTRODUCTION
1.1 Scope
This document covers the philosophy and bolt stress levels for steel flanges and clamp
connectors. Other flange materials are not considered (eg. cast iron, plastic). Refer to
the Mechanical Integrity Custodian for the make up of these flanges.
1.2 Summary
It is important for flanges to be tightened up correctly to minimise problems such as
gasket deformation, leaks and misalignment.
This standard outlines the procedures that shall be used within Woodside to
standardise the method in which flanges and clamp connectors are made up.
• To specify a bolt stress level that can be safely applied to ASME flanges and
Clamp Connectors for each flange and bolt material type.
• To develop a philosophy for the controlled bolt loading of ASME flanges and
Clamp Connectors to include:
- Bolting procedures for different flange installations.
- Procedures on the use of tensioning and torquing equipment.
- Checklists for the correct installation of flanges, connectors and sight-
glasses.
- Calibration requirements for equipment.
- Instructions on the re-use of stud bolts.
- Instructions on the use of threaded inserts.
- Procedures for the refurbishment of sight-glasses.
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Title: Flange Bolting Standard
Note: The minimum yield value for bolts varies with the material grade and the bolt diameter. In
the bolt yield column above, the lowest minimum yield value is shown.
e.g. For B7 bolts of diameter 2 1/2” and less, the minimum yield is 725 MPa.
For B7 bolts of diameter greater than 2 1/2”, the minimum yield is 655 MPa.
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Controlled Ref No: W1000SM3131997 Revision: 2 DRIMS No: 3131997 Page 7 of 53
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Title: Flange Bolting Standard
All flanges in critical services such as hydrocarbons, glycol and hot oil or rated 900 lbs
and above non critical services shall have their bolts tightened to the stipulated stress
levels for their piping material class and a Flange Checklist must be used.
a) Whenever physically possible all flanges with bolt diameters 1 3/8” and greater
shall be tensioned using Hydraulic Bolt Tensioning equipment. Refer to Appendix
B for the offshore bolt tensioning procedure.
b) Whenever physically possible all flanges with bolt diameters 1 3/8” and greater
shall be tensioned using Hydraulic Bolt Tensioning equipment.
(Hydraulic Bolt Tensioning equipment produces a more accurate bolt tensile stress in
flange make ups; however it does require additional stud length to facilitate the use of
the specialised equipment, for this reason it may not be practicable to use on all WEL
facilities)
These tables provide the recommended tool type and its corresponding pressure for
each bolt size 1-3/8” and greater. Care must be taken to use the correct pressure for the
listed equipment and tools as the hydraulic areas on different tools vary. (Note that the
pressures have been calculated to obtain the bolt stress specified in Section 2.2.)
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Title: Flange Bolting Standard
Appendix C details the procedure to be used on torquing equipment. This shall be used
in all cases. Also in Appendix C is a chart detailing recommended bolt torques. This
assumes a friction factor of 0.11 (This friction factor is based on the use of graphite based
anti-seize and is not affected significantly by the respective stud and bolt surface
treatment).
The torque table can also be used to determine the pressures for the “HyTorc”
equipment. Conversion charts are attached to Appendix D and for a bolt torque give a
corresponding hydraulic pressure. It is important, however, that for a particular bolt size
the correct pressure is used with the correct tool. There is potential for over/under
torquing of bolts if pressures and tools are mixed.
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Title: Flange Bolting Standard
In order to obtain the best flange joints possible it is important that equipment is
adequately maintained. Hired tensioning equipment should be serviced every 3 months
by the manufacturer’s service representative. The content of this service can be as
recommended by the service representative, however, should involve tool stripping,
cleaning, checking of seals and a visual examination. The equipment should also be
calibrated against a test gauge and a service record maintained.
In addition to the above points, please note the following about the re-use of bolts:
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Title: Flange Bolting Standard
For joint assemblies on the critical path of a maintenance or shutdown program (or
where tight time schedules are to be adhered to), it is recommended that replacement
bolting be made available in case the existing bolting is found to be unfit to return to
service.
For joint assemblies on the critical path of a maintenance or shutdown program (or
where tight time schedules are to be adhered to), it is recommended that replacement
RTJ rings be made available in case the existing ring is found to be unfit to return to
service.
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Title: Flange Bolting Standard
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Title: Flange Bolting Standard
To check the integrity of the flange is not compromised during this operation, the Taylor-
Forge method from ASME was used to generate the calculations in A8000CM001.
Based on these calculations hot bolting shall only be carried out on Class 150 and 300
flanges that have 8 or more securing fasteners. Hot bolting on Class 600 and 900
flanges that have 8 or more studs is also acceptable if the operating pressures are limited
to 8 MPa and 12 MPa respectively, due to inadequate bolting after allowance has been
made for corrosion.
On 4 bolt flanges it is feasible to hot bolt up to Class 900 based on the calculations,
however, the possibility of a leak is quite high due to the large bolt spacing. It is therefore
allowable to hot bolt flanges with 4 securing fasteners only with the installation of two
external clamps. See Appendix K for guidelines on selection and placement. The flange
clamps that are readily available in the market (Lindapter) are only suitable for Class 150
and 300 flanges. These clamps cannot be used on Class 600 or 900 flanges due to
limited space and/or inadequate capacity. Therefore, hot bolting of the flanges with 4
securing fasteners is limited to Class 150 and 300.
Hot bolting is not permitted on Class 1500 and 2500 flanges due to inadequate bolting
strength and the heightened consequences of a leak developing.
8 or more securing
Class 4 securing fasteners
fasteners
150 Yes (with clamps installed) Yes
300 Yes (with clamps installed) Yes
600 No Yes (limit pressure to 8 MPa)
Yes (limit pressure to 12
900 No
MPa)
1500 No No
2500 No No
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Title: Flange Bolting Standard
In all cases the tightening of joint fasteners shall be done by controlled means. The
‘flogging’ of fasteners is not permitted. The removal or existing studs should be done
without applying excess strain, shocks or heat on the system.
Hot bolting shall be controlled under the Permit to Work system. The possibility of a leak
should always be considered and such scenarios should be fully developed, with
personnel protection and support services available on stand-by. If leaks develop then it
is permissible to ‘nip-up’ these joints whilst the system is pressurised in accordance with
Section 5.0. It is preferred that every attempt be made to depressurise the line prior to
attempting any tightening of leaking joints.
A summary of the hot bolting procedure to replace non-corroded bolts is given below.
8 or more securing
Class 4 securing fasteners
fasteners
150 Yes (with clamps installed) Yes
300 Yes (with clamps installed) Yes
600 No Yes
900 No Yes
5B15
No No
00
2500 No No
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Title: Flange Bolting Standard
The results of trials undertaken by SIPM (see reference 12) support this view and prove
that tightening leaking joints even under full test pressure can reduce down time without
compromising safety.
Procedures for tightening leaking joints will vary from case to case depending on the
operational constraints affecting a particular activity. The following criteria should be used
b) Tightening should be attempted with the system pressure at less than 4 MPa.
c) Bolt loads shall only be applied using controlled techniques and equipment such
as torque wrenches, torque guns and hydraulic tensioning gear.
Note: Working outside the above instructions should not be attempted without prior
consultation with the appropriate Technical Authority.
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Title: Flange Bolting Standard
7 INSULATING FLANGES
The sketch below shows a flange type insulation joint using an insulating gasket
assembly to provide electrical isolation between dissimilar piping materials. Insulating
joints are designed to prevent galvanic corrosion and/or cathodic current cross flow.
Flanges shall be free of pits, gouges, rust, debris, oil and grease. Surface finish shall be
no greater than 250 RMS. Check and remove burrs from bolt holes and flanges.
Ensure bolts and nuts are clean and nuts rotate freely along length of the stud.
Minimise the possibility of steel washer distortion and subsequent damage to insulating
washer. Nuts should be flat faced to maximise contact area with washer and minimise
possibility of deflection. Steel washers should be flat and extra thick for strength.
Open the insulating kit and confirm components are as specified. Check the gasket ID.
It should be no greater than the flange ID. The insulating washers shall have sealed
edges to prevent ingress of moisture.
Insulating gaskets that lack history of successful application shall be tested to the
satisfaction of the Principal; prior to being considered for evaluation along with already
proven gaskets.
Align flanges so they are concentric and parallel and insert gasket carefully. No
lubricant, grease or adhesives shall be used on the gasket or flange faces. Do not
damage sealing element.
Line up bolt holes with non-tapered drift pins using preferably three at 120 degrees
separation (large flanges) but at least two at 180 degrees separation. Insert bolt
sleeves. Do not force! If force is needed recheck / realign flanges.
Apply non-conductive lubricant to threads and the nut face contacting the steel washer.
This will help to reduce galling of the insulating washer on the flange.
WARNING: Do not use nickel based anti-seize. It is electrically conductive and will
provide a path for current leakage across the flange.
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Title: Flange Bolting Standard
Install studs, steel washers, insulating washers and nuts. Cross-tighten bolts until
flange to gasket contact has been made. Check for a flange segment that may show a
gap or separation between gasket and flanges using a feeler gauge. If a gap exists the
flanges are not parallel and shall be realigned. Misaligned flanges can result in
excessive flange to gasket contact forces when nuts are tightened. The subsequent
gasket damage may destroy electrical insulation properties.
WARNING: The non-conductive lubricant will have a different friction factor that
invalidates the torque values listed in section 7.4. Seek engineering advice from the
mechanical integrity custodian to determine appropriate torque values
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Title: Flange Bolting Standard
8 REFERENCES
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Title: Flange Bolting Standard
APPENDIX A
The line class and diameter specified on the P&ID is cross-referenced with the ‘Offshore Piping
Material Specification’ to determine the correct gasket.
P – 80 – X – 9A
The new offshore piping class in the rationalised piping specification is selected using the ‘Cross
Reference for Replaced Offshore Piping Classes’ table in W9000MX001 part 1.
Eg. NRA piping class ‘9A’ is equivalent to piping class 91428 in the rationalised piping
specification from the table:
C.A. Temp.
Class Material Notes GWA NRA
(mm) Range
91428 CS 0°C min 1.5 0 / 250°C 9C1, 9C3 9A
All relevant information pertaining to each piping class is contained within the data sheets.
SWCI CLASS 900 10060927 10060928 10060929 10061055 10060931 10060921 1000922
Therefore, for an 80mm Class 9A flange assembly (corresponding to rationalised piping class
91428 in the new piping specification W9000MX001), the correct gasket selection is material no.
10060921.
Note: prior to installation the gasket dimensions should be checked with the manufacturer’s
catalogue to ensure correctness.
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Title: Flange Bolting Standard
APPENDIX B
1. Ensure that adequate safety gear is being worn and that work permit
requirements are being met.
2. Particularly ensure that glasses and thin gloves that do not restrict hand
movements are worn.
4. When first applying pressure to the system recheck for any leakage of hydraulic
fluid.
1. Before torquing the bolts, ensure that the threads and the nut/flange contact face are
coated with nickel based anti-seize. Anti-seize should not be applied to the gaskets.
PTFE coated bolts should also be lubricated with anti-seize.
2. Install bolts and hand-tighten. Flanges should be squared and concentric using a
straight edge and verniers. Check for correct positioning of both the bolts and the
gasket.
3. Ensure exposed stud bolt thread above each nut is at least 1.5 bolt diameters. This is
to accommodate the jacking nut of the hydraulic tensioning equipment.
WHEN USING ENOUGH TENSIONERS FOR HALF OF THE BOLTS. (i.e. 50% TENSIONING)
1. Using the tables attached select the hydraulic pressures A & B along with the
appropriate tool type for the bolt size to be tightened.
2. Fit tensioning tools to every other bolt and apply pressure A. Tighten nuts and relax
pressure. (Note that the nuts should be quite firmly tightened by hand using a Tommy
bar. Nuts should be tightened as uniformly as possible.)
3. Reapply pressure A, tighten the nuts and relax the pressure. Repeat this step once
again. I.e. there should be 3 applications of pressure and relaxation before the next
set of nuts is started.
4. Shift the tensioning tools to the other half of the bolts and apply pressure B.
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Title: Flange Bolting Standard
5. Reapply pressure B, tighten the nuts and relax the pressure. Repeat this step
once again. I.e. there should be 3 applications of pressure and relaxation before
the next set of nuts is started.
6. Shift the tensioning tools back to the first half of the bolts and apply pressure B.
Check the nuts are tight. If any nuts require tightening repeat this step for the
other half of the bolts. Continue this until no nut rotation occurs.
1. Using the tables attached select only hydraulic pressure B along with the appropriate
tool type for the bolt size to be tightened.
2. Fit tensioning tools to the first set of bolts as per the diagram attached and apply 40%
of pressure B. Tighten nuts and relax pressure. (Note that the nuts should be quite
firmly tightened by hand using a Tommy bar. Nuts should be tightened as uniformly
as possible.)
3. Following the sequence on the diagram shift the tensioning tools to the next set of
bolts and apply 40% of pressure B. Tighten nuts and relax pressure.
6. Finally to ensure even tensioning, repeat steps 5 - 7 at 100% of pressure B until all
nuts are tight.
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Title: Flange Bolting Standard
Note: These pressures are for “Hydratight” Equipment only. Tools for other equipment can
have different hydraulic areas which require different applied pressures to get the desired
bolt loads.
For more information, contact Mechanical Integrity Custodian - OZE4.
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Title: Flange Bolting Standard
Bolt Size Tool Type Tool Marking Pressure A Pressure B Pressure A Pressure B
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Title: Flange Bolting Standard
Note: 1. These pressures are for “Hedley Purvis Hypur-Mate” Equipment only. Tools for other
equipment can have different hydraulic areas which require different applied pressures to
get the desired bolt loads.
2. If bolt length:diameter ratio varies from approximately 6.5:1 then OZE4 should be
consulted for modified pressures.
3. PS4 head will clash if used on a DN350, class 900 flange which requires a 1 1/2” bolt.
PS3 is acceptable. PS4 is acceptable for a 1 ½” bolt with large flange. PS3 should be
strongly considered.
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Title: Flange Bolting Standard
APPENDIX C
1. Ensure that adequate safety gear is being worn and that work permit
requirements are being met.
2. Particularly ensure that glasses are being worn and thin gloves, that do not
restrict hand feel or movements are worn.
4. When first applying pressure to the system recheck for any leakage of hydraulic
fluid.
Caution: be careful not to trap fingers between the flange and tool reaction bar.
1. Before torquing the bolts, ensure that the threads and the nut/flange contact face are
coated with nickel based anti-seize. Anti-seize should not be applied to the gaskets.
PTFE coated bolts should also be lubricated with anti-seize.
2. Install bolts and hand-tighten. Flanges should be squared and concentric using a
straight edge and verniers. Check for correct positioning of both the bolts and the
gasket.
3. Obtain the final bolt torque setting from the tables attached.
4. Torque the bolts first to 30% of this setting following a standard star pattern across
the flange. This is VERY IMPORTANT to ensure that the flange remains aligned.
5. Repeat step 5 for 60% and then 100% of the torque setting.
6. Finally, starting at bolt number 1 and proceeding clockwise around the flange, re-
torque each bolt to 100% of the setting. Continue until all bolt torques are even.
7. Ensure the stud protrudes past the nut i.e. at a minimum the thread on the stud is
partially exposed.
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Title: Flange Bolting Standard
1/2” 50 40 30 25
5/8” 100 75 60 45
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Title: Flange Bolting Standard
Notes
1. The above bolt torque values assume a friction factor u = 0.11, and have been rounded for
ease of application. (This friction factor is based on the use of graphite based anti-seize and is
not affected significantly by the respective stud and bolt surface treatment)
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APPENDIX D
HYTORC ULC-SERIES
Pressure / Torque Conversion Chart (- in ft-lb)
Pressure (psi) HY-4ULC HY-7ULC HY-10SL
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Title: Flange Bolting Standard
HYTORC ULC-SERIES
Pressure / Torque Conversion Chart (- in ft-lb)
Pressure (psi) HY-4ULC HY-7ULC HY-10SL
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APPENDIX E
Additional Precautions
1. Ensure that adequate safety gear is being worn and that work permit
requirements are being met. Particularly ensure that glasses are being worn
and thin gloves, that do not restrict hand feel or movements are worn.
2. When first applying pressure to the system recheck for any leakage.
1. Before torquing the bolts, ensure that the threads are clean and are coated with nickel-
based anti-seize. Lubricated washers should be used under the nuts and bolt heads to
protect flange back-facing. Anti-seize should not be applied to the gaskets. PTFE bolts
should also be lubricated with anti-seize.
2. Install bolts and hand-tighten. Flanges should be squared and concentric using a straight
edge and verniers. Check for correct positioning of both the bolts and the gasket.
3. Obtain the final bolt torque setting from the tables attached.
5. After all nuts have been tightened to the recommended torque value, recheck the torque
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Title: Flange Bolting Standard
on each bolt in the same sequence, since previously tightened bolts may have relaxed.
Caution: Excess torque can prevent sealing and can damage moulded flanges.
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Note: all Bondstrand flanges listed in the piping specification mate with other Bondstrand flanges
and flat-faced steel flanges using these bolt torque values. Moulded flanges should not be
connected to wafer valves or raised-face steel flanges.
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APPENDIX F
GX8 1 3/8” 718 (530) 500 (369) 540 (398) 376 (277)
G10 1 5/8” 1,216 (897) 842 (621) 914 (674) 633 (467)
G12 1 3/4” 1,533 (1,131) 1,059 (781) 1,153 (851) 796 (587)
GZ16, 1 7/8”
1,902 (1,403) 1,310 (967) 1,430 (1,055) 985 (727)
GZ18
GP, 2”
GX12, 2,324 (1,715) 1,599 (1,179) 1,748 (1,289) 1,202 (887)
GZ20
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APPENDIX G
S, U, 32, 36, 3W, 5P 2 1/2” 22”, 31”, 29 1/2”, 20” 3,485 (2,570)
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APPENDIX H
AP 2” 1,951 (1,439)
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Title: Flange Bolting Standard
APPENDIX I
Medium - High
Low Pressure Flange
Pressure Flange
(2 ksi, 3 ksi)
(5 ksi, 10 ksi, 20 ksi)
If Bolt Size > 2 1/2" then Bolt
Bolt stress = 290 MPa Stress = 340 MPa otherwise
Bolt Stress = 390 MPa
Bolt Bolt
Nm Nm
size size
1/2" 50 1/2" 70
5/8" 100 5/8" 135
3/4" 180 3/4" 235
7/8" 280 7/8" 370
1" 420 1" 550
1 1/8" 610 1 1/8" 800
1 1/4" 845 1 1/4" 1,110
1 3/8" 1,130 1 3/8" 1,500
1 1/2" 1,480 1 1/2" 1,950
1 5/8" 1,900 1 5/8" 2,500
1 3/4" 2,350 1 3/4" 3,100
1 7/8" 2,950 1 7/8" 3,850
2" 3,600 2" 4,700
2 1/4" 5,150 2 1/4" 6,750
2 1/2" 7,050 2 1/2" 9,300
2 3/4" 11,200
3" 14,600
3 1/4" 18,600
3 1/2" 22,600
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APPENDIX J
“FLANGE CHECKLIST”
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Title: Flange Bolting Standard
FLANGE CHECKLIST
Flange Details: No.: Flng Size: Rating: Pipe Class:
Bolting Details: Qty: Stud Size: Nut Size: Stud Mat'l:
Line No./Description: Project:
INSPECTION REQUIRED PASS FAIL COMMENTS
(YES) (NO)
FOR THE FLANGES:
1 Is either flange made from a material other than steel? (eg. cast If yes or unsure, refer to mechanical
iron, plastic) integrity custodian (OETM)
2. Check both Flange Faces are Clean, Damage Free and that the
Gramaphone Finish is in Good Condition
4. Are the Flanges Aligned within Tolerance, see the Chart Below
(Record the Maximum Angular Mis-Alignment in the Comments Column)
5. Are the Flanges parallel within Tolerance, see the Chart Below
(Record the Maximum Parallel Mis-Alignment in the Comments Column)
9. Check that the Studs are in Good Condition and are the Correct
Size and Material for the Pipe Class
11. TORQUEING
- Confirm approved Anti-seize has been Applied to the
Studs and the Nut Seating Area.
- Torque Studs at: 30% N.m (for DN > 20" only)
60% N.m
100% N.m
- Confirm all studs 100% tight
##
C Pipe Size: Tolerance:
A+B
"B & C"
Up to 4" 1.0mm
6" to 10" 2.0mm
A
10" to 24" 3.5mm
Angular mis-alignment Parallel mis-alignment #REF!
CHECKED BY NAME SIGNATURE DATE
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FITTER
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SUPERVISOR
AND OR QC Uncontrolled when printed. Refer to electronic version for most up to date information.
Title: Flange Bolting Standard
6. Check the seal ring is the correct size and type for the
pipe class.
9. Check that the studs are in good condition and are the correct
size and material for the pipe class.
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Seal Ring New Seal Minimum Seal Ring New Seal Minimum
Size Rings for Re-Use Size Rings for Re-Use
62 .093 .030
66 .087 .043
72 .104 .040
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Title: Flange Bolting Standard
1. Check that both Grayloc hubs and clamps are clean and free of damage.
2. Check that the hub sealing surfaces are in good condition and ensure that
there is NO:
- Circumferential scoring deeper than the depth of machining.
- Radial scoring longer than 1/4 the raised face width.
- Localised defect more than 2mm deep or wide.
3. Ensure that a small clearance, or stand-off exists between the ring rib
hub face.
NOTE: If no stand-off is present, use a new seal ring.
5. Confirm that the nut seating area on the Grayloc clamps is clean, smooth
and free of paint.
6. Check the seal ring is the correct size and type for the pipe class.
Check and record the material type.
7. Is the seal ring free of damage? Check for defects in the sealing
8. Check that the studs are in good condition and are the correct size and
material for the pipe class.
9. Ensure that stud length is correct and that studs do not bottom out.
10. Check that the nuts run freely for the full length of stud thread.
11. Check that the studs have a sliding fit into the body before torquing.
12. Install the seal ring in the sealing surface of the hubs.
NOTE: The seal ring should rock slightly (ie. the seal ring rib
to firmly contact the hub face). If it does not rock, use a new seal
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14. Confirm that Nickel based anti-seize has been applied to the studs
nut seating area.
NOTE: When applying lubricant, tak e special care to ensure that no solid or
particles are present in the lubricant. Also, tak e care to prevent
damage to the seal ring and the hub sealing surfaces.
15. Insert the stud bolts into the bolt holes of the clamp ears. Install the
ensuring that the spherical surfaces of the nuts and the clamp are in
position for mating.
17. Tighten the bolting in a criss-cross pattern (ie. bolt #1, #3, #2, #4) to
each half of the clamp at a similar distance apart along each stud.
NOTE: Assembly should include jarring the clamps during the bolting
sound blow to the back of the clamp with a soft hammer (torque, jar,
jar, etc.) until bolt torque does not change after jarring.
1 8. Ensure that the hub faces will sit with the shoulder flush against the
ring rib at full make-up.
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Stand-off dimensions for both new and re-used seal rings must be within the minimum and
maximum limits provided below:
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6. C heck the seal ring is the correct size and type for the
pipe class.
9. C heck that the studs are in good condition and are the
correct size and material for the pipe class.
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IN S PE C T IO N R E Q U IR E D PA S S FA IL CO M M EN TS
(Y e s) (N o )
M A K IN G U P T H E G A L P E RT I C L A M P :
1 3 . TO R Q U E G U N / W R EN C H - To rq ue S e tting :_ _ _ _ _ _ _
To rq ue stud s in a c riss- c ro ss p a tte rn (ie . stud # 1 , # 3 , # 2 , # 4 ).
K e e p sp a c ing b e tw e e n c la mp ha lve s a p p ro xima te ly e q ua l.
N O T E : A ss e m b l y sh o u l d i n c l u d e ja rr i n g t h e c l a m p s d u ri n g t h e
b o l t i n g p ro c e d u re . A p p l y a so u n d b l o w t o t h e b a c k o f t h e
c l a m p w i t h a s o ft h a m m e r. R e -t i g h t e n st u d s a ft e r ja r ri n g .
G A L P E RT I H U B M IS A L IG N M E N T :
R E PO R T A N Y M IS A L IG N M E N T A T " B " T O YO U R S U PE R V IS O R
C H EC K ED B Y :_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ D A TE :_ _ _ _ _ _ _ _ _ _ _ _
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6 1 1/8” 15.8
8 1 1/4” 19.4
AP 2” 25.4
3V 2 1/4” 25.4
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APPENDIX K
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1. Check that both cover faces are clean, free of damage and in
good condition
3. Confirm the nut seating area on the cover is clean, smooth and free
of paint
4. Check that the NEW sightglass are the correct size (34mm) and
type (transparent, clear or reflex)
5. Check that the NEW cushion and gasket are the correct size and
type (Klingersil C4430)
7. Check that both the cushion and gasket fit snugly in the cover and
chamber recesses so that they can NOT be offset on assembly
8. Check that the bolts are in good condition and the correct material
has been used (Duplex)
9. Ensure that bolt length is correct and that bolts do not bottom out
10. Check that the nuts run freely for the full length of bolt thread
11. Check that the bolts have a sliding fit into the body before torquing
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13. Assemble the gauges, confirming that the following items are used:
(a) NEW Duplex bolting
(b) Loctite Nickel Anti-seize lubricant applied to the bolts
(c) NEW transparent sightglass (34mm)
(d) Klingersil C4430 cushions and gaskets
15. Leave the sightglass for 12 hours to allow the gaskets to settle
17. Nitrogen pressure test to 1.5 x Design P ressure - hold for 2 hours
18. Recheck bolt torques. If the torque values have fallen, repeat
from step 14
Parts Lis t
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APPENDIX L
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LINDAPTER FLANGE CLAMP SELECTION AND PLACEMENT
4
3
2
1 1 1
150
2 3
1 1
300
15 20 25 40 50 80
Note: Clamps should be placed so that the clamp bolt is as close as possible to the flange whilst still leaving clearance for the wrench.
Caution: Do not use clamps on tapered flanges.
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Safe Working
Bolt Load* Torque
Dimensions (mm)
Clamp Size Tensile (kN) (Nm)
Number (per single bolt)
Bolt Grade
Z Bolt Grade 4.6 X W V T S
4.6
1 M10 1.96 20 25 19 - 42 13 19 24
2 M12 2.8 39 35 26 - 60 17 24 30
3 M16 5.6 93 43 29 - 69 21 28 35
4 M20 8.4 177 51 32 - 82 25 35 44
* Safety factor of 5
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