Plant Client Code Doc ID Code Project No.

Fertilizer NCIC
Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

Method Statement For Bolt Tightening

Page 1 of 28

Method Statement For Bolt Tightening

00 IFE ISSUED FOR EXECUTION 22-06-2021 A.EL SHAFEY 22-06-2021 A.EL SHAFEY 22-06-2021 A.KHEDR
Rev. Status Description Date Prepared Date Checked Date Approved AC
3
Category Code

Bar code
Plant Client Code Doc ID Code Project No.
Fertilizer NCIC
Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

Method Statement For Bolt Tightening

REV. 02 Page 2 of 28

CONTENT
1. Scope

2. References

3. Responsibilities.

4. Pre-Assembly Inspection

5. Torquing

6.Torquing Tools

7. Stud Bolt Tightening Procedure

9. Report's
Plant Client Code Doc ID Code Project No.
Fertilizer NCIC
Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

Method Statement For Bolt Tightening

REV. 02 Page 3 of 28

Index:

Subject Page No.

Figure.1 Tightening Sequences

Table- 01 – Friction Factors for Different Lubricants

ANNEX A – BOLT Torque Value

BOLT TIGHTENING CERTIFICATE

1.0 Scope

1.1 this procedure defines minimum requirements for tightening bolted flanged joints. it is
applicable for all flanges not included during hydrotesting or disassembled after test.

1.2 this procedure for carbon steel flanges , stanless steel flanges and steel alloy only , other
material identify by vendor .

1.3 this procedure is applicable for all pressure piping systems in conjunction with piping
systems .

2.0 Codes & Standards

2.1 PES-PIP-35 PIPING BOLT TIGHTENING

2.2 ASME PCC-1 GUIDELINES FOR PRESSURE BOUNDARY BOLTED FLANGE JOINT
ASSEMBLY.

3- Responsibilities:
3.1 construction engineer responsibility to check for paralism, flange surface,
gasket material, shall be done during construction phase .

3.2 Applying required torque values as per attached tables, will be hydrotest engineer
responsibility.

3.2 ASME PCC-1 has been referenced to be used as a document for more guidance

3.3 Gaskets should be standard and validaty , if defferent type or material of gasket is used
the value for torque and tension need to be recaculated by TKIS engineering .
Plant Client Code Doc ID Code Project No.
Fertilizer NCIC
Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

Method Statement For Bolt Tightening

REV. 02 Page 4 of 28

*PTJ should be assigned separate teams with focal point to check all flange management
application.( parallelism, flange surface, gasket material,bolts, tightening,......)

4- Pre-Assembly Inspection:
4.1 Pre-Assemby for flange out of scope of this procedure, and shall be covered by construction team
during construction stage and shall include checks for following:-

- during erection of piping spools, The gasket and flange surface will be verified for correct
type, rating, material and compatibility with the flange facing.
- during construction stage Bolts, nuts and washers will be visually checked for proper size,
grade, dimension and for any physical damage to shanks or threads which would affect the
bolt assembly or performance.

5- Torquing:
5.1 torque tightening will be conduct after hydrotest for only flange joints which not included
during accepted hydrotesting ( end limits, temporary connections …etc) or joints which
disassembled after test.
5.2 Molykote 1000 will be used as lubricant for bolts and nuts. Which has 0.11 friction
coefficient (group B as per attached table) on all bolts with design temperature <=650C
except 3 isos in the erection line list with temperatures above 650 C
These isos are:
1031B002.P1
1081B001.P2
3121U005-R02.P1
5.3 tightening tools will be checked for adequacy, performance and calibration, if required.
5.4 verify that lubricant is not used on the gasket seating area.
5.5 Torque values will be according to flange rating, bolt size, type of gasket, and friction
factor of the thread lubricant as per attached tables.

6- Torquing Tools:
6.1 tools which will be used ,manual torque wrenchs upto 1200 n.m and hydraulic
torque wrench up to 12000 n.m
6.2 The manufacturer's instructions will be followed for the operation, limitation and
maintenance of all torque wrenches used to perform flange bolts tightening.

7- Stud Bolt Tightening Procedure:

Step 1 Check align flanges and gasket. Forced tightening is not allowed to overcome non
acceptable alignment tolerances.
Step 2 Apply lubricant to stud threads over length and nut engagement and to face of nut
which contacts flange. Ensure that the nuts run freely down the thread of the
studs.
Step 3 Tighten studs per the Stud Bolt Tightening Sequence per Annex A with an
appropriate tool.
Plant Client Code Doc ID Code Project No.
Fertilizer NCIC
Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

Method Statement For Bolt Tightening

REV. 02 Page 5 of 28

Step 4 Tighten the stud bolts in stages to obtain the final required torque from the
appropriate torque Tables attached.

9- Reports:
Figure -01 – Stud Bolt Tightening Sequence
Plant Client Code Doc ID Code Project No.
Fertilizer NCIC
Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

Method Statement For Bolt Tightening

REV. 02 Page 6 of 28

Table.01 Lubricants Friction Factors

Notes

1 - Lines for oxygen service, lubricants shall not be used at all on any part of the joint.
2- Bolt torque per bolt shall be as per details of tkIS approved values for bolt sizes and application where torque
wrench is sufficient or use of hydraulic bolt tightening tool is mandatory.
3- Whether hand or hydraulic operated calibrated tightening tool shall be used
4- Each bolt shall be numbered so that the sequence of tightening can be easily followed.
5- In the case of a jointing of flanges from different pipe classes (different materials of construction) e.g. carbon
steel to stainless steel, the lowest bolt torque / bolt tension force shall be used based on bolt size and application.
Plant Client Code Doc ID Code Project No.
Fertilizer NCIC
Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

Method Statement For Bolt Tightening

REV. 02 Page 7 of 28

6- The flanged joint shall be tightened using a 30 %, 70 % and 100 % pass procedure as per bolt tightening
pattern shown in Annex D to ensure homogenous bolt loading.
7- THINNER will be used to clean the seating face of stainless steel materials.

ANNEX.A TORQUE VALUES:

Plant Client Code Doc ID Code Project No.
Fertilizer NCIC
Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

Method Statement For Bolt Tightening

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Plant Client Code Doc ID Code Project No.
Fertilizer NCIC
Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

Method Statement For Bolt Tightening

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Plant Client Code Doc ID Code Project No.
Fertilizer NCIC
Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

Method Statement For Bolt Tightening

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Plant Client Code Doc ID Code Project No.
Fertilizer NCIC
Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

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Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

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Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

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Plant Client Code Doc ID Code Project No.
Fertilizer NCIC
Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

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Plant Client Code Doc ID Code Project No.
Fertilizer NCIC
Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

Method Statement For Bolt Tightening

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Plant Client Code Doc ID Code Project No.
Fertilizer NCIC
Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

Method Statement For Bolt Tightening

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Plant Client Code Doc ID Code Project No.
Fertilizer NCIC
Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

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Intermediate Chemicals

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Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

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Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

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Plant Client Code Doc ID Code Project No.
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Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

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Plant Client Code Doc ID Code Project No.
Fertilizer NCIC
Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

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Plant Client Code Doc ID Code Project No.
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Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

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Plant Client Code Doc ID Code Project No.
Fertilizer NCIC
Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

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Plant Client Code Doc ID Code Project No.
Fertilizer NCIC
Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

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Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

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Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

Method Statement For Bolt Tightening

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 After completion of tightening, each flange connection shall be physical tagged involves :
1 – test pressure system .
2 - isometric nomber .
3 - torque or tension value .
4 - tools ( type and serial nomber )
5 – tightening date .

 Calibration certificates of torque wrenches, tensioners, pumps, and pressure gauges shall be submitted
for review by tkIS.

 Any connection point with equipment shall be witnessed by TKIS and PTJ should be send notification

 Plastic tie wrap should be used to connect the tag with flange .
Plant Client Code Doc ID Code Project No.
Fertilizer NCIC
Complex El Nasr Company for NCIC PTJ-CMM-8831-EC-00003 KXEO-01100
Intermediate Chemicals

Method Statement For Bolt Tightening

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