Bolt-Up Procedure for OFON Phase 2 Project

Document Identification Number
BOLT-UP PROCEDURE NG-018-XX-PNL-430911

Revision : 02 Status: AFC
Document Type : PRC System/Subsystem: 00 Discipline : QUA Rev. Date : 29-Mar-2013
Contractor document number NG-018-XX-PNL-430911 Page 1 of 30
Joint Venture Asset
OFON PHASE 2 PROJECT

CONTRACT D029 ±Tie-in and Integration
BOLT-UP PROCEDURE
Approved for
02 AFC 29-Mar-2013 I. Imuki S Ghosh BL
construction
Approved for
01 AFC 23-Feb-2013 SG AP BL
construction
00 IFR 27-Dec-2012 Issue for review JP FN BL
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Rev. Status Date Revision memo Issued by Checked by Approved by
CHANGE RECORD PAGE
REVISION DESCRIPTION OF REVISION
00 Issue For Review

01 CPY comments incorporated
02 CPY comments incorporated
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CONTENTS
1. General ............................................................................................................................................................ 5
1.1 DEFINITION ........................................................................................................................................ 5

1.2 REFERENCE DOCUMENTS .............................................................................................................. 5
1.2.1 Codes ................................................................................................................................................ 5
1.2.2 TOTAL general specification .......................................................................................................... 5
1.3 PURPOSE ........................................................................................................................................... 6
1.4 RANGE OF APPLICATION ................................................................................................................ 6
2. RESPONSIBILITY ........................................................................................................................................... 6
3. PERSONNEL QUALIFICATION ..................................................................................................................... 6
4. MATERIAL ...................................................................................................................................................... 6
5. ASSEMBLING EXECUTION ........................................................................................................................... 7
5.1 General ............................................................................................................................................... 7

5.2 Checklist before erection ................................................................................................................. 7
5.3 Assembly ........................................................................................................................................... 9
5.4 Checklist after assembly ................................................................................................................ 10
6. Tightening ..................................................................................................................................................... 10
6.1 Choice of the method ..................................................................................................................... 10

6.2 Manual Tightening .......................................................................................................................... 10
6.3 Bolt Torquing................................................................................................................................... 10
6.3.1 General ............................................................................................................................................ 10
6.3.2 Preparation ..................................................................................................................................... 10
6.3.3 Torque tightening sequence ......................................................................................................... 11
6.4 Bolt tensioning ................................................................................................................................ 11
6.4.1 General ............................................................................................................................................ 11
6.4.2 Bolt tensioning procedure ............................................................................................................ 12
7. MAXIMUM BOLT STRESS ........................................................................................................................... 13
7.1 Correspondences............................................................................................................................ 13
7.2 Check of final bolt stress ............................................................................................................... 13
8. ASSEMBLY PROCEDURE QUALIFICATION ............................................................................................. 14
8.1 Mock-up qualification procedure .................................................................................................. 14

8.2 Bolt elongation procedure ............................................................................................................. 14
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8.3 Bolt tensioning calculation note ................................................................................................... 15

8.3.1 Determining the LTF (Load Transfer Factor) .............................................................................. 15
8.3.2 Determining the Tool Pressure .................................................................................................... 15
8.3.3 Design Check ................................................................................................................................. 16
9. Disassembling .............................................................................................................................................. 17
10. IDENTIFICATION AND FOLLOW UP ....................................................................................................... 17
10.1 Color code ....................................................................................................................................... 17

10.2 Label ................................................................................................................................................. 18
Appendix A Tightening sequence: «CRISS-CROSS» method .................................................................... 19
Appendix B Anomaly report card .................................................................................................................. 20
Appendix C Security instruction C.90 ........................................................................................................... 21
Appendix D Security instruction C.91 A & B ................................................................................................ 22
Appendix E Security instruction C.39 ........................................................................................................... 23
Appendix F Recommend torques and tensions for flange bolting ............................................................ 24
Appendix G Flange assembly check list ....................................................................................................... 25
Appendix H Bolt marking for bolt tensioning ............................................................................................... 26
Appendix I Bolt Elongation record sheet .................................................................................................... 27
Appendix J Bolt tensioning checklist ........................................................................................................... 28
Appendix K Bolt tensioning Tools ................................................................................................................ 29
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1. GENERAL
1.1 DEFINITION
COMPANY: means TEPNG ± Total E&P Nigeria Ltd and, on behalf, OFON PHASE 2
PROJECT
CONTRACTOR: means PNL ± Ponticelli Nigeria Ltd and Ponticelli Upstream that has been
awarded the CONTRACT by COMPANY
CONTRACT: means the document linking COMPANY and CONTRACTOR within the
framework of OFON PHASE 2 PROJECT
1.2 REFERENCE DOCUMENTS
1.2.1 CODES
Reference Title
ASME B 31.3 Process Piping
Alloy Steel and Stainless Steel Bolting Material for High

ASTM A 193 Temperature Service.
ASME B 18.2.1 Square and Hex. Bolts and Screws
Carbon and Alloy Steel Nuts for Bolts for High-pressure and
ASTM A 194 High Temperature Service.
ASTM A 320 Alloy Steel Bolting Materials for Low Temperature Service.
1.2.2 TOTAL GENERAL SPECIFICATION
Reference Title
GS PVV 146 Bolting for piping
GS PVV 112 Piping material class
GS PVV 171 Steel Piping Fabrication
External protection of off-shore and Coastal Structures and

GS COR 350
Equipment by Painting
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1.3 PURPOSE
The object of this procedure is to describe the method used to achieve correct flange
alignment and uniform bolt tension.
1.4 RANGE OF APPLICATION
Unless otherwise noted, this procedure is applicable to all assemblies carried out by
CONTRACTOR for equipment and pipes during new works, modifications or repairs
required in the frame of OFON Phase 2 Project.
2. RESPONSIBILITY
This procedure is managed by the CONTRACTOR Quality Manager and he is responsible
for the application of this procedure.
In accordance with project Codes and Standards, CONTRACTOR personnel is responsible
on applying correct bolt up procedure on all piping and equipment assembly.
He will perform the bolt-up activity of:
- Piping assembly as per CONTRACTOR procedure.
- Equipment assembly as per Vendor procedure.
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Flange assembling is carried out under responsibility of the Pipe Fitter Foreman. He is
responsible to monitor staff competence in term of Quality and Safety for the assembling
work achievement.
The Pipe Fitter FOREMAN is, consequently, responsible for applying this procedure.
3. PERSONNEL QUALIFICATION
The personnel carrying out assembling operations shall be qualified. This qualification is
obtained through internal CONTRACTOR training or from a training given by an external
company.
4. MATERIAL
The Pipe Fitter FOREMAN must check that the material is adapted for the work:
- Individual and collective adapted tools (bronze tools on high explosive risks zone,
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- Adapted security, insulation or test spades,
- Insulation gasket in conformity with the specifications,
- Adapted tightening tools.
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5. ASSEMBLING EXECUTION
5.1 GENERAL
The major factors for successfully sealing a bolted assembly and eliminating leakage are:
x proper selection and design of the components, i.e. flanges, gaskets and bolts;
x proper preparation, inspection and installation;
x correct bolt-up procedure
All gasket sealing surfaces shall be protected from damage (shock, stripe, corrosion,
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lifting, offshore transfer and final installation.
5.2 CHECKLIST BEFORE ERECTION
1) Review potential risks for damage from surround area or activities.

2) Confirm correct type, size and rating to be installed or dismantled. Check the
location of the gasket to be erected or dismantled (refer to the assembling
drawings and associated documents)
3) Inspect gasket sealing area and confirm it is free from defects or damage such
as:
x scores,
x erosion/corrosion,
x Deformation
Flange faces with coarse tool marks or scratches that may cause the joint to leak
should be rejected and where necessary remachined if required.
4) Clean the gasket seating facing using extra fine sand paper in order to remove
any oxidation or protection (varnish).
5) Check that flange facing, dimensions and type of bolting are in accordance with
the general specifications.
6) Use straight steel rule edge to check facing flatness. Flange shall have bearing
surfaces for bolting that are parallel to the flange face within 1 degree. Damaged
or badly corroded flanges should be repaired or replaced.
7) Flanges at rest should be parallel, in case of misalignment; corrective measure
will be defined with COMPANY and witnessed by COMPANY. Completed flanged
connections shall be free of residual stresses during assembly, particularly in
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alignment allowance are given in figure n° 1 for pipe flanges. Any anomaly shall
be filed and reported usLQJWKH³$VVHPEO\DQRPDO\UHSRUWFDUG´JLYHQLQAppendix
B which is then transmitted to COMPANY for decision.
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Figure 1: Alignment raised face allowances for piping flanges
A = 1 mm / 200 mm - Maximum Out of Parallel alignment of the flanges measured across any
diameter
B = 3 mm - Maximum translation of branches or connections
8) All gaskets shall be new and unused whenever an opened assembly is to be

closed again. Check conformity of the gasket (material, dimensions, series,
thickness, type) to ensure that it is in compliance with the piping specification,
class, pressure rating or the dismantled gasket.
9) Check the general aspect of the gasket:
x coating,
x geometry,
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x crushing,
x spiral windings,
x traces of corrosion or erosion.
All damaged gasket (including loose spiral winding) shall be rejected.
10) Check studs and nuts :
x grade
x coating damage
x threading,
x bolts,
x nut,
x Dimensions.
If necessary, stud bolts shall be cleaned using wire brush to remove any dirt on the
threads. Visually examine studs and nuts to ensure it is free from burrs. Nuts should
turn freely on the studs for a distance equal to their in-service distance. In the case of
existing stud bolts re-assembly, wires brush them before greasing.
11) Check the supporting quality of the line and report any anomaly.
5.3 ASSEMBLY
1) The gasket is under responsibility of pipe fitter foreman (final or temporary)

2) If required, grease RTJ seating face and if necessary seal the gasket.
CAUTION: Some services such as Oxygen or Hydrogen are not compatible with the
use of grease.
3) Centre the flange faces using appropriate tool (pin, cantering device, etc.). Align
flange faces exactly, leaving just enough space to insert a gasket. Once flanges
have been aligned up, visually examine them to assure that an acceptable fit has
been obtained.
4) Install the first stud bolts.
Note: For a gasket in vertical plane, it is necessary to start the assembly by placing
the lower stud bolts which will be used as support for the gasket before tightening,
5) Install the gasket.
6) Centre the gasket.
7) Insert all remaining studs and nuts on hand-tight. Do not pull up studs in a
manner that reaches uneven compression of the gasket.
8) Ensure all bolts are tensioned evenly and in sequence with at least two threads
protrusion through the nuts at both sides. Otherwise, distribute protrusion equally
from the sealing facing
Note: If bolt tensioner is to be used, over length bolt are required (protrusion shall be at
least one bolt diameter on one of the two sides). Attention is to be paid for allowance
for tensioning equipment access.
9) Tighten the stud bolts with manual wrench to obtain the parallelism of the flange
faces.
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5.4 CHECKLIST AFTER ASSEMBLY
The Pipe fitter Foreman (or a person whom he designates), checks by surveying:
1) The parallelism of the flanges
2) The remaining length of stud bolt
3) The correct torque values have been applied and recorded.
6. TIGHTENING
6.1 CHOICE OF THE METHOD
The method of tightening commonly used is the manual tightening method.

The use of bolt torqueing or pre-tensioning (bolt tensioning) is determined by COMPANY
piping specifications.
6.2 MANUAL TIGHTENING
1) Tighten with "CRISS-CROSS" method (sketch in Appendix A) with the suitable

wrench keys while controlling parallelism.
2) Ensure the tightening of all the bolts is sufficient. (interaction between various
tightening)
3) See NOTE section from paragraph 6.4.2 for RTJ flanges.
6.3 BOLT TORQUING
6.3.1 GENERAL
1) Hydraulic, pneumatic or beam type torque wrenches are commonly used

in bolt torqueing. The hydraulic wrenches are normally preferred.
2) Reference to the tensioning equipment manufactures hydraulic
pressure/tensioning values shall be used for guidance.
3) The pressure to be applied is indicated in the equipment pressure / torque
conversion specific chart.
6.3.2 PREPARATION
1) Using Appendix F table, determine the torque values necessary to achieve

the desired bolt stress.
2) Bring all nuts up snug-tight with a short wrench using the "CRISS-CROSS"
pattern shown in Appendix A. Do not tighten the bolts using impact force.
3) All torque wrenches shall be of adequate capacity and recently calibrated.
Certificates of torque wrenches calibration shall be available.
4) In the event that seizure of the nut being torqued is encountered, back the
nut off until seizure is eliminated and torque again. Apply lubricant if
necessary and replace the nut and/or bolt if seizure occurs.
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6.3.3 TORQUE TIGHTENING SEQUENCE
1) Torque bolts and nuts in a "CRISS-CROSS" pattern as shown in Appendix A

using a minimum of three torqueing stages and recommended final torque as
defined in Appendix F.
2) STAGE 1 Torque to a maximum of 40% of the final torque value and in
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bearing uniformly on the gasket. Then tighten with 40% of the final torque
value in clockwise circular sequence.
3) STAGE 2 Torque to a maximum of 70% of the final torque value with the
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method.
5) After these three basic torque stages completed, repeat torqueing the nuts
at least once using the final torque in a "CRISS-CROSS" sequence until
no further rotation of the nut is observed.
6) Continue torqueing with the final torque in a circular sequence to ensure
no further rotation.
7) All torque readings and sequences of tightening shall be filed and
recorded for future reference using the form given in Appendix G.
6.4 BOLT TENSIONING
6.4.1 GENERAL
1) The advantage of this method lies mainly in the homogeneity of tightening. It

requires stud bolts over lengths to be equal to one bolt diameter. However,
its implementation shall be carried out strictly in accordance with the
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2) The hydraulic pressure to be applied is function of the bolt diameter and
the type of tool; it is indicated in the equipment specific tables as shown in
Table n° 3 in paragraph 8.3.
3) The tensioning of bolts shall be performed by trained personnel with
appropriate equipment (bridges, pullers, hydraulic pumps, connection
pipes, manometers, etc.). Tools are shown in Appendix K.
4) Ideally all bolts should be tensioned in one operation to ensure even
loading on the bolts and gaskets. It may not be practical to tension all bolts
in one operation, but at least 2 bolts diametrically opposed should be
tightened in one operation to ensure an acceptable degree of uniformity in
loading.
CAUTION: Bolt tensioning should not be carried out on equipment or systems which are
in service.
5) The trained personnel selected to perform the controlled bolt tensioning
shall develop in the preliminary operation a diagram correlating the
required pressure to be reached in the hydraulic circuit connected to the
tensioners and the required load in each bolt. (See paragraph 8.3)
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6.4.2 BOLT TENSIONING PROCEDURE
The following procedure provides an example of 20" - 900# flange and 4 bolts tightened
at the same time. In case the quantity of tensioner is different, each group below will
have the same quantity as quantity of tensioner.
1) Group the 20 bolts into five groups (quantity of tensioners is the quantity of
each group, 4 A's, 4 B's, 4 C's, 4 D's and 4 E's) as shown in Appendix H and
then mark them accordingly on the flange.
2) Mount the 4 hydraulic tensioners on the first 4 bolts A's group of bolts.
3) Check the hydraulic system if there is any pressure problem.
4) Check that the specified hydraulic pressure is applied to the tensioner
before running the nut down on each stud.
5) Apply equivalent hydraulic pressure by operating the hydraulic pump to
give a bolt load equal to 40% of the maximum bolt stress (see paragraph
7).
Note: It is often advisable to continuously re-apply the bolt stress, especially with Ring
Type Joints, until no further movement of the flange nuts can be obtained. Also, it may
be beneficial to allow a few minutes between each pressurization to allow the gasket to
bed in.
6) Shift the tensioners to the next group and repeat the steps 3 to 5 until all
group are 40% tightened.
7) Repeat the steps 2 to 5 with 70% of the maximum bolt stress
8) Shift the tensioners to the next group and repeat the steps 3 to 5, but
applying a bolt load equal to 70% of the maximum bolt stress.
9) Repeat the steps 2 to 5 with 100% of the maximum bolt stress
10) Shift the tensioners to the next group and repeat the steps 3 to 5, but
applying a bolt load equal to 100% of the maximum bolt stress.
11) Repeat steps 3 to 5 on all group of bolts to check if the hydraulic pressure
required is enough to obtain the required bolt stress.
Note: As a check to see if an excessive load has been lost in the initial groups,
assemble two tensioning tools to randomly select but diametrically opposite group bolts.
Apply 100% final hydraulic pressure and attempt to further tighten the flange nuts. If the
nuts cannot be further tightened, then tensioning is complete and the tensioners may be
removed. If the flange nuts can be further tightened, then repeat steps 2 to 5 by
increasing the hydraulic pressure to 100% of final hydraulic pressure, on the bolts of
each group.
12) The bolt tensioners may now be removed.
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bolts remain
14) The Pipe fitter Foreman and the trained personnel selected to perform the
bolt tensioning shall fill the forms given in Appendix I and Appendix J
stating the procedures adopted during the operations and the parameters
adopted (pressure in the hydraulic circuit, temperature of flanged joints,
etc). The form shows also the original length of bolts (unstressed
conditions) and the final length of bolts (stressed conditions). As the
hydraulic operating pressure varies according to the type and size of tools
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used, reference shall be made to the equipment's manufacturer

specifications.
CAUTION: Never exceed the tensioner maximum working pressure
15) Never exceed the tensioner maximum piston/ram stroke
7. MAXIMUM BOLT STRESS
7.1 CORRESPONDENCES
The bolt-up procedure with torque wrench method is based, as an example, on the bolt
stress of A-193 Grade B7 or A-320 Grade L7 in making up the flange, while the bolt
tensioning method is referred to a generic maximum bolt stress.
Table n° 1 indicates the maximum bolt stress values recommended, it is important to notice
that there are some flanges where lower bolt stress values are appropriate depending on
the flange rating, and/or type bolting. In case of the Ring Joint Flanges, lower maximum bolt
stress values are recommended for the higher flange ratings to avoid excessive bolt loads
which can lead to undesirable deformations to ring gasket and flange groove seating
surfaces. Unlike raised face flanges, there is a little difference in gasket seating area with
ring joint flanges as flange ratings increase so bolting loads are more concentrated in
narrow zones of the ring groove. The remaining situations are all governed by the material
strength of the specific bolt indicated. See Appendix F for correspondence between bolt load
and bolt diameter depending on flange class and face type.
7.2 CHECK OF FINAL BOLT STRESS
The check of final bolt stress shall be performed for critical flange by means of the bolt
elongation method described at the paragraph 8.2.
The check will be spot, 10% of flanged joint (for piping) and at least 4 bolts of every joint for
equipment tightened by each crew, and it shall be performed as follows:
1) measure with calliper the bolt elongation of the four bolts diametrically opposite;
2) check the correspondence of the specified bolt stress in the range of ± 10% of the
bolt elongation measured;
3) if the above tolerance is not achieved in one bolt, then all the bolting of the joint
will be checked and, in case of no compliance, retensioned; in case of no
compliance of all 4 bolts for more than two joints in the same sampling, all the
flanged joint tensioned by the crew who performed the bolt-up during that working
day, will be completely checked.
MAXIMUM BOLT STRESS
BOLT MATERIAL MAX. BOLT STRESS, ı (Mpa)

max
A-193 Grade B7 360

A-193 Grade B8 360
A-193 Grade B8M 360
A-193 Grade B16 360
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A-320 Grade L7 360

A-453 Grade 660 360
Table n° 1
8. ASSEMBLY PROCEDURE QUALIFICATION

Each size of bolts for flange shall be submitted to a qualification procedure. The qualification
shall be carried out on mock-up flange and elongation of each bolt shall be measured to
ensure uniform bolt tension. For the finished joint, bolt elongation should correspond to
maximum bolt stress value determined as per Appendix F ± 10%.
8.1 MOCK-UP QUALIFICATION PROCEDURE
1) Prepare the stud bolt ends to improve accuracy of stretch measurement. The
stretch measurement will be tenths of millimetres accurate.
2) Using Appendix I form, number each bolt
3) Measure and record the initial length of each bolt.
4) Tighten the bolts, measure and record the final length of each bolt.
5) Record the desired stretch and also the recommended tool setting (torque value).
6) The crew is considered "qualified" after having assembling two sets of bolted
flanges with the maximum bolt stress ± 10%.
8.2 BOLT ELONGATION PROCEDURE
A suitable device for measuring bolt elongation is the use of a calliper.

The formula derived from the basic stress-strain relationship is:
Where L is the effective bolt length measured from center of nuts (as shown in Appendix I).
Bolt Material E (Gpa) A

A-193 Grade B7 205 0.001756
A-193 Grade B8 205 0.001756
A-193 Grade B8M 205 0.001756
A-193 Grade B16 205 0.001756
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A-320 Grade L7 205 0.001756
A-453 Grade 660 195 0.001846
Table n° 2
8.3 BOLT TENSIONING CALCULATION NOTE
Before any bolt tensioning, it is necessary to calculate the correlation between required
pressure to be reached in the hydraulic circuit connected to the tensioners and the required
stress in each bolt.
Load Transfer Factor = 1.01 + (Bolt Dia / Clamp Length)
Tool Pressure = (Reqd Bolt Load x LTF) / Tool Hydraulic Pressure Area
8.3.1 DETERMINING THE LTF (LOAD TRANSFER FACTOR)
Any stretch Bolt Tensioner regardless of make, exhibits a Load Transfer Loss as the bolt
load is transferred from the Tensioner to the joints hexagon or round nuts. The Bolt load
loss is a direct loss of stud elongation, this is due to many different factors, such as
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reaction surface. Because of this phenomenon it is essential that a load allowance is
made when calculating the required operating pressure of a Tensioner, to achieve a
known residual bolt load, extra load must be applied so the bolt will relax down to the
required load on transfer. The load transfer factor can be accurately calculated and is a
direct function of joint clamp length and the nominal diameter of the stud:
Load Transfer Factor = 1.01 + (Bolt Dia / Clamp Length)

Units:
D = Nominal Thread Diameter (mm or In)
C = Bolt Clamp Length (mm or In)
Note: If the calculated LTF is less than 1.1, then use a 1.1 LTF
CAUTION: Applying the Load Transfer Factor to the required bolt Stress will Increase
the % of yield being generated on the bolt this value must be checked again
8.3.2 DETERMINING THE TOOL PRESSURE
Tool Pressure = (Required Bolt Load x Load Transfer Factor) / Tool Hydraulic Pressure Area
Units:
Tool Pressure = (N/mm2 or Ton/In2)
Required Bolt Load = (N or Ton)
LTF = (No Units)
Tool Hydraulic Pressure Area = (mm2 or In2)
*To convert N/mm2 to bar: Multiply by 10
* To Convert Ton/In2 to psi: Multiply by 2240
CAUTION: Check that the calculated tool pressure does not exceed the Maximum
Working Pressure of the tool. This value is hard stamped on all tools and is documented
on the tool technical data sheet which came with the tools.
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8.3.3 DESIGN CHECK
It is always good practice to determine the % of bolt yield applied, if the final bolt stress
exceeds 75% of the bolt yield strength, then it may be necessary to consider the fatigue
characteristics of the bolt and joint.
CAUTION: NEVER EXCEED 95% OF THE BOLT YIELD STRENGH
% of Yield = (Bolt Stress Required / Yield Strength of bolt) x 100

Units:
Bolt Stress Required = (N/mm2 or Ton/In2)
Yield Strength of Bolt = (N/mm2 or Ton/In2)
Step 2:
Example:
Bolt Clamp Length = 144mm
Bolt Diameter M36 x 4
Bolt Yield Strength = 720 N/mm2
Tool Hydraulic Pressure Area = 2955mm2 (Tool data)
Required Bolt Load = 299kN
LTF= 1.01 + (Bolt Dia / Clamp Length)
= 1.01 + (36/144) = 1.26
% Yield Check = (Reqd Bolt Stress / Bolt Yield Strength) x LTF x 100
= (365.8 / 720) x 1.26 x 100 = 64.01%
Tool Pressure = (Reqd Bolt Load x LTF) / Tool Hydraulic Pressure
Area
= (298858 x 1.26) / 2955
= 127.43 N/mm2 = 1274.3 bar
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Tools Pressure / Tension corresponding table:

Step 4:
Tool reference Tool T22 Tool T23 Tool T24 Tool T25
Pressure Area (mm²) 2,884 5,271 8,445 12,197
Max Pressure (bar) 1500 1500 1500 1500
Max Load (kN) 433 791 1267 1830
Max Piston Stroke (mm) 15 15 15 12
Dia Dia L L Tension Pressure (bar) Pressure (bar) Pressure (bar) Pressure (bar)
LTF
(in) (mm) (in) (mm) (kN) 40% 70% 100% 40% 70% 100% 40% 70% 100% 40% 70% 100%
1 1/2 M39 10 1/2 219 1,15 346 553 968 1383 303 530 757 189 331 472 131 229 327
1 1/2 M39 12 3/4 276 1,13 346 541 947 1353 296 518 740 185 323 462 128 224 320
2 M52 14 1/4 298 1,15 644 562 984 1405 351 614 877 243 425 607
2 M52 15 3/4 337 1,14 644 556 972 1389 347 607 867 240 420 600
2 M52 20 3/4 464 1,11 644 541 946 1352 337 591 844 234 409 584
2 1/2 M64 20 1/4 435 1,13 1032 554 970 1385 384 671 959
2 1/2 M64 20 1/4 435 1,13 1032 554 970 1385 384 671 959
2 1/2 M64 30 1/2 695 1,09 1032 534 934 1334 370 647 924
2 3/4 M70 22 1/4 478 1,13 1146 615 1077 1538 426 746 1065
Table n° 3
9. DISASSEMBLING
1) Respect security instructions C.39 in Appendix E, and C90-C91A-C91B in
Appendix C and Appendix D if asbestos or ceramic fibers are sealing the flanged
assembly.
2) Chock the flanged assembly to be dismantled with wood chocks and/or hoist and
sling.
3) Loosen the bolts without removing them,
4) Use flange spreader instead of wedges. Space the flanges, facing the flanged
assembly which will be in the direction of the wind (wind in the back),
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6) Inspect the supports, gaskets, stud bolts and line. In the event of an anomaly the
Pipe fitter Foreman fills the anomaly report card (Appendix B) which is then
transmitted to COMPANY for decision,
7) If necessary, grease the nuts, bolts, stud bolts.
10. IDENTIFICATION AND FOLLOW UP

According to the Quality requirements required by COMPANY, the flanged assembly can be
identified by a color code or/and a label.
10.1 COLOR CODE
A color code can be used to identify:

x provisional gaskets : none
x not tested final gaskets : red painting on the flange edge
x tested final gaskets : green painting on the flange edge
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x in the case of systems for which the leak test is not required, the flange edge is
directly painted in green after tightening.
The colours being specific to each production site, Pipe fitter Foreman will take care of
giving information to the assembling affected personnel on each working site.
10.2 LABEL
The label ensures the traceability of the executants for each assembly. Labels shall include
specific valve / equipment tag numbers, where necessary.
It is fixed by a wire to one of the stud bolts and at least includes the following indications:
x Ponticelli Nigeria Ltd
x ([HFXWDQW¶VQDPH
x Execution date
The figure 2 shows CONTRACTOR label:
PNL
Name : «««..
Date : ««««.
Fig.2
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Appendix A Tightening sequence: «CRISS-CROSS» method
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Appendix B Anomaly report card
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Appendix C SAFETY instruction C.90
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Appendix D Safety instruction C.91 A & B
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Appendix E Safety instruction C.39
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Appendix F Recommend torques and tensions for flange bolting
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Appendix G Flange assembly check list
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Appendix H Bolt marking for bolt tensioning
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Appendix I Bolt Elongation record sheet
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Appendix J Bolt tensioning checklist
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Appendix K Bolt tensioning Tools
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Bolt-Up Procedure for OFON Phase 2 Project

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Bolt-Up Procedure for OFON Phase 2 Project

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Document Identification Number

BOLT-UP PROCEDURE NG-018-XX-PNL-430911

Joint Venture Asset

OFON PHASE 2 PROJECT

00 IFR 27-Dec-2012 Issue for review JP FN BL

Rev. Status Date Revision memo Issued by Checked by Approved by

CHANGE RECORD PAGE

REVISION DESCRIPTION OF REVISION

00 Issue For Review

1.1 DEFINITION ........................................................................................................................................ 5

3. PERSONNEL QUALIFICATION ..................................................................................................................... 6

5. ASSEMBLING EXECUTION ........................................................................................................................... 7

5.1 General ............................................................................................................................................... 7

6.1 Choice of the method ..................................................................................................................... 10

8.1 Mock-up qualification procedure .................................................................................................. 14

8.3 Bolt tensioning calculation note ................................................................................................... 15

10. IDENTIFICATION AND FOLLOW UP ....................................................................................................... 17

10.1 Color code ....................................................................................................................................... 17

Appendix B Anomaly report card .................................................................................................................. 20

Appendix C Security instruction C.90 ........................................................................................................... 21

Appendix D Security instruction C.91 A & B ................................................................................................ 22

Appendix E Security instruction C.39 ........................................................................................................... 23

Appendix F Recommend torques and tensions for flange bolting ............................................................ 24

Appendix G Flange assembly check list ....................................................................................................... 25

Appendix H Bolt marking for bolt tensioning ............................................................................................... 26

Appendix I Bolt Elongation record sheet .................................................................................................... 27

Appendix J Bolt tensioning checklist ........................................................................................................... 28

Appendix K Bolt tensioning Tools ................................................................................................................ 29

1.2 REFERENCE DOCUMENTS

ASME B 31.3 Process Piping

Alloy Steel and Stainless Steel Bolting Material for High

ASME B 18.2.1 Square and Hex. Bolts and Screws

1.2.2 TOTAL GENERAL SPECIFICATION

GS PVV 146 Bolting for piping

GS PVV 112 Piping material class

GS PVV 171 Steel Piping Fabrication

External protection of off-shore and Coastal Structures and

1.4 RANGE OF APPLICATION

5.2 CHECKLIST BEFORE ERECTION

1) Review potential risks for damage from surround area or activities.

Figure 1: Alignment raised face allowances for piping flanges

B = 3 mm - Maximum translation of branches or connections

8) All gaskets shall be new and unused whenever an opened assembly is to be

1) The gasket is under responsibility of pipe fitter foreman (final or temporary)

5.4 CHECKLIST AFTER ASSEMBLY

6.1 CHOICE OF THE METHOD

The method of tightening commonly used is the manual tightening method.

6.2 MANUAL TIGHTENING

1) Tighten with "CRISS-CROSS" method (sketch in Appendix A) with the suitable

6.3 BOLT TORQUING

1) Hydraulic, pneumatic or beam type torque wrenches are commonly used

1) Using Appendix F table, determine the torque values necessary to achieve

6.3.3 TORQUE TIGHTENING SEQUENCE

1) Torque bolts and nuts in a "CRISS-CROSS" pattern as shown in Appendix A

6.4 BOLT TENSIONING

1) The advantage of this method lies mainly in the homogeneity of tightening. It

6.4.2 BOLT TENSIONING PROCEDURE

used, reference shall be made to the equipment's manufacturer

7. MAXIMUM BOLT STRESS

7.2 CHECK OF FINAL BOLT STRESS

MAXIMUM BOLT STRESS

BOLT MATERIAL MAX. BOLT STRESS, ı (Mpa)