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For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Ltd, India

Best Practices For Flange Tightening
Please send your comments and suggestions to the author. This document is intended for guidance purpose and may be adopted with minor modifications by any functional department within RIL group of companies. Reproduction of this document or parts thereof in not allowed unless written permission is obtained from the approving authority.

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services
Engineering Services Dept

DOC. No: GMS/RP/30

Page: 1 of 31 Date: 21-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited
INDEX

Copyright: Reliance Industries Ltd, India

1 2 3 4 5 5.1 5.2 5.3 5.4 5.5 5.6 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 7.0 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 8.0 8.1 8.2 9 10 11 12 13 14

Introduction Scope Objective Applicable codes Design calculation Gasket seating Bearing stress on flanges Pressure thrust Dead load bending moment Thermal bending moment Thermal gradient at the bolts General requirement Material identification Flanges Hardware Lubricants Gaskets Flange fit up Manual tightening Manual torque Hydraulic torque Tensioning Disassembly and retightening Installation procedure Pre bolting inspection Flange and gasket assembly Stud bolt torquing Bolt tensioning Tightening Manual tightening Manual torque Hydraulic torque Quality assurance Tool calibration Compliance with installation procedure Annexure I – Tolerance flange alignment Annexure II- Tensioning torque details Annexure III- Tightening/torquing/tensioning record Annexure IV- Flange Fit up/Tightening check list Annexure V- Bolt tightening sequence References

03 03 03 03 03 03 03 03 03 04 04 04 04 04 05 05 05 05 06 06 06 06 06 06 06 06 08 08 08 09 09 09 09 09 10 11 12 24 25 26 31

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services
Engineering Services Dept

DOC. No: GMS/RP/30

Page: 2 of 31 Date: 21-Mar-07 Revision no.: 0.0

For Internal Circulation Only
1.0 INTRODUCTION

Reliance Industries Limited

Copyright: Reliance Industries Ltd, India

Tightening of the flanges is a common and important maintenance activity in a continuous process industry. Maintenance crew must be highly skilled & the supervisor handling the job should be well conversant with the details & procedures. Since the failure of the flange joint can lead to hazardous situation as well revenue loss to the organization in the form of direct cost as well as in the form of opportunity cost, enough importance should be given to this maintenance activity. 2.0 SCOPE In summary, this will consist of pipe to pipe, pipe to equipment, instrument to pipe, flanged connections, their associated component parts, and preparation i.e. gaskets, studs, bolts, nuts, cleaning, lubrication, alignment, manual tightening, manual torquing, hydraulic torquing, and associated documentation. Then procedure is based on standard ANSI 16.5 and B16.74 3.0 OBJECTIVE Objective of this document is to lay down the best practices & procedures to be adopted in Reliance Industries Ltd for tightening the flanges. 4.0 APPLICABLE CODES ƒ ƒ ƒ ANSI B 1.1 - Unified Inch Screw Threads ASME Section VIII - Boiler and Pressure Vessel Code, Pressure Vessels Division 1 Code for Pressure Piping • B31.1 - Power Piping • B31.3 - Chemical Plant and Petroleum Refinery Piping • B16.5 - Steel Pipe Flanges and Fittings • B16.47 -Large Diameter Steel Flanges

5.0 DESIGN CALCULATIONS The design calculations used to arrive at the minimum bolt loading include the following criteria. 5.1 Gasket Seating. The minimum load on the gasket which will seat the gasket on the flange faces. This load is equal to the optimum gasket seating stress specified by the gasket manufacturer at the operating temperature. 5.2 Maximum Bearing Stress on Flanges 1. Austenitic stainless steel flanges 2. Ferritic steel flanges 350N/mm2 450N/mm2

5.3 Pressure Thrust The hydrostatic end thrust that tends to separate the flanges. 5.4 Dead Load Bending Moment The maximum moment occurring at the flange joint when dead weight loading is considered independently of all other loadings.

Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau

Group Manufacturing Services
Engineering Services Dept

DOC. No: GMS/RP/30

Page: 3 of 31 Date: 21-Mar-07 Revision no.: 0.0

causing differential thermal expansion across the bolted joint.0 . If a bolt or stud graded for a lower temperature is used in a high temperature system. Specifically.1 GENERAL REQUIREMENTS Material Identification The operating process temperature to which a piping system is designed is a critical factor. minimum profiles are required for optimum gasket performance. the flange may require re-machining. if approved by Field Engineering. Field Engineering shall contact procurement and project controls for evaluation of potential back charges. it can catastrophically fail. Additionally if the flange joint will be subjected to high temperatures. the bolts are assumed to be a different temperature from the flanges. considering loss of bolt load due to the effect of "creep and relaxation" on the bolts. and shall not show evidence of damage. 6. Note: Cast firewater valves / flanges are an exception to this rule.0 6. and cause great loss of life. India The maximum moment occurring at the flanged joint when thermal loading is considered independently of all other loadings. 5. 6. No: GMS/RP/30 Page: 4 of 31 Date: 21-Mar-07 Revision no. Power brushes shall only be used. In extreme case. Take care not to over smooth the finish. Gasket surface areas shall be cleaned in accordance with the gasket manufacturer’s installation instructions. and at the very least leak.e. ensure the wire brush is compatible with the flange material i. and use only Hand brushes. full contact area for bolt head or nut. the initial calculated bolt load shall be increased by the amount necessary to ensure an adequate working life for the joint. I. Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC. Depending on gasket type. it may stretch. Div. this differential will tend to tighten the joint. oil. Discrepancies shall be addressed to Field Engineering for evaluation. For mechanical equipment stresses are compared against the lowest minimum yield stress determined for bolting materials found in the ASME VIII.: 0. The hydrostatic test condition shall be also considered. or contaminants. 1. For systems operating below the installation temperature this differential will tend to open the joints.5 Thermal Bending Moment Reliance Industries Limited Copyright: Reliance Industries Ltd. The bolt or nut seating surface shall be flat and provide a low friction. Gasket relaxation should be incorporated as well. Typically previous gasket materials and contaminants such as dirt.For Internal Circulation Only 5. uniform preservative coatings are generally acceptable. bolts and studs stretch easier at higher temperatures. At worst. Gasket surfaces shall be inspected by the fit up crew. When using a wire brush for cleaning.2 Flanges Flange surfaces shall be finished in accordance with the flange finish description referred to by the Piping Class. do not use carbon steel bristles on stainless steel flanges. Thin. The direction of brushing shall also follow the seating surface grooves or finish.6 Thermal Gradient at the Bolts For un-insulated flanged joints. Should this situation arise. lose its memory. For systems operating above installation temperatures. Temperature affects and dictates the materials specified in the design of flanged joints. Provided they do not fill seating finish or show evidence of build up or runs. and grease.

Studs. check with the Field Engineer for approved spray contact adhesive. 3. 7. around their circumference. For un-tested joints this activity shall also be noted on Annexure III. For gasket centering or vertical applications. Studs shall be of sufficient length to achieve full thread engagement plus a minimum of two threads beyond the nut.: 0. corrosion. 2. Any discrepancies or questions shall be addressed to Field Engineering for resolution.6 Flange Fit up. and deemed free of damage.For Internal Circulation Only Reliance Industries Limited Copyright: Reliance Industries Ltd. 6. Contact Field Engineering should there be any problem. dents. without flanged joint degradation. Flanged equipment shall be properly supported. and other damage. The pipe itself shall be inspected. some deviation can be accommodated. Flange seating surfaces shall also be monitored for flatness. Flange face alignment shall be within 1 mm per 10 inch pipe diameter. It is preferable that final grouting and curing be complete. When performing pipe to equipment fit up. 3. and bolting hardware shall be inspected. Contact Field Engineering if further interpretation is required. 6. nuts.5 Gaskets Design engineering selects gaskets as a joint system to provide optimum performance through out the range of expected operating pressures and temperatures. and cleanliness. Regardless of gasket type: 1. Studs greater than 1-1/8" diameter shall have one full stud diameter beyond the nut to allow tensioning. aligned. the Tightening/Torquing/Tensioning Record.0 . and contaminants. the gasket shall remain horizontal. and piping system’s in general. Depending on the gasket type. Any problems shall be addressed to Field Engineering. 6.3 Hardware The fit up crew shall verify all studs. Special attention shall be paid to appropriate material selection. only the pipe shall be adjusted. and locked in its final position. and any dirt. Flanged piping shall be properly supported. 4. 2. It is preferable that pipe be in its final position with permanent supports installed. Studs. No: GMS/RP/30 Page: 5 of 31 Date: 21-Mar-07 Revision no. nuts. when installing gaskets. nuts. 5.4 Lubricants Shall be used only the approved lubricants: Loctite Anti Seize Paste # 771 6. India 2. The Fit up crew foreman shall indicate the pipe is clean on Annexure IV. scoring. or threaded flange. and extent of imperfections. loosen adjacent pipe supports and adjust to achieve proper alignment. 1. All above preparations and verifications must have been performed prior to flange fit up. On pipe to pipe flanges. identification. ensure all flange and gasket surfaces are cleaned and dry. The fit up crew shall follow the procedure below. shall the equipment be adjusted to achieve alignment. Until ready for installation. and bolting hardware against the respective ISO’s and MTO’s to ensure the correct components are used when assembling flange joints. In no case. and bolting hardware threads shall be coated with an approved lubricant. or construction debris removed. the Flange Fit up / Tightening / Torquing Checklist. And attached to its accompanying packaging. Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC. tools. 3. Prior to installing gasket. leveled. 6. pipe size. Flange gasket seating surfaces shall be inspected for scratches.

Install sufficient studs to locate the gasket. Hammer tightening of bolts or studs in any hydrocarbon system are not permitted. No: GMS/RP/30 Page: 6 of 31 Date: 21-Mar-07 Revision no. the Flanged Joint / Tightening Checklist. rated utility piping systems only. For any given material type and diameter of bolt or stud. there is maximum stress allowed. 11. 13. Specifically.10 Tensioning Stud and bolt sizes 1-1/8 inches and greater. this stress is adequate to maintain the integrity of flanged joint. shall the equipment be adjusted to achieve alignment. and continue the very least leak. require tensioning. it can catastrophically fail. 6. and /or nuts. Flange face stud. bolts and studs may stretch or break. without a permanent stretch or change in length. If the flanged joint will not be hydro-tested. and specified critical flanged joints. finger tight. requested by Field Engineering.: 0. 14. and cause injury or lose of life. And are ready for the appropriate tightening. or bolt. Instructions accompanying the torquing equipment shall be strictly followed.ft (678 Nm) to be applied. 12. or tensioning procedure. Using Annexure IV. and turnover to client.For Internal Circulation Only Reliance Industries Limited Copyright: Reliance Industries Ltd. all we have is a “longer” bolt or stud with less corresponding stress. and free of any foreign debris. or flange faces may be damaged.9 Hydraulic Torque When specified. Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC. gaskets. At worst. Install the remaining studs. hole alignment shall be within 1. 10. and prior to mechanical completion. calibrated hydraulic torquing will be utilized. Tensioning requires one stud diameter extending beyond the nut.8 Manual Torque Flange bolts shall be tightened with calibrated torque wrenches / tools on all hydrocarbon systems for all rated pressures up to 1” and on all utility systems rated 300 and greater. uses the pitch of a threaded bolt or stud to transform rotational movement (relative to the nut or threaded flange). 9. India 8. Stud/bolt. or when the flanged joint requires a torque value of greater than 500 Ibf. This input sheet shall than be turned into Field Engineering. It will be entered into the database to ensure the flanged joint will receive additional quality control surveillance during hydro-test restoration. 6. Annexure IV the fit up crew foreman shall sign. The fit up crew foreman shall assure all tested flanged joints have been properly assembled with the correct components. Contact Field Engineering if problems arise. This debris will contaminate flange and gasket surfaces. At this point. 6. Contact Field Engineering should there be any problem.7 Manual Tightening Flange bolts may be tightened by non-calibrated hand combination and hammer wrenches on 150 lb.5 mm. Exceeding this may cause a bolt or stud to stretch and “lose its memory” of its original length. torquing.0 . Do not use force or use seating compounds. regardless of service or rating. Properly designed. In no case. date and note his badge number on the Flange Fit up / Tightening/Torquing Completion Record shall also be completed. on the most accessible side of the flange. bolts. to provide stress or tension in the bolt or stud. When performing pipe to equipment fit up. holes shall be clean. Torque tightening of flanged joints. only the pipe shall be adjusted. either during torquing or operation. Install the gasket. Over torque of flanged joints is not allowed. 6.

For Internal Circulation Only 6. check the flanges are parallel and co-axial (When none of the bolts is installed in the flange). and bolting hardware shall be re-tightened in accordance with the procedures INSTALLATION PROCEDURE Pre-Bolting Inspection Inspect the gasket material for possible defects such as bends or creases. permitted tolerances are as follows: Flange faces shall be aligned to the design plane within 1mm in 200mm (1/16 in. • Finger tightens all studs and nuts. /ft) measured across any diameter. except for oxygen lines.0 .1 • • Reliance Industries Limited Copyright: Reliance Industries Ltd. Studs. They should be free of dirt and corrosion. and bolting hardware shall be loosened in the sequence show in Figures 1 thru 5. The contact area of the flanges should be free from excessive pitting. 335-C. Use a suitable solvent to clean the surfaces. • • Before inserting the gasket in between the pipe flanges. radial tool marks and scratches.: 0.0 7. all inspections and verifications shall be performed as shown in above paragraphs. When tensioning is required a threaded length of one times bolt diameter should protrude at the end where the bolt tensioners are to be placed. nuts. Gasket shall be located correctly to ensure full sealing as indicated in drawing. No: GMS/RP/30 Page: 7 of 31 Date: 21-Mar-07 Revision no. Every nut or bolt shall backed off at 1/2 turn before completely loosening any nut or bolt.3 clause no. • For tolerances on flange joints see Annexure I Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC.2 • • Ensure gasket of correct dimension and of specified material is used. Molykote. Center studs between nuts so an equal number of threads project at each end. India Disassembly and re-tightening of previously tightened flanged joints Studs. Before application the studs shall be degreased. as applicable. Inspect the studs and nuts. The stud end away from the tensioned side shall be flush or maximum protrude two thread windings. • • If pipe flanges are not meeting the ANSI B31. piping shall be rectified.11 • • • • 7. mechanical damage and corrosion. If serration is damaged. flange bolts holes shall be aligned within 3mm (1/8 inch) maximum offset. Prior to re-tightening. P 37 shall be used as lubricant / anti seize compound. nuts. Inspect the mating flanges for dirt. Flange and Gasket Assembly • 7. As per ANSI B 31. For example gasket on tube sheet of exchanger needs to be located so that outer periphery of gasket matches with OD of tube sheet at all points. All gaskets seating area shall be cleaned properly before gasket insertion. burrs and chips. reserration must be done. Using Figures 1 thru 5 loosen each nut by l/2 in sequence.3 requirement. The studs should be straight and the threads free from nicks.

: 0. it will be necessary to treat the thread of the bolts with an acceptable anti-seize compound before fitting the nuts. 7. • To facilitate loosening of the nuts when required at some later date. Using torque loadings given in Annexure II. • Lubricant shall not be applied on bolts used in oxygen systems.5 TIGHTENING • • It is important that all bolted joints are tightened uniformly and in a diametrically staggered In case of pipe flanges 8"NB & up to 12"NB and having a pipe with spacer piece and minimum of two gaskets (which are getting compressed simultaneously during tightening) the distance between two Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC. Bolt torquing shall be applied for bolt sizes 1 inch and smaller. Follow the tightening sequence from Annexure II. 7. • • After the tightening procedure is completed the extended thread lengths of uninsulated connections (including H2 lines) shall be protected against the effects of corrosion to allow the nuts to be subsequently unscrewed.0 . Make the first pass. Upon completion of bolt tensioning each flange connection shall be provided with a wire seal 1) Materials to be used for wire seal: 2) Wire: stainless steel 3) Seal: stainless steel or aluminimum. Make the second pass. Make the final pass. a suitable hydraulic torque wrench should be used at all times.3 • • • Stud Bolt Torquing Ensure that material of all bolts and nuts is as specified. The bolt shall be lubricated with molybdenum di-sulfide and it is essential especially in all bolts of size 7/8” and above to check the application as the bolt load developed by torque is dependent on the lubrication of threads. No: GMS/RP/30 Page: 8 of 31 Date: 21-Mar-07 Revision no. Protection shall be done using suitable (aluminum) screwed endcaps covering the full extended thread length. especially in threaded portion. • • • • • • It is recommended to avoid use of short bolts on the flange joints. India 7. Bring the nuts up to the final torque value.4 Bolt Tensioning Bolt tensioning shall be applied in accordance with Annexure II. The application of bolt-tensioning equipment shall be in strict accordance with the manufacturer's instruction manual and safety procedures. Be sure to follow the same sequence. 7. a manual torque wrench may be used. • The personnel using the equipment shall be adequately trained in its application. For larger bolts (> 1 inch). Bolts & nuts shall be cleaned with suitable solvents like Diesel using wire brush.2 The use of "low melting" metals such as zinc or lead is prohibited.4.1 7.4.For Internal Circulation Only Reliance Industries Limited Copyright: Reliance Industries Ltd.

Manual Torque Verify that the general requirements above have been completed. India flanges should be measured at four locations like 12’o clock. Torque shall be applied in stages of 30%. 50 & 70 percent of the final torque value.0 .1 • • • 7. The tightening shall be gradual and uniform.5.5.For Internal Circulation Only Reliance Industries Limited Copyright: Reliance Industries Ltd. 8 QUALITY ASSURANCE 8. The tightening shall be carried out in three or four stages in steps of 30. Any tools that are out of calibration shall be rejected. At the request of Field Engineering. all procedures that apply to manual torquing. 7. While tightening the bolt with torque wrenches (for pipe / Manway flanges) ensure that tightening load to each bolt is applied as uniformly as possible.Some tightening Methods are 7.1 Tool Calibration • • Acceptable makes of bolt tensioning equipment. No: GMS/RP/30 Page: 9 of 31 Date: 21-Mar-07 Revision no. Also apply to hydraulic torquing. • At the request of Field Engineering. To ensure even tightening of the flanged joint.5.2 Hydraulic Torque With the exception. Tightening shall be accomplished utilizing non-calibrated hand tools. hydraulic torquing or tensioning may substitute manual torquing. The tightening sequence shown in Figures 1 thru 5 shall be adhered to regardless of the tightening technique. • For heat exchangers flanges torque values to be 30. In case of flanges above 12” NB distance between the flanges shall be measured in 8 locations for uniform tightening. At fourth stage again use 70 percentage of the final torque value. 60% and 100% of the specified torque values. 3’o clock’ 6’o clock and 9’on clock positions and maintained equal for even tightening.100 and 100 percent of the final torque value. To ensure even tightening of the flanged joint. Where recommended to use hydraulic tensioner for bolt tightening follow the manufacturer recommendations.: 0. 70. Any discrepancies shall be noted for resolution and / or replacement. The calibration of torque wrenches and tensioners shall be checked against the manufacturer’s specifications upon receipt. • All stud bolts of 7/8" and above shall be tightened using torque wrench. Tools shall also be inspected for any indication of damage.2 • • Manual Tightening Verify that the general requirements above have been completed. Including verification of tool calibration and range. torquing may substitute manual tightening. The tightening sequence shown in Figures 1 thru 5 shall be adhered to regardless of tightening technique. Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC. of the type of tool.

Any tool found to be out of calibration shall immediately be taken out of service for repair. shall be as follows. Contractor shall prepare a bolt torquing/tensioning record per flange joint.: 0. Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC. All flanged joints secured with tools found to be defective shall be rechecked with a properly functioning tool. Those records shall be issued as part to the turnover packages. The procedure shall show all required information amongst others: • • • • • • Type of bolt torquing tensioning equipment Pre-installation measurements Precautions to be taken Record preparation instructions Establishment of the "break loose" torque based on minimum 4 tensioners 24 hours recheck procedure.2 Reliance Industries Limited Copyright: Reliance Industries Ltd. Compliance with Installation Procedures Contractor shall provide a bolt tensioning and bolt torquing procedure for approval. The numbering system for flanged joints of equipment not part of a piping system. F2. Each equipment flange set shall be identified with the nozzle number as shown on the equipment drawing followed by the equipment number. F3. No: GMS/RP/30 Page: 10 of 31 Date: 21-Mar-07 Revision no. Records for flange joints requiring bolt torquing using bolts with bolt diameter < 1 inch are not required. etc.For Internal Circulation Only • • 8. India A recheck of the calibration shall be made as per tool manufacturer standard. and line number. The flange numbering shall be added to the isometric line over by erection contractor.0 . ie manholes etc. Subject non documented flange connections shall be checked and signed after torquing in the field The numbering system for flanged joints in piping systems shall be as follows: Starting with the flow direction of each line number within one unit the flange sets shall be identified as Fl.

76 2. 68 2. 37mm 0.0 TOLERANCE FLANGE ALIGNMENT FLANGE SIZE/RAT' G 1" 2” 4” 6” 10" 12” 16” 20" 24" 1" 2" 4” 6" 10" 12" 16" 20" 24" 600LB 600LB 600LB 600LB 600LB 600LB 600LB 600LB 600LB 1500LB 1500LB 1500LB 1500LB 1500LB 1500LB 1500LB 1500LB 1500LB FLG 0/D 124mm 165 273 356 508 559 686 813 940 149mm 216 311 394 584 673 826 984 1168 Recommended tol.5mm/m) 0 . India 1. 93 1. 78 0. 37 1. 46 1. 3 7mm 0.I Copyright: Reliance Industries Ltd. 07 2. 27 1. 14 2. (2.0 .69 1. 59 0. 53 1. 03 2 . 54 0.5mm/m) 0 . 40 0. 60 0. 46 2. 21 1. No: GMS/RP/30 Page: 11 of 31 Date: 21-Mar-07 Revision no.: 0. 99 1. 35 0 . B9 1. 73 0. 91 Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC.68 1. 54 0. (2.40 1 .68 0. 72 2. 92 FLG FLANGE SIZE/RAT' G O/D C 1" 900LB 2" 4" 6" 10" 12" 16" 20" 24" 1" 2500LB 2" 4" 6" 10" 12" " 14 9mm 216 292 381 546 610 705 857 1041 15 9mm 235 356 483 673 762 Recommen ded tol.For Internal Circulation Only Reliance Industries Limited ANNEXURE . 3 1mm 0.41 0.

India 1. Hydraulic tensioning shall also be required on all utility systems with flange ratings 300# ANSI and greater. nitrogen 3. 2. This generally means manual torquing can be used for stud sizes up to 38mm (1 1/8”) diameter and hydraulic torque tightening is required for larger studs.0 .: 0. The following table summarizes the studs.For Internal Circulation Only Reliance Industries Limited ANNEXURE II TORQUE /TENSIONING DETAILS Copyright: Reliance Industries Ltd. Utilities 150 # ANSI class is exempted from tensioning or torquing. which require torque control during tightening.0 TORQUING All hydrocarbon line classes with flange studs 16 mm (5/8”) up to 25 mm (1”) inclusive shall have flanged connections tightened with the use of torque control. instrument air.0 TENSIONING Hydraulic tensioning shall be required on all hydrocarbon line classes flanged connections with studs sizes 28 mm (1 1/8”) and greater.0 BOLT TENSIONING/TORQUING TABLE 150/300 LBS B _ A 1/2 5/8 5/8 3/4 5/8 3/4 7/8 1 600 LBS B to to to to to to to to* A 3/4 3/4 7/8 1 7/8 7/8 1 1/8 1 1/8 900 LBS B to to to to to to to* to* A 3/4 3/4 7/8 1 7/8 1 1/8 1 1/4 1 3/8 1500 LBS B to to to to to to* to* to* 2500 LBS A 3/4 3/4 7/8 1 1/8 1 1 1/4 1 1/2 2 B to to to to* to to* te te Tensioning 16mm 5/8” 25mm 1‘ 28mm 1 1/8 “ 31mm 1¼“ 34mm 1 3/8 “ 38mm 1½“ 44mm 1¾“ 50mm 2“ plus flange size DN 15 20 25 40 50 80 100 150 Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC. SERVICE CLASS Tightening Method Torquing All Hydrocarbon All Utilities 300# Notes: (1)(2) NOTES: 1. No: GMS/RP/30 Page: 12 of 31 Date: 21-Mar-07 Revision no. Manual torque tightening is acceptable up to torque values greater than 500 ft-lbs. 2. Utilities means line classes: low pressure steam.

: 0.0 .For Internal Circulation Only 200 250 300 350 400 450 500 600 650-700 800-1000 1050 _ - Reliance Industries Limited 1 1/8 1 1/4 1 1/4 1 3/8 1 1/2 1 5/8 1 5/8 1 7/8 > > > to* to* to* to* te te te te te te te 1 3/8 1 3/8 1 3/8 1 1/2 1 5/8 1 7/8 2 2 1/2 > > > to* to* to* te te te te te te te te 1 5/8 1 7/8 2 2 1/4 2 1/2 2 3/4 3 3 1/2 > > > Copyright: Reliance Industries Ltd.e = tensioning and documentation required. 1. No: GMS/RP/30 Page: 13 of 31 Date: 21-Mar-07 Revision no. 2nd Pass 20 50 60 110 170 240 340 460 550 Final Pass 35 75 100 160 250 360 510 690 820 Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC.= Manual wrench tightening (no torquing/tensioning required) To = Torquing and no documentation required (bolt size < 1") To* = Torquing with Hydraulic torque wrench and complete documentation required (bolt size > 1") t. Calculations of bolt torquing result in required torque figures are as shown in the below table.Bolt size diameter (inch) .4 Calculations for Bolt Torquing. Stainless steel stud bolts (b8 & b8m) bolt stress: (25. India te te te te te te te te te te te 2 2 1/2 2 3/4 > > > > > > > > te te te te te te te te te te te A .000 psi) 172375 kpa Torque (Nm) Bolt Size ½” 5/8” 3/4" 7/8" 1" 1-1/8" 1-1/4" 1-3/8" 1-1/2" 1st Pass 10 25 30 50 80 120 170 230 270.

1 3 365 509 509 682 700 993 1004 1016 1610 1523 1561 1547 1561 1588 1606 1611 1627 3178 3212 3248 3269 3299 3318 PUM P Psi 2688 3748 3748 5027 5157 4874 4930 4987 3578 3385 3470 3439 3470 3530 3569 3581 3617 7066 4121 4167 4195 4233 4257 PUM P Psi 2801 3921 3921 5505 5645 5357 5617 5686 4027 3864 3961 3928 3961 4030 4075 4091 4130 6930 4716 4767 4800 4843 4871 PUMP Psi 3789 5317 5317 7465 7465 7264 7340 7430 5357 5067 5194 5149 5194 5281 5341 5360 5414 9112 6202 6268 6312 6367 6406 *0. India 150lb TORQUE VALUES FOR STANDARD ANSI / MSS FLANGES MIN. NOMIN AL SIZE (INCH) BOLTING NO. / SIZE (INCH) BOLT STRE S TO SEAL 12 14 16 18 20 24 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 12 X 7/8 12 X 1 16 X 1 16 X 1 1/8 20 X 1 ¼ 20 X 1 ¼ 28 X 1 ¼ 28 X 1 1/4 28 X 1 ½ 32 X 1 1/2 32 X 1 ½ 32 X 1 1/2 36 X 1 1/2 36 X 1 1/2 40 X 1 1/2 40 X 1 1/2 44 X 1 1/2 44 X 1 7/8 44 X 1 7/8 44 X 1 7/8 48 X 1 7/8 48 X 1 7/8 52 X 1 7/8 25.1 SUGGESTED APPLIED TORQUE VALUES (NM) BASED ON RESIDUAL BOLT STRESS & PUMP PRESSURE PUM P Psi 2039 2858 2858 2978 4187 3855 3895 3942 2815 2665 2761 2707 2731 2776 2809 2818 2846 4742 3231 3266 3288 3318 3337 *0. No: GMS/RP/30 Page: 14 of 31 Date: 21-Mar-07 Revision no.15 380 532 532 747 766 1091 1144 1158 1812 1738 1782 1767 1782 1813 1833 1840 1858 3117 3676 3715 3741 3775 3797 *0. BOLT STRE S(PSI ) 48000 45000 45000 41160 42195 43250 43790 43790 38980 36880 37797 37460 37797 38441 38882 39013 39408 38285 38708 39124 39398 39742 39982 277 388 388 404 568 785 793 803 1267 1199 1242 1218 1229 1249 1264 1268 1280 2133 2518 2545 2563 2586 2601 *0.012 19575 18777 16321 13234 14928 14928 11238 10941 12395 13634 14933 14624 14433 15625 15329 11842 12707 13603 13318 14195 13938 RES.For Internal Circulation Only Reliance Industries Limited Copyright: Reliance Industries Ltd.338 21.2 515 721 721 1013 1013 1479 1495 1513 2410 2279 2336 2316 2336 2376 2403 2411 2435 4099 4834 4886 4920 4963 4993 Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC.0 .: 0.

For Internal Circulation Only Reliance Industries Limited Copyright: Reliance Industries Ltd. / SIZE (INCH) MIN.1 3 PUM P Psi *0.15 PUM P Psi *0.0 . India 300 lb TORQUE VALUES FOR STANDARD ANSI / MSS FLANGES NOMINA L SIZE (INCH) BOLTING NO. BOLT STRE S(PSI ) 53599 47117 48843 49546 47426 45626 41818 42457 42791 41104 41442 39429 39707 36098 39121 39466 37615 44064 44952 45276 41682 44509 44850 40422 42993 40016 42337 40413 42920 193 170 175 178 274 393 549 557 785 727 759 1279 1656 1893 2545 2567 2986 1405 1801 1888 2186 2895 2918 3208 3142 4559 4823 4604 4890 *0.2 PUMP Psi Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC. BOLT STRE S TO SEAL 3 1/2 4 5 6 8 10 12 14 16 18 20 24 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 8 X 3/4 8 X 3/4 8 X 3/4 12 X 3/4 12 X 7/8 16 X 1 16 X 11/8 20 X 11/8 20 X 11/4 24 X 1 1/4 24 X 1 1/4 24 X 1 1/2 28 X 1 5/8 28 X 1 3/4 28 X 1 7/8 28 X 1 7/8 32 X 2 32 X 1 1/2 32 X 1 5/8 32 X 1 5/8 32 X 1 3/4 28 X 1 7/8 32 X 1 7/8 32 X 2 32 X2 28 X 2 1/4 28 X 2 1/4 32 X 2 1/4 32 X 2 1/4 17846 21871 29311 26247 28034 21792 22379 20608 20722 22117 26007 23523 21321 20598 19940 22061 18694 34901 32680 35637 33553 35446 33781 32018 34336 32884 35094 32958 35025 RES. No: GMS/RP/30 Page: 15 of 31 Date: 21-Mar-07 Revision no.: 0.1 SUGGESTED APPLIED TORQUE VALUES (NM) BASED ON RESIDUAL BOLT STRESS & PUMP PRESSURE PUM P Psi 1419 1249 1289 1309 2019 2898 4047 4107 5786 3569 3728 2843 2124 2429 3266 3293 2974 1802 2310 2422 2804 3714 3744 3195 3129 3054 3232 3084 3276 254 224 232 235 359 515 693 704 993 953 961 1629 2106 2412 3248 3275 3814 1820 2385 2401 2785 3695 3726 4360 4360 5838 6171 5890 6257 1869 1649 1709 1729 2648 3798 5107 5187 7315 4681 4720 3620 2702 3095 4167 4201 3799 2335 3060 3081 3573 4741 4781 4342 4342 3911 4135 3947 4192 275 241 248 255 391 561 789 801 1132 1088 1096 1859 2407 2758 3715 3748 4366 2077 2726 2745 3185 4227 4259 4990 4990 6682 7070 6749 7168 2029 1779 1829 1879 2878 4137 5816 5906 8345 5340 5380 4133 3088 3539 4766 4809 4349 2665 3497 3521 4087 5423 5465 4970 4970 4477 4737 4522 4802 358 315 325 331 509 731 1029 1044 1479 1421 1432 2437 3159 3625 4885 4929 5745 2724 3577 3603 4185 5558 5602 6567 6567 8807 9318 8894 9446 2638 2319 2398 2438 3748 5387 7585 7695 10903 6978 7031 5417 4054 4650 6267 6324 5722 3495 4589 4623 5369 7131 7187 6541 6541 5901 6243 5959 6329 *0.

For Internal Circulation Only Reliance Industries Limited Copyright: Reliance Industries Ltd. BOLT STRE S(PSI ) 45681 45487 42753 43965 40070 40070 39689 39689 40724 38207 40258 38725 39572 40227 42821 43097 43972 44619 44850 42702 43081 44463 42544 45055 44887 45133 45282 39832 263 262 561 805 991 991 1290 1290 1698 2004 2111 2519 3142 3193 3399 3421 2307 2903 2918 3390 3420 5065 4846 5132 7062 7092 7123 8404 *0. / SIZE (INCH) MIN.1 SUGGESTED APPLIED TORQUE VALUES (NM) BASED ON RESIDUAL BOLT STRESS & PUMP PRESSURE PUM P Psi 1939 1929 4137 3955 4867 4867 2867 2867 3774 2571 2709 3232 3129 3181 3386 3408 2297 3725 3744 4349 3406 5044 3247 3439 3460 3475 3490 4118 347 346 708 1020 1258 1258 1639 1639 2160 2553 2690 3215 4012 4079 4342 4370 2938 3703 3724 4330 4368 6482 6208 6567 9050 9099 9129 10784 *0. No: GMS/RP/30 Page: 16 of 31 Date: 21-Mar-07 Revision no.15 PUM P Psi *0. BOLT STRES TO SEAL 4 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 8 X 7/8 12 X 7/8 16 X 11/8 16 X 11/4 20 X 1 3/8 20 X 1 3/8 24 X 1 1/2 24 X 1 1/2 24 X 1 5/8 24 X 1 3/4 28 X 1 3/4 28 X 1 7/8 28 X 2 28 X 2 28 X 2 32 X 2 32 X 1 3/4 32 X 1 7/8 32 X 1 7/8 32 X 2 36 X 2 28 X 2 1/4 32 X 2 1/4 32 X 2 1/4 28 X 2 1/2 32 X 2 1/2 32 X 2 1/2 32 X 2 3/4 20765 24920 21826 21324 22002 22002 22726 22726 21830 22077 21161 20506 20263 22852 25282 24641 33794 31919 34785 33006 321365 34850 32758 35159 34618 32326 24428 30279 RES.2 PUMP Psi Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC. India 400 lb TORQUE VALUS FOR STANDARD ANSI / MSS FLANGES NOMINA L SIZE (INCH) BOLTING NO.0 .: 0.13 PUM P Psi 2558 2548 5217 5007 6179 6179 3644 3644 4802 3276 3452 4125 3996 4063 4325 4353 2927 4751 4777 5555 4350 6456 4159 4400 4434 4458 4473 5284 377 376 807 1162 1436 1436 1871 1871 2469 2919 3077 3677 4593 4669 4970 5002 3360 4238 4259 4956 5001 7425 7105 7524 10375 10432 10466 12371 2778 2768 5946 5706 7051 7051 4160 4160 5489 3746 3947 4718 4574 4650 4950 4982 3347 5437 5465 6359 4981 7396 4761 5041 5084 5112 5128 6062 490 488 1051 1520 1879 1879 2453 2453 3241 3836 4042 4837 6045 6145 6541 6583 4415 5573 5602 6524 6581 9786 9366 9916 13687 13763 13808 16336 3608 3598 7745 7464 9228 9228 5453 5453 7204 4922 5186 6206 6021 6120 6515 6557 4397 7150 7187 8370 6554 9747 6275 6644 6707 6744 6766 8005 *0.

: 0.0 . No: GMS/RP/30 Page: 17 of 31 Date: 21-Mar-07 Revision no. India 600lb TORQUE VALUES FOR STANDARD ANSI / MSS FLANGES NOMI NAL SIZE (INCH ) 4 5 6 8 10 12 14 16 20 22 24 26 28 30 32 38 40 42 44 46 48 50 52 54 56 58 60 8 X 7/8 8X1 12 X 1 12 X 11/8 16 X 11/4 20 X 1 1/4 20 X 1 1/2 20 X 1 1/2 24 X 1 5/8 24 X1 3/4 24 X 1 7/8 28 X 1 7/8 28 X 2 28 X 2 28 X 2 1/4 28 X2 1/4 32 X 2 1/4 28 X 2 1/2 32 X 2 1/2 32 X 2 1/2 32 X 3 1/4 28 X 3 32 X 3 32 X 3 32 X 3 1/4 32 X 3 1/4 28 X 3 1/2 31148 31809 28484 32092 25698 27787 25763 27162 28554 27833 28425 27246 26741 30394 26628 34756 38389 33703 32279 34864 30883 31582 29599 31890 28716 30787 32202 44436 45158 46004 45464 44626 45237 41257 40678 42743 36526 39467 40132 38261 40818 34936 44463 47083 44793 40471 43068 39974 41061 39114 41617 39965 40145 39246 188 389 393 597 818 830 1021 1322 1782 1916 2567 2610 3037 3119 3980 5065 5363 7047 6366 6776 8434 11285 10749 11437 14026 14089 17256 BOLTING NO.For Internal Circulation Only Reliance Industries Limited Copyright: Reliance Industries Ltd.15 PUM P Psi 2698 4097 4177 6306 8715 5872 3286 4265 5760 3582 489 4890 4423 4719 3909 4975 5269 6937 4583 4878 6083 8151 5641 6002 7369 5095 3751 476 721 727 1119 1549 1563 1935 2515 3401 3668 4929 3656 5844 6232 7689 9786 10363 13659 12341 13133 16394 21982 20939 22280 27376 27500 33764 3508 5317 5357 8245 11413 7677 4302 5592 7560 4706 6324 4690 5821 6207 5151 6557 6943 9152 6047 6435 8033 10771 7932 7932 9746 6737 4963 *0. BOLT STRES( PSI) *0.2 PUM P Psi Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC. / SIZE (INCH) MIN.1 SUGGESTED APPLIED TORQUE VALUES (NM) BASED ON RESIDUAL BOLT STRESS & PUMP PRESSURE PUM P Psi 1389 2868 2898 4397 6026 4075 2270 2939 3961 2458 3293 3349 3025 3106 2667 3393 3593 4722 3120 3320 4133 5529 3827 4071 4993 3452 2537 338 510 519 754 1036 1050 1295 1680 2267 2441 3276 3332 3880 4139 5092 6482 6863 9031 8159 8682 10822 14494 13807 14690 18031 18112 22218 *0.13 PUM P Psi 2488 3758 3828 5557 7635 5153 2879 3735 5040 3132 4203 4275 3864 4122 3411 4343 4598 6051 3998 4254 5303 7102 4915 5229 6419 4437 3266 366 556 567 856 1182 1196 1478 1919 2591 2792 3748 3812 4441 4738 5835 7425 7863 10353 9354 9954 12414 16634 15845 16859 20701 20794 25517 *0. BOLT STRES TO SEAL RES.

BOLT SUGGESTED APPLIED TORQUE VALUES (NM) BASED ON RESIDUAL BOLT STRESS & PUMP PRESSURE Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC. No: GMS/RP/30 Page: 18 of 31 Date: 21-Mar-07 Revision no. India 900lb TORQUE VALUES FOR STANDARD ANSI FLANGES NOMINA L SIZE (INCH) BOLTING NO.0 .15 PUM P Psi 2998 5976 5752 6296 3192 3286 3412 4395 6113 4353 4915 4353 5316 5196 4414 3312 529 1058 1531 1116 1879 1935 2003 2593 3614 11723 6494 11723 14325 19589 23826 29808 3898 7795 7517 8225 4178 4302 4452 5764 8033 5744 6468 5744 7019 6867 5837 4382 *0. BOLT STRE S TO SEAL 3 4 5 6 8 10 12 14 16 18 20 24 26 30 32 34 36 38 40 42 44 46 48 8X 7/8 8 X 1 1/8 8 X 1 1/4 12 X 1 1/8 12 X 1 3/8 16 X 1 3/8 20 X 1 1/2 20 X 1 1/2 20 X1 7 /8 20 X 2 1/2 20 X 2 20 X 2 1/2 20 X 2 3/4 20 X 3 20 X 3 1/4 20 X 3 1/2 20 X 3 1/2 20 X 3 1/2 24 X 3 3/4 24 X 3 3/4 24 X 3 3/4 24 X 4 24 X 4 32399 26946 28347 32338 30318 30929 33443 31684 33998 27490 32478 27490 25057 26793 25521 24161 26912 30809 28547 30954 29256 28064 30134 RES.: 0. BOLT RES.13 PUM P Psi 2758 3288 3229 3948 2116 2158 2333 2909 4009 2716 3279 2716 3324 3367 2821 2011 2239 2564 2376 2576 3004 3511 3770 407 811 1172 854 1436 1478 1535 1977 2750 8885 4934 8885 10848 14596 18016 22252 7 22527 24415 23358 23619 28076 32685 34659 3312 3589 3434 3472 4127 4805 5095 29808 32305 30909 31252 37168 43289 45905 4382 4749 4544 4594 5464 6363 6748 *0. / SIZE (INCH) MIN. BOLT STRE S(PSI ) 49331 43039 44293 45462 40071 41257 42707 41940 45436 38441 42507 38441 34928 36031 34782 34277 34648 37550 35927 36326 34989 37421 35440 285 564 690 597 991 1024 1060 1363 1889 6048 3374 6048 7370 9902 12207 15083 15247 16523 15810 15985 19038 22081 23414 *0.1 SUGGESTED APPLIED TORQUE VALUES (NM) BASED ON RESIDUAL BOLT STRESS & PUMP PRESSURE PUM P Psi 2099 4157 3389 4397 2204 2276 2357 3029 4199 2963 3360 2963 3611 3525 2991 2217 2241 2429 2324 2350 2799 3246 3442 374 446 658 536 952 971 1050 1309 1803 5542 3292 5542 6784 9457 11514 13678 15235 17441 16161 17524 20435 23883 25646 *0. / SIZE MIN.For Internal Circulation Only Reliance Industries Limited Copyright: Reliance Industries Ltd.2 PUMP Psi TORQUE VALUES FOR STANDARD ANSI FLANGES 1500lb NOMINA L SIZE BOLTING NO.

B16 SWJ or RTJ soft iron / Carbon steel / Stainless steel Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC. ASSUMED BOLT MATERIAL ASSUMED GASKET : ASTM 193-B7 . India *0.15 PUM P Psi *0.15 PUM P Psi 872 1195 2007 1546 2774 4309 4566 6080 8989 12010 15338 22290 6426 5866 4461 3436 6167 5529 4547 4074 4405 5885 5460 3277 1138 1561 2631 2023 3641 5667 6008 8013 11860 15860 20271 29493 8385 7663 5848 4497 8094 7270 5984 5368 5811 7771 7216 4335 *0.13 PUM P Psi 5646 5147 3907 3011 5396 4833 3972 3556 3842 5130 4758 2853 Copyright: Reliance Industries Ltd. No: GMS/RP/30 Page: 19 of 31 Date: 21-Mar-07 Revision no. BOLT STRES TO SEAL 3 4 5 6 8 10 12 8 X 1/4 8 X 1 1/2 8 X 1 1/2 8X2 12 X 2 12 X 2 /2 12 X 2 3/4 41801 39662 38108 37736 38138 32272 35161 RES.For Internal Circulation Only (INCH) (INCH) STRE S TO SEAL 3 4 5 6 8 10 12 14 16 18 20 24 8 X 1 1/8 8 X 11/4 8 X 1 1/4 12 X 1 3/8 12 X 1 5/8 12 X 1 7/8 16 X 2 16 X 2 1/4 16 X 2 3/4 16 X 2 3/4 16 X3 16 3 1/2 31167 35144 31223 33971 34729 34466 30375 27161 27787 29008 28424 28029 Reliance Industries Limited STRE S(PSI ) 46236 45175 42550 43148 45758 45377 39334 36409 38891 38670 37864 34282 607 829 1383 1069 1907 2952 3123 4148 6118 8160 10406 15086 *0.: 0.0 .2 PUMP Psi TORQUE VALUES FOR STANDARD ANSI FLANGES NOMINA L SIZE (INCH) BOLTING NO. BOLT STRE S(PSI ) 51000 45300 45250 44750 46400 40050 42100 936 1473 2373 3553 3683 6300 8883 *0. / SIZE (INCH) MIN.1 PUM P Psi 4477 4068 3075 2375 4238 3787 3110 2779 2998 3999 3705 2218 766 1048 1757 1355 2427 3767 3988 5307 7840 10470 13365 19407 *0.1 2500lb RESIDUAL BOLT STRESS & PUMP PRESSURE SUGGESTED APPLIED TORQUE VALUES (NM) BASED ON PUM P Psi 4594 3274 3045 3539 3668 3087 4353 *0.13 PUMP Psi *0.2 PUMP Psi 1184 1871 3024 4537 4705 8074 11399 5812 4160 3880 4519 4686 3956 5585 1349 2136 3458 5195 5386 9256 13075 6625 4748 4436 5174 5364 4535 6407 1763 2800 4544 6836 7088 12213 17266 8655 6225 5830 6808 7059 5985 8460 * CO-EFFICINT OF FICTION DEPENDS ON LUBRICATION DONE ON BOLTS.

BOLT STRESS TO SEAL RES. TOMMY BAR SIZE SOCKET (mm) TOM MY BAR SIZE PUL LER (mm ) 32 34 36 38 40 42 44 46 48 52 54 56 58 60 28 x 11/2 32 x / 1/2 32 x 1 1/2 32 x 1 1/2 36 x 1 1/2 36 x 1 1/2 40 x 1 1/2 40 x 1 1/2 44 x 1 7/8 44 x 1 7/8 44 x 1 7/8 48 x 1 7/8 48 x 1 7/8 52 x 1 7/8 11238 10941 12395 13634 14933 14624 14433 15625 15329 127070 13603 13318 14195 13938 38980 36880 37797 37460 37797 38441 38882 39013 39408 38708 39124 39392 39742 39982 : 425 Psi 14000 13500 13500 13500 13500 13500 13500 13500 13500 14000 14000 14000 14000 14000 11000 10500 10500 10500 10500 10500 10500 10500 10500 11000 11000 11000 11000 11000 2 2 2 2 2 2 2 2 2 4 4 4 4 4 10 10 10 10 10 10 10 10 10 10 10 10 10 10 12 12 12 12 12 12 12 12 12 12 12 12 12 12 Assumed standard test pressure of TENSIONING VALUES FOR STANDARD ANSI / MSS FLANGES NOMINAL PIPE SIZE (INCH) BOLTING NO./SIZE MIN./SIZE MIN. 300LB TOMMY BAR SIZE SOCKET (mm) TOM MY BAR SIZE PUL LER (mm ) 24 28 30 32 24 X 1 1/2 28 X 1 5/8 28 X 1 3/4 28 X 1 7/8 23523 21321 20598 19940 39429 39707 36098 39121 14500 12500 14000 13000 11500 9500 11000 10000 2 3 3 4 10 10 10 10 12 12 12 12 Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC. No: GMS/RP/30 Page: 20 of 31 Date: 21-Mar-07 Revision no. BOLT STRESS (Psi) PUMP PRESSURE A PUMP PRESSURE B TOOL NO. BOLT STRESS TO SEAL RES.: 0.0 . BOLT STRESS (Psi) PUMP PRESSURE A PUMP PRESSURE B TOOL NO. India 150 lb TENSIONING VALUES FOR STANDARD ANSI / MSS FLANGES NOMINAL PIPE SIZE (inch) BOLTING NO.For Internal Circulation Only Reliance Industries Limited Copyright: Reliance Industries Ltd.

TOMMY BAR SIZE SOCKET (mm) TOM MY BAR SIZE PUL LER (mm ) 16 18 20 22 24 26 28 30 32 34 36 38 40 20 X 1 1/2 20 X 1 5/8 24 X 1 5/8 24 X 1 3/4 24 X 1 7/8 28 X 1 7/8 28 X 2 28 X 2 28 X 2 1/4 28 X 2 1/4 28 X 2 1/2 28 X 2 1/4 32 X2 1/4 27162 29141 28554 27833 28425 27246 26741 30394 26628 29459 26206 34756 38389 40678 42008 42743 36526 39467 40132 38261 40818 34936 37490 37155 44463 47083 14500 13000 13000 14000 13000 13000 14000 14500 11000 11000 11000 12000 15500 11500 10000 10000 11000 10000 10000 11000 11500 8000 8000 8000 9000 12500 2 3 3 3 4 4 4 6 6 6 6 6 6 10 10 10 10 10 10 10 10 12 12 12 12 12 12 12 12 12 12 12 12 12 14 14 14 14 16 Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC. BOLT STRESS TO SEAL RES. No: GMS/RP/30 Page: 21 of 31 Date: 21-Mar-07 Revision no.0 . India 4 4 3 3 3 3 4 4 4 4 6 6 6 6 10 10 10 10 10 10 10 10 10 10 12 12 12 12 600 LB 12 12 12 12 12 12 12 12 12 12 14 14 14 14 TENSIONING VALUES FOR STANDARD ANSI / MSS FLANGE NOMINAL PIPE SIZE (INCH) BOLTING NO.For Internal Circulation Only 34 36 38 40 42 44 46 48 50 52 54 56 58 60 28 X 1 7/8 32 X 2 32 X 1 1/2 32 X 1 5/8 32 X 1 5/8 32 X 1 3/4 28 X 1 7/8 32 X 1 7/8 32 X 2 32 X 2 28 X 2 1/4 28 X 2 1/4 32 X 2 1/4 32 X 2 1/4 Reliance Industries Limited 22061 18694 34901 32680 35637 33553 35446 33781 32018 34336 32884 35094 32958 35025 39466 37615 44064 44952 45276 41682 44509 44850 40422 42993 40016 42337 40413 42920 13000 14000 14500 13000 13000 14500 13500 13500 14000 14500 11000 11500 11000 11500 10000 11000 11500 10000 10000 11500 10500 10500 11500 11500 8000 8500 8000 8500 Copyright: Reliance Industries Ltd.: 0./SIZE MIN. BOLT STRESS (Psi) PUMP PRESSURE A PUMP PRESSURE B TOOL NO.

5 8.5 10 10 10 10 10 10 10 12 12 14 14 16 14 14 14 14 14 16 16 16 12 12 12 12 16 16 16 16 16 16 16 16 16 16 16 16 16 Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC.5 8.0 . BOLT STRESS TO SEAL RES.For Internal Circulation Only 42 44 46 48 50 52 54 56 58 60 28 X 2 1/2 32 X 21/2 32 X 21/2 32 X 2 3/4 28 X 3 32 X 3 32 X3 32 X 3 1/4 32 X 3 1/4 28 X 3 1/2 Reliance Industries Limited 33703 32279 34864 30883 31582 29599 31890 28716 30787 32202 44793 40471 43068 39974 41061 39114 41617 39965 40145 39246 15000 14000 14500 13500 12000 12000 12000 14000 14000 15500 12000 11000 11500 10500 9000 9000 9000 11000 11000 12500 Copyright: Reliance Industries Ltd.5 8.: 0.5 8. TOMMY BAR SIZE SOCKET (mm) TOM MY BAR SIZE PUL LER (mm ) 14 16 18 20 24 26 28 30 32 34 36 38 40 42 44 46 48 20 X 1 1/2 20 X 1 5/8 20 X 1 7/8 20 X 2 20 X 2 1/2 20 X 2 3/4 20 X3 20 X3 20 X 3 1/4 20 X 3 1/2 20 X 3 1/2 20 X 3 1 24 X 3 1/2 24 X 3 1/2 24 X 3 1/2 24 X 4 24 X 4 31684 33998 31770 32478 27490 25057 23573 26793 25521 24161 26912 30809 28547 30594 29256 28064 30134 41940 45436 42089 42507 38441 34928 33284 36031 34782 34277 34648 37550 35927 36326 34989 37421 35440 14500 13500 13500 15000 14000 13000 11500 12000 13500 15000 15000 15500 15000 15000 14000 15000 15500 11500 10500 10500 12000 11000 10000 8500 9000 10500 12000 12000 12500 12000 12000 11000 12000 12500 2 3 3 4 6 7 8.5 8.5 8.5 8.5 8. BOLT STRESS (Psi) PUMP PRESSURE A PUMP PRESSURE B TOOL NO.5 8. India 6 6 6 7 8.5 8.5 8.5 8./SIZE MIN.5 12 12 12 14 14 14 14 14 14 14 16 16 16 16 16 16 16 16 16 16 900LB TENSIONING VALUES FOR STANDARD ANSI / MSS FLANGES NOMINAL PIPE SIZE (INCH) BOLTING NO. No: GMS/RP/30 Page: 22 of 31 Date: 21-Mar-07 Revision no.

0 . BOLT STRESS (Psi) PUMP PRESSURE A PUMP PRESSURE B TOOL NO. BOLT STRESS (Psi) PUMP PRESSURE A PUMP PRESSURE B TOOL NO. India TENSION VALUES FOR STANDARD ANSI / MAA FLANGES NOMINAL PIPE SIZE (INCH) BOLTING NO. TOMMY BAR SIZE SOCKET (mm) 1500LB TOM MY BAR SIZE PUL LER (mm ) 5 8 10 12 14 16 18 20 24 8 X 1 1/2 12 X 1 5/8 12 X 1 7/8 16 X 2 16 X 2 1/4 16 X 2 1/2 16 X 2 3/4 16 X3 16 X 3 1/2 31223 34729 34466 30375 27161 27787 29008 28424 28029 42550 45758 45377 39334 36409 38891 38670 37864 34282 15000 13500 14000 14000 11000 14000 13500 12000 14500 12000 10500 11000 11000 8000 11000 10500 9000 11500 2 3 4 4 6 6 7 8. 2500 LB TOMMY BAR SIZE SOCKET (mm) TOM MY BAR SIZE PUL LER (mm ) 4 5 6 8 10 12 8 X 1 1/2 8 X 1 3/4 8X2 12 X 2 12 X 2 1/2 12 X 2 3/4 39662 38108 37736 38138 32272 35161 45300 45250 44750 46400 40050 42100 15500 15500 15500 15500 14000 14000 12500 12500 12500 12500 11000 11000 2 3 4 4 6 7 10 10 10 10 12 12 12 12 12 12 14 16 ASSUMED BOLT MATERIAL ASSUMED GASKET: ASTM 193-B7. BOLT STRESS TO SEAL RES. B16 SWJ or RTJ soft iron / Carbon steel / Stainless steel Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC. BOLT STRESS TO SEAL RES.: 0./SIZE MIN.5 8./SIZE MIN.For Internal Circulation Only Reliance Industries Limited Copyright: Reliance Industries Ltd. No: GMS/RP/30 Page: 23 of 31 Date: 21-Mar-07 Revision no.5 10 10 10 10 12 12 12 14 14 12 12 12 12 14 16 16 16 16 TENSION VAULES FOR STANDARD ANSI / MSS FLANGE NOMINAL PIPE SIZE (INCH) BOLTING NO.

No: GMS/RP/30 Page: 24 of 31 Date: 21-Mar-07 Revision no. India ANNEXURE III Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC.For Internal Circulation Only Reliance Industries Limited Copyright: Reliance Industries Ltd.0 .: 0.

Flange Fit Up Check List: Correct Studs / Bolts / Nuts Correct Gasket Pipe(s) properly supported Equipment Anchored / Leveled / Aligned Pipe Clean Flange Clean Flange Face Aligned Flange Holes Aligned Studs / Bolts / Nuts / Threaded holes Clean & Lubricated Flanged Joint Properly Tightened Work Completed Satisfactory Maintenance manager: Date: FLANGE SIZE (No.0 . Instrument Tag No. India ANNEXURE .: 0. of Bolts) STUD / BOLT SIZE: TIGHTENING METHOD Manual Torque Hydr-Torque Tool Calibration Due Date: Tensioning Torque Value: Ye s Engineer Initial Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC. Manual Tighten Tool Serial No.IV FLANGE FIT UP / TIGHTENING / CHECKLIST ISO No. P&ID No.For Internal Circulation Only Reliance Industries Limited Copyright: Reliance Industries Ltd. No: GMS/RP/30 Page: 25 of 31 Date: 21-Mar-07 Revision no.

0 .For Internal Circulation Only Reliance Industries Limited Copyright: Reliance Industries Ltd. India ANNEXURE V TORQUING SEQUENCE Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC.: 0. No: GMS/RP/30 Page: 26 of 31 Date: 21-Mar-07 Revision no.

: 0.0 .For Internal Circulation Only Reliance Industries Limited Figure 1 Copyright: Reliance Industries Ltd. India Figure 2 Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC. No: GMS/RP/30 Page: 27 of 31 Date: 21-Mar-07 Revision no.

0 . No: GMS/RP/30 Page: 28 of 31 Date: 21-Mar-07 Revision no.: 0. India Figure 3 Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC.For Internal Circulation Only Reliance Industries Limited Copyright: Reliance Industries Ltd.

0 . India Figure 4 Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC. No: GMS/RP/30 Page: 29 of 31 Date: 21-Mar-07 Revision no.: 0.For Internal Circulation Only Reliance Industries Limited Copyright: Reliance Industries Ltd.

No: GMS/RP/30 Page: 30 of 31 Date: 21-Mar-07 Revision no.: 0.0 . India Figure 5 Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC.For Internal Circulation Only Reliance Industries Limited Copyright: Reliance Industries Ltd.

JG 3. E&M Documents.: 0.0 . Shell DEP 2. Literatures from internet Prepared by : K Gopalakrishnan Checked by : A Venkatraman Approved by : V V SuryaRau Group Manufacturing Services Engineering Services Dept DOC.For Internal Circulation Only Reliance Industries Limited Copyright: Reliance Industries Ltd. No: GMS/RP/30 Page: 31 of 31 Date: 21-Mar-07 Revision no. India REFERENCE 1.