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ABU DHABI GAS INDUSTRIES LTD. (GASCO)


BOLT TORQUING/TENSIONING PROCEDURE FOR FLANGED CONNECTIONS

DESIGN GENERAL SPECIFICATION

BOLT TORQUING/TENSIONING PROCEDURE


FOR FLANGED CONNECTIONS

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4
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0 27/05/01 ALI A.FATTAH S. EL TAKI ABDUL AZIZ AL AMERI ISSUED FOR IMPLEMENTATION
A 04/10/00 ALI A.FATTAH S. EL TAKI ABDUL AZIZ AL AMERI ISSUED FOR COMMENTS
Rev Date WRITTEN BY CHECKED BY APPROVED BY STATUS
DD/MM/YY

DOCUMENT REVISIONS
Sections changed in last revision are identified by a vertical line in the left margin

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BOLT TORQUING/TENSIONING PROCEDURE FOR FLANGED CONNECTIONS

CONTENTS

1. GENERAL ..............................................................................................................................................3
1.1 INTRODUCTION ....................................................................................................................................3
1.2 DEFINITIONS........................................................................................................................................3
1.3 EXCLUSIONS .......................................................................................................................................3
2. CODES AND STANDARDS ...................................................................................................................4

3. REFERENCE DOCUMENTS..................................................................................................................4

4. DOCUMENT PRECEDENCE .................................................................................................................4


4.1 COMPLIANCE WITH STANDARDS ...........................................................................................................5
4.2 CONFLICT RESOLUTION .......................................................................................................................5
5. SPECIFICATION DEVIATION/CONCESSION CONTROL....................................................................5

6. QUALITY ASSURANCE/QUALITY CONTROL .....................................................................................4


6.1 QA/QC PROGRAM ..............................................................................................................................6
6.2 TOOL CALIBRATION .............................................................................................................................6
6.3 COMPLIANCE WITH INSTALLATION PROCEDURES ..................................................................................6
6.4 CRITICALITY RATINGS ..........................................................................................................................6
7. DOCUMENTATION ................................................................................................................................7
7.1 BOLT TORQUING/TENSIONING DOCUMENTS ...........................................................................................7
7.2 TECHNICAL DEVIATION DOCUMENTS .....................................................................................................7
8. CONTRACTORS/SUBCONTRACTORS................................................................................................7
8.1 ROLES AND RESPONSIBILITIES .............................................................................................................7
9. DESIGN ..................................................................................................................................................7

10. MATERIALS .........................................................................................................................................8


10.1 COMPONENTS ...................................................................................................................................8
11. INSTALLATION....................................................................................................................................8
11.1 PRE-BOLTING INSPECTION.................................................................................................................8
11.2 FLANGE AND GASKET ASSEMBLY .......................................................................................................8
11.3 STUD BOLT TORQUING ......................................................................................................................9
11.4 BOLT TENSIONING .............................................................................................................................9
CHART 1 ...............................................................................................................................................11
APPENDIX A .........................................................................................................................................12
APPENDIX B .........................................................................................................................................13

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BOLT TORQUING/TENSIONING PROCEDURE FOR FLANGED CONNECTIONS

1. GENERAL

1.1 Introduction
This specification provides bolt torquing and tensioning requirements and installation
procedures for flanged connections in piping systems and piping connections to
equipment.

1.2 Definitions
For the purposes of this specification, the following definitions shall apply.

1.2.1 COMPANY ABU DHABI GAS INDUSTRIES LTD. (GASCO)

1.2.2 CONCESSION REQUEST - A deviation requested by the MANUFACTURER/ VENDOR


or SUBVENDOR, usually after receiving the Contract Package. Often, it refers to an
authorization to use, repair, recondition, reclaim, or release materials, components or
equipment already in progress or completely manufactured but which does not meet or
comply with COMPANY requirements. A Concession Request is subject to COMPANY
approval.

1.2.3 CONTRACTOR The party, which carries out all or part of the Design, Engineering,
Procurement, Construction and Commissioning or Management of the Project.

1.2.4 MANUFACTURER/VENDOR - The party which manufactures and/or supplies piping and
services to perform the duties specified by COMPANY/CONTRACTOR.

1.2.5 PROJECT To be defined.

1.2.6 SHALL - Indicates a mandatory requirement.

1.2.7 SHOULD - Indicates a strong recommendation.

1.2.8 SUBCONTRACTOR/SUBVENDOR - The party(s) which carries out all or part of the
design, procurement, installation and testing of the System(s), as specified by the
MANUFACTURER/VENDOR.

1.2.9 PROJECT MANAGEMENT TEAM (PMT) - The COMPANY authorized party responsible
for the overall day-to-day execution of the PROJECT. PMT is to serve as liaison between
COMPANY and the CONTRACTOR(S) on the PROJECT.

1.3 Exclusions
The following are excluded from the requirements of this specification:

1.3.1 Pre-assembled equipment packages (i.e., equipment provided on skids). Please note that
piping connecting to equipment packages are in accordance with paragraph 1.3.2.

1.3.2 All other flanged connections shall be excluded only as specified in CHART 1 of this
specification.

1.3.3 Grayloc type coupler assemblies shall be torqued using MANUFACTURERS


procedures.

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BOLT TORQUING/TENSIONING PROCEDURE FOR FLANGED CONNECTIONS

2. CODES AND STANDARDS

The following codes and standards, to the extent specified herein, form a part of this
specification. When an edition date is not indicated for a code or standard, the latest
edition in force at the time of contract award shall apply.
American Society of Mechanical Engineers (ASME)
ASME/ANSI B1.20.1 Pipe Threads (except Dryseal)
ASME/ANSI B107.14 Hand Torque Tools
ASME B31.3 Process Piping
ASME/ANSI B16.5 Pipe Flanges and Flanged Fittings
ASME B16.47 Large Diameter Steel Flanges
ASME Section VIII (Division 1), Boiler and Pressure Vessels
ASME Section VIII (Division 2), Boiler and Pressure Vessels
International Organization for Standardization (ISO)
ISO 9000 Quality management and quality assurance standards
guidelines for Selection and Use

3. REFERENCE DOCUMENTS

The following documents are part of this specification.


Project Specifications

DGS-1300-010 Piping Systems ( Piping classes )

DGS-1300-185 Fabrication, Handling and Installation of Process and


Utility Piping

DGS-0000-004 Criticality Rating System

4. DOCUMENT PRECEDENC

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BOLT TORQUING/TENSIONING PROCEDURE FOR FLANGED CONNECTIONS

4.1 Compliance with standards


It shall be the VENDORS responsibility to be, or to become, knowledgeable of the
requirements of the referenced Codes and Standards.

4.2 Conflict resolution


The VENDOR shall notify the CONTRACTOR of any apparent conflict between this
specification, national and/or local regulations, the Codes and Standards, and any other
specifications noted herein. Resolution and/or interpretation of precedence shall be
obtained from the CONTRACTOR in writing before proceeding with the
design/manufacture.
In case of conflict, the order of precedence shall be:
National and/or Local Regulations
Project Specifications and Standards
Industry Codes and Standards

5. SPECIFICATION DEVIATION/CONCESSION CONTROL


Any technical deviations to the Purchase order and its attachments including, but not
limited to, the Piping Drawings and Project Specifications shall be sought by the VENDOR
only through CONCESSION REQUEST format. CONCESSION REQUESTS require
CONTRACTORS and COMPANYS review/approval, prior to the proposed technical
changes being implemented. Technical changes implemented prior to COMPANY
approval are subject to rejection.

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BOLT TORQUING/TENSIONING PROCEDURE FOR FLANGED CONNECTIONS

6. QUALITY ASSURANCE/QUALITY CONTROL

6.1 QA/QC Program

6.1.1 To ensure that all bolt tensioning/torquing is being performed consistently and accurately,
the VENDOR shall have in effect at all times, a QA/QC program which clearly establishes
the authority and responsibility of those responsible for the quality system. Persons
performing quality functions shall have sufficient and well defined authority to enforce
quality requirements that initiate, identify, recommend and provide solutions to quality
problems and verify the effectiveness of the corrective action.

6.1.2 A copy of the VENDORS QA/QC program shall be submitted to the CONTRACTOR with
its quotation for CONTRACTORS review and concurrence prior to award. If VENDORS
QA/QC program is ISO 9000 certified, then only a copy of the VENDORS ISO 9000
certificate is required. In addition, if VENDORS facility is ISO certified, CONTRACTORS
QA audit requirements will be waived in favor of ISO 9000 registrar audits, unless the
CONTRACTORS trend analysis program indicates areas of concern.

6.1.3 The VENDOR shall identify in documents to its SUBVENDOR(S) all applicable QA/QC
requirements imposed by the CONTRACTOR, and shall ensure compliance thereto. On
request, VENDOR shall provide objective evidence of its QA/QC surveillance of its
SUBVENDOR activities.

6.1.4 VENDOR shall furnish CONTRACTOR with copies of VENDORS Quality Control Plan,
Inspection and Test Plan.

6.2 Tool Calibration

6.2.1 The calibration of torque wrenches and tensioners shall be checked against the
MANUFACTURERS specifications upon receipt. Any tools that are out of calibration shall
be rejected.
Calibration certificates shall be available at Site.

6.2.2 A recheck of the calibration shall be made on a regular basis. Any tool found to be out of
calibration shall immediately be taken out of service for repair.

6.2.3 All flanged joints secured with tools found to be defective shall be rechecked with a
properly functioning tool.

6.3 Compliance with Installation Procedures

6.3.1 Compliance reports and bolt torquing/tensioning records, as specified in Section 7.0, shall
be reviewed on a regular basis.

6.4 Criticality ratings


The Criticality Rating (CR) listed on the Piping Line List, shall be used to determine factory
inspection and testing requirements as required by Project Specification DGS-0000-004.

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BOLT TORQUING/TENSIONING PROCEDURE FOR FLANGED CONNECTIONS

7. DOCUMENTATION

7.1 Bolt torquing/tensioning documents

7.1.1 Data and Information to be submitted before award of work :


Compliance Reports - A method shall be revised which documents compliance with the
instructions in SECTION 11, INSTALLATION, including the 24 hour recheck.

7.1.2 Data and information to be submitted after award of work:


Bolt Torquing/Tensioning Records - A record of bolt torquing/tensioning by joints and
line numbers shall be maintained.

7.2 Technical deviation documents


If appropriate, the VENDOR shall issue a Concession Request, showing each deviation
from the Purchase Order

8 CONTRACTORS / SUBCONTRACTORS
8.1 Roles and responsibilities

8.1.1 The VENDOR (conducting the bolt torquing/tensioning) shall assume responsibility and
overall guarantee compliance to this specification.

8.1.2 The VENDOR shall transmit all relevant documents and specifications to its
SUBVENDORS.

8.1.3 It is the VENDORS responsibility to enforce all specification requirements on its


SUBVENDORS.

8.1.4 The VENDOR shall submit all relevant drawings and engineering data from its
SUBVENDORS to the COMPANY.

8.1.5 The VENDOR shall obtain and submit all SUBVENDOR warranties to the CONTRACTOR/
COMPANY, in addition to the system warranty.

9. DESIGN

9.1 The design calculations for minimum bolt load shall be based on ASME Boiler and
Pressure Vessel Code Section VIII (Division I), Pressure Vessels: Appendix S Design
Considerations For Bolted Flange Connections and Appendix 2 Rules For Bolted Flange
Connections With Ring Type Gaskets.
Bolting calculations for Grayloc type connectors shall be per MANUFACTURERS
specifications.

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BOLT TORQUING/TENSIONING PROCEDURE FOR FLANGED CONNECTIONS

9.2 Bolt Stresses shall be compared against the Design Stress Value For Bolting Materials
found in ASME B31.3 Table A-2.

9.3 In preparation for the application of bolt tensioning equipment, the following information
shall be available for each flange of the equipment to be tightened:
Required bolt stress, from the flange calculation, load factor and hydraulic pressure(s).
Tool size and number of tools to be applied.
The maximum work load that can be applied by the tool at maximum pressure.
Provision of bolts with extra threaded lengths for attachment of the bolt tensioners.

10. MATERIALS

10.1 Components

10.1.1 For this specification, components shall consist of flanges, gaskets, bolting and lubricants
for bolting.

10.1.2 Piping components shall be in accordance with DGS-1300-010.

10.1.3 Lubricants used for bolting shall be anti-seize lubricants suitable for operating
temperatures between 200C and 450C.

10.1.4 Alloy steel bolting intended for use up to 200C shall be supplied with suitable protective
coating. Lubrication should not be necessary.

11.1.5 The material for torque wrenches and tensioning equipment shall be of forged quality and
heat treated to meet high toughs requirements.

11. INSTALLATION

11.1 Pre-Bolting Inspection

11.1.1 Inspect the gasket material for possible defects such as bends or creases.

11.1.2 Inspect the mating flanges for dirt, mechanical damage and corrosion. Use a suitable
solvent to clean the surfaces. The contact area of the flanges should be free from
excessive pitting, radial tool marks and scratches. (See Attachment of Specification DGS-
1300-185).

11.1.3 Inspect the studs and nuts. They should be free of dirt and corrosion. The studs should be
straight and the threads free from nicks, burrs and chips. Check for damage to protective
coating.

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BOLT TORQUING/TENSIONING PROCEDURE FOR FLANGED CONNECTIONS

11.2 Flange and Gasket Assembly

11.2.1 Align the flanges properly. The bolt holes should match so the studs can be inserted
freely.

11.2.2 Refer to Appendix A of this specification, Stud Tightening Pattern. Use for studs in
positions 1, 2, 3 and 4 as centering guides for the gasket. In the case of spiral wound
gaskets, insure that the centering ring is at all points within the outside diameter of the
raised face. Clamp securely in place.

11.2.3 Insert the balance of the studs. Apply a suitable lubricant (heavy graphite and oil mixture)
to the threads, the face of the nut that contacts the flange.

11.2.4 Finger tighten all studs and nuts. Center studs between nuts so an equal number of
threads project at each end. When tensioning is required a threaded length of one (1)
times bolt diameter should protrude at the end where the bolt tensioner is to be placed.

11.2.5 The gasket shall be properly handled to avoid and/or minimize damage to it, prior to
installation.

11.3 Stud Bolt Torquing

11.3.1 Bolt torquing shall be applied in accordance with Chart 1 and/or specific equipment
specifications.

11.3.2 For bolt sizes 1 inch and smaller, a manual torque wrench may be used. For larger bolts,
a suitable hydraulic torque wrench should be used, i.e., Ingersoll-Rand or approved equal.

11.3.3 Use the final torque values derived from Design section 9.1. Make the first pass. Torque
the nuts not more than 30 percent of the final torque value on the first pass. Follow the
tightening sequence from Appendix A.

11.3.4 Make the second pass. Following the same sequence, torque the nuts not more than
60 percent of the final torque value.

11.3.5 Make the final pass. Bring the nuts up to the final torque value. Be sure to follow the
same sequence.

11.3.6 Repeat the last step 11.3.5 again after 24 hours.

11.4 Bolt Tensioning

11.4.1 Bolt tensioning shall be applied in accordance with Chart 1 and/or specific equipment
specifications.

11.4.2 The application of bolt-tensioning equipment shall be in strict accordance with the
MANUFACTURERS instruction manual and safety procedures.

11.4.3 The personnel using the equipment shall be adequately trained in its application.

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BOLT TORQUING/TENSIONING PROCEDURE FOR FLANGED CONNECTIONS

11.4.4 The tensioning of the bolts is carried out in a number of stages or cycles, depending on
the number of tools that can be applied simultaneously. Please see Appendix B for
bolting-up sequence.

11.4.5 To facilitate loosening of the nuts when required at some later date, it will be necessary to
treat the thread of the bolts with a suitable lubricant before fitting the nuts. The
MANUFACTURERS instructions shall always take preference.(Not required for bolting
protected by TAKE COAT-1000).

11.4.6 All relevant information and bolt tensioning details shall be recorded for such application
for subsequent reference and reapplication.

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BOLT TORQUING/TENSIONING PROCEDURE FOR FLANGED CONNECTIONS

CHART 1
BOLT TORQUING/TENSIONING CHART

ASME B16.5 Flange Rating


Flange
Size 150 lb 300 lb 600 lb 900 lb 1500 lb 2500 lb
NPS No. of Bolt Note No. of Bolt Note No. of Bolt Note No. of Bolt Note No. Bolt Note No. of Bolt Note
(in) Bolts Dia. No. Bolts Dia. No. Bolts Dia. No. Bolts Dia. No. of Dia. No Bolts Dia. No.
(in) (in) (in) (in) Bolts (in) (in)
4 1/2 1 4 1/2 1 4 1/2 1 4 3:4 1 4 3:4 1 4 3/4 1
4 1/2 1 4 5/8 1 4 5/8 1 4 3/4 1 4 3/4 1 4 3/4 1
1 4 1/2 1 4 5/8 1 4 5/8 1 4 7/8 1 4 7/8 1 4 7/8 1
1 4 1/2 1 4 3/4 1 4 5/8 1 4 1 1 4 1 1 4 1 1/8 1
2 4 5/8 1 8 5/8 1 8 5/8 1 8 7/8 1 8 7/8 1 8 1 1
3 4 5/8 1 8 3/4 1 8 3/4 1 8 7/8 1 8 1 1/8 1 8 1 1/4 1
4 8 5/8 1 8 3/4 1 8 7/8 1 8 1 1/8 1 8 1 1/4 1 8 1 1/2 2
6 8 3/4 1 12 3/4 1 12 1 1 12 1 1/8 1 12 1 3/8 2 8 2 3
8 8 3/4 1 12 7/8 1 12 1 1/8 1 12 1 3/8 1 12 1 5/8 2 12 2 3
10 12 7/8 1 16 1 1 16 1 1/4 1 16 1 3/8 1 12 1 7/8 2 12 2 1/2 3
12 12 7/8 1 16 1 1/8 1 20 1 1/4 1 20 1 3/8 1 16 2 3 12 2 3/4 3
14 12 1 1 20 1 1/8 1 20 1 3/8 1 20 1 1/2 1 16 2 1/4 3
16 16 1 1 20 1 1/4 1 20 1 1/2 1 20 1 5/8 1 16 2 1/2 3
18 16 1 1/8 1 24 1 1/4 1 20 1 5/8 1 20 1 7/8 1 16 2 3/4 3
20 20 1 1/8 1 24 1 1/4 1 24 1 5/8 1 20 2 3 16 3 3
24 20 1 1/4 1 24 1 1/2 1 24 1 7/8 1 20 2 1/2 3 16 3 1/2 3
26 24 1 1/4 1 28 1 5/8 1 28 1 7/8 1 20 2 3/4 3
28 28 1 1/4 1 28 1 5/8 1 28 2 3 20 3 3
30 28 1 1/2 1 28 1 3/4 1 28 2 3 20 3 3
32 28 1 1/2 1 28 1 7/8 1 28 2 1/4 3 20 3 1/4 3
34 32 1 1/2 1 28 1 7/8 1 28 2 1/4 3 20 3 1/2 3
36 32 1 1/2 1 32 2 3 28 2 1/2 3 20 3 1/2 3
42 36 1 1/2 1

Notes
1. No Torquing or Tensioning required for these sizes except as per note 4 below.
2. Flange bolting to be tightened to recommended Torque value for these sizes.
3. Flange bolting to be hydraulically tensioned for all services in these sizes. The bolt lengths
specified include an additional length of 1 bolt diameter to facilitate the use of bolt tensioning
equipment.
4. Flange bolting to be tightened to recommended Torque value for the following pipe classes:

11051 13030 31055 61055 91055 251055


11051A 13031 31377 61377 91377
11055 13460 33460 61655 93460
11377 63031
63460

5. At flanged joints subject to frequent changes in temperature and pressure, and at flanged joints
which continue to leak after repeated application of conventional methods.
Bolt sizes = < 1 3/8" shall be torqued and bolt sizes = > 1 1/2" shall be hydraulically tensioned.

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BOLT TORQUING/TENSIONING PROCEDURE FOR FLANGED CONNECTIONS

APPENDIX A
STUD TIGHTENING PATTERN

1
26 5

20 9
1
20 5

13
16
16 1 9

16 5

12 1 17
12 9 13
12
12 5

8 8 8 8 5 9 13 17 21
8

4 4 4 4 4 4 3 3 3 3 3 3

10 6 7 7 7
14 7 7
18
22
2

6 11
11 11 11
10
14 2
18

6 15
2 15 15
10
14

6 19
2
19
10

6 23
2

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BOLT TORQUING/TENSIONING PROCEDURE FOR FLANGED CONNECTIONS

APPENDIX B
RECOMMENDED BOLTING-UP SEQUENCE AND NUMBER OF TOOLS TO BE APPLIED

Number of Bolts in Flange Number of Tensioners

No. of bolts in flange No. of tensioners to use


64 16
48 12
36 12

24 and less on a 50% basis


Bolting sequence for 36 bolt flanges
using 12 tensioners

2 3 1
1 2
3 3

2 1

2
1

3 3

2 1

1 2

3 3

2 1

1 2

3 3

2 1

1 2
3 3
2 1
1 3 2

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