BOLT TENSIONING SPECIFICATION

PROJECT: CAPACITY AUGMENTATION OF IOCL LPG IMPORT TERMINAL, KANDLA, GUJARAT.

Owner:

INDIAN OIL CORPORATION LIMITED,

MUMBAI

Consultant:
PROJECTS & DEVELOPMENT INDIA LTD,
VADODARA

VTV JOB NO. : 3281

DOCUMENT NO. : VTV-3281-LIT-9511-PP-DOC-052

1 04-02-2021 ISSUED FOR REVIEW G.A RV KRM

0 27-01-2021 ISSUED FOR REVIEW G.A RV KRM

PREPARED CHECKED APPROVED

REV DATE DESCRIPTION
BY BY BY
 Owner INDIAN OIL CORPORATION LIMITED
Consultant PROJECTS & DEVELOPMENT INDIA LTD
Document
BOLT TENSIONING SPECIFICATION
Name
Doc. No. VTV-3281-LIT-9511-PP-DOC-052
VTV Job No.: 3281
Date 04-02-2021 Rev. 1

CONTENTS

1.0 INTRODUCTION 3

2.0 SCOPE OF WORK 3

3.0 APPLICATION OF BOLT TENSIONING 3

4.0 TERMINOLOGY 3

5.0 REFERENCE CODES AND STANDARDS 4

6.0 ENVIRONMENTAL CONDITIONS 4

7.0 GENERAL REQUIREMETS: 4

8.0 BOLTS REQUIREMENT: 6

9.0 REQUIRED BOLT TORQUE AND BOLT STRESS: 6

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 Owner INDIAN OIL CORPORATION LIMITED
Consultant PROJECTS & DEVELOPMENT INDIA LTD
Document
BOLT TENSIONING SPECIFICATION
Name
Doc. No. VTV-3281-LIT-9511-PP-DOC-052
VTV Job No.: 3281
Date 04-02-2021 Rev. 1

1.0 INTRODUCTION
IOCL Kandla, LPG import facility which is stored imported pure propane & butane in
refrigerated condition in two above ground Tanks of approx. 15,000 MT capacities each.
Presently the plant is operating at through put capacity about 1 MMTPA. Work site is located
at LPG import plant, Kandla near Kandla Port (KPT) and around 8 km from nearest city
Gandhidham
IOCL intends to augment the capacity of LPG import plant, Kandla from present capacity of
about 1 MMTPA to 2.5 MMPTA

2.0 SCOPE OF WORK

This standards defines the minimum requirements procedures for tightening bolts on
mechanical installations required for IOCL pipeline and related facilities.

3.0 APPLICATION OF BOLT TENSIONING

3.1 Bolt tensioning is now the preferred method of tightening of bolts and studs on all critical
applications. Bolt tensioners are designed for operation in a wide variety of applications
including pipeline flanges, heat exchangers, Pressure vessels, compressor covers, boiler feed
pumps, etc., In comparison to traditional tightening methods, tightening with bolt tensioners
offers significant advantages:
• No torsional loading of fasteners
• Direct loading – no damage to assembly
• Easy and fast operation
• Very high accuracy and repeatability
• Automation feasible and can be used for critical applications
3.2 Bolt tensioners offer the quickest, safest and most accurate means of applying a specific
residual load to stud bolts. Stud bolt tensioners can be used to easily achieve an accurate and
pre-determined bolt loading in a single, simultaneous operation the providing uniform gasket
compression, essential for the integrity of critical bolted connections.
3.3 Ideally all bolts in the joint should be tensioned simultaneously (100%), however 50%, 33%
or even 25%. Simultaneous tensioning can be carried out, which then requires the operator to
make two, three or four tensioning operations by moving around the bolts in diametrically
opposed fashion. Whilst partial tensioning will take longer to complete the task, it enables the
user to optimise between the cost of the equipment and the available time.

4.0 TERMINOLOGY
• IOCL INDIAN OIL CORPORATION LIMITED
• LPG LIQUEFIED PETROLEUM GAS

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 Owner INDIAN OIL CORPORATION LIMITED
Consultant PROJECTS & DEVELOPMENT INDIA LTD
Document
BOLT TENSIONING SPECIFICATION
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Doc. No. VTV-3281-LIT-9511-PP-DOC-052
VTV Job No.: 3281
Date 04-02-2021 Rev. 1

5.0 REFERENCE CODES AND STANDARDS

5.1 In the event of conflict between this specification and the codes referenced herein, the
most stringent requirements shall apply, unless otherwise specified.
Any exceptions or deviations from this document, along with their merits & justification,
shall be brought to the attention of IOCL controlling department for their review,
consideration and amendment by standards division (if required).
5.2 List of applicable codes and standards (Latest revision shall be applicable):
ASME B16.5 Pipe flanges and Flanged fittings NPS 1/2 through NPS 24
ASME B31.3 Process Piping
ASME B16.20 Metallic gaskets for pipe flanges: Ring joint, spiral wound and
Jacketed
ASME B16.21 Non-metallic Flat gaskets for pipe flanges
ASME PCC-1 Guidelines for Pressure Boundary Bolted Flange Join Assembly
ASME B18.2.1 Square, Hex, Heavy Hex, and Askew Head Bolts and Hex, Heavy
Hex, Hex flange, Lobed Head, And Lag Screws (Inch Series)
ASME B18.2.2 Nuts for general applications: Machine screw nuts, Hex, Square,
Hex flange, and coupling nuts (Inch Series)
VTV-3281-LIT-9511- Piping Material Specification
PP-DOC-002
ASME Section-VIII
Boiler and Pressure Vessel Code
Div.1 & Div. 2 1

6.0 ENVIRONMENTAL CONDITIONS

6.1 The Environment of India is moderate, and pipes will be subjected to rain, dust, chemical
contaminants and extreme temperature. The maximum metal temperature (MMT) due to solar
Gain: 65 Deg C
Minimum ambient Temperature : 7 Deg C (for Hot service)
Maximum Ambient temperature : 41 Deg C (for Cryogenic service)

7.0 GENERAL REQUIREMETS:

7.1 The contractor shall follow the “Legacy-Cross-Pattern-Bolt-Tightening-Procedure using
single tool, which is recommended by the ASME, and has been successfully applied
throughout the industry as the standard Best Practices.

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 Owner INDIAN OIL CORPORATION LIMITED
Consultant PROJECTS & DEVELOPMENT INDIA LTD
Document
BOLT TENSIONING SPECIFICATION
Name
Doc. No. VTV-3281-LIT-9511-PP-DOC-052
VTV Job No.: 3281
Date 04-02-2021 Rev. 1

7.2 The procedure and tightening sequence is illustrated in Table-1, Table-2 and Table-3 and
Figure-1 & Figure-2 of the appendices.
7.3 The contractor shall not adopt or apply alternative Bolt-Tightening Procedures without the
permission and approval of IOCL.
7.4 The relationship used by ASME SEC VIII.Div.1 and ASME PCC-1 for the determination of
Bolt-Torque for any bolted assembly is given below:
a) Bolt Torque – T(ft-lb) = [Bolt stress (PSI) x Bolt Dia. (in) x Bolt Root Area (in^2) x Coef.of
Friction] / 12
b) Bolt stress – S (Psi) = [Gasket stress (Psi) x Gasket Area (in^2)] / (No. of Bolts x Bolts root
area (in^2))
7.5 The contractor shall maintain a record (in tabulated form) of Bolt-torque, Bolt-tightening
sequence and other necessary details for each flanged joints which has bolt size one inch and
above for all flange ratings (Class 150 and above) for all services and shall submit the record
to IOCL for review and comments / approval.
7.6 The contractor shall appoint suitable flanged-joint-assemblers exclusively and adequately
trained and well-experienced with torque-tools, tension-tools and other bolt-tightening tools to
carry out the bolt-tightening appropriately.
7.7 The contractor shall adopt the measures as described below before starting the bolt
tightening procedure:
7.7.1 Ensure the faces of mating flanges are parallel and they touch the gasket all around
uniformly and evenly when loosely assembled before tightening of bolts.
7.7.2 Ensure that the gaskets lies perfectly between the raised faces and is in full contact
with the raised faces of flanges in case of raised face flanges.
7.7.3 Bolt threads shall be free of foreign matter such as rust, sand or grit and shall be
well lubricated with the recommended lubricant suitable for the service and the system
temperature.
7.7.4 All nuts should run-up finger tight before applying wrench.
7.7.5 Appropriate torque wrench (adjustable tension meter) shall be used to achieve the
required bolt torque as recommended.
7.7.6 The recommended bolt stress or torque shall be applied incrementally on flange
bolts in a Legacy-Cross-Pattern-Sequence as illustrated in Figure-1 and Figure-2 and
Table-1, Table-2 and Table-3.
7.7.7 Appropriate pneumatic or hydraulic wrench shall be used to tighten the flange bolts.
It is not recommended to use ordinary wrenches or spanners or non-standards tools.

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 Owner INDIAN OIL CORPORATION LIMITED
Consultant PROJECTS & DEVELOPMENT INDIA LTD
Document
BOLT TENSIONING SPECIFICATION
Name
Doc. No. VTV-3281-LIT-9511-PP-DOC-052
VTV Job No.: 3281
Date 04-02-2021 Rev. 1

7.7.8 It shall be ensured that pre-stress should not be more than 20-30%of the final /
target bolt stress.
7.7.9 A final tightening of bolts in circular pattern shall be performed to ensure that all
bolts have been evenly and fully stressed.

8.0 BOLTS REQUIREMENT:

8.1 The contractor shall fully ensure that the stud bolts & nuts used for each flanged joint are
appropriate material, type, size and length.
8.2 Use of appropriate bolt is highly essential to transfer proper, uniform and required bolt load
or exert pressure on flange to seat the gasket perfectly and achieve a fully tight and leak-free
joint.
8.3 Using stud bolts of inappropriate size, type and material shall fail to transfer the required
load/ pressure on the gaskets and as a result the joint may leak any time during the operation.
8.4 The improper bolts generally fail from the threads or elongate (extend) due to applied
torque / force combined with high operating temperature and thus give way to leakage.

9.0 REQUIRED BOLT TORQUE AND BOLT STRESS:

9.1 Appropriate torque shall be applied on all bolts equally and uniformly in order to induce
uniform pressure to properly seat the gasket.
9.2 The bolt pressure transferred to the flange depends on several variables as described
below:
• Diameter of the bolt
• Diameter of bolt at the root of threads
• Type and number of threads on the bolt
• Material Specification of the bolt
• Lubrication of bolt threads and nut bearing surfaces
9.3 To determine the correct bolt-torques and stresses required for appropriate seating of the
gasket to achieve a leak free joint.
9.4 The use of appropriate torque-wrench that should be capable to produce the
recommended / required torque in the bolt.

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 Owner INDIAN OIL CORPORATION LIMITED
Consultant PROJECTS & DEVELOPMENT INDIA LTD
Document
BOLT TENSIONING SPECIFICATION
Name
Doc. No. VTV-3281-LIT-9511-PP-DOC-052
VTV Job No.: 3281
Date 04-02-2021 Rev. 1

APPENDIX I:

FIGURE-1: LEGACY-CROSS-PATTERN TIGHTENING SEQUENCE FOR 12 BOLTS

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 Owner INDIAN OIL CORPORATION LIMITED
Consultant PROJECTS & DEVELOPMENT INDIA LTD
Document
BOLT TENSIONING SPECIFICATION
Name
Doc. No. VTV-3281-LIT-9511-PP-DOC-052
VTV Job No.: 3281
Date 04-02-2021 Rev. 1

APPENDIX I: - cont.+.

FIGURE-2: LEGACY-CROSS-PATTERN TIGHTENING SEQUENCE FOR 48 BOLTS

Note 1: In large size flanges, the bolt holes may be grouped, as shown above, in order to
determine the next / subsequent bolt while tightening.

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 Owner INDIAN OIL CORPORATION LIMITED
Consultant PROJECTS & DEVELOPMENT INDIA LTD
Document
BOLT TENSIONING SPECIFICATION
Name
Doc. No. VTV-3281-LIT-9511-PP-DOC-052
VTV Job No.: 3281
Date 04-02-2021 Rev. 1

APPENDIX II:
TABLE-1: LEGACY-CROSS-PATTERN TIGHTENING PROCEDURE USING SINGLE TOOL

S.NO Tightening Steps Description

Hand tighten from 15 Nm (10 ft-lb) to 30 Nm (20 ft-lb) approximately

(not to exceed 20% of target torque) check flange gap around
1 INSTALL circumference for uniformity. If the gap around the circumference is
not reasonably uniform, make the appropriate adjustments by
selective hand-tightening before proceeding to next step.

Tighten form 20% to 30% of target torque. Check flange gap around
circumference for uniformity. If the gap around the circumference is
2 ROUND 1
not reasonably uniform, make the appropriate adjustments by
selective tightening / loosening before proceeding.

Tighten to 30% to 70% of target torque. Check flange gap around

circumference for uniformity. If the gap around the circumference is
3 ROUND 2
not reasonably uniform, make the appropriate adjustments by
selective tightening / loosening before proceeding.

Tighten to 100% of target torque. Check flange gap around

circumference for uniformity. If the gap around the circumference is
4 ROUND 3
not reasonably uniform, make the appropriate adjustments by
selective tightening / loosening before proceeding.

Continue tightening the bolts, but on circular clockwise pattern until

no further nut rotation occurs at the Round 3 Target torque value.
5 ROUND 4
For indicator bolting, tighten bolts until the indicator rod retraction
readings for all bolts are within the specified range.

Time permitting: Wait a minimum of 4hrs and repeat the Round 4:

this will restore the short term creep relaxation / embedment losses.
If the flange is subjected to a subsequent test pressure higher than
6 ROUND 5
its rating. It should be repeated after the test is completed. Also
round 5 may be repeated after the system has attained the desired
temperature service.

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 Owner INDIAN OIL CORPORATION LIMITED
Consultant PROJECTS & DEVELOPMENT INDIA LTD
Document
BOLT TENSIONING SPECIFICATION
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Doc. No. VTV-3281-LIT-9511-PP-DOC-052
VTV Job No.: 3281
Date 04-02-2021 Rev. 1

APPENDIX II: ++.cont.

TABLE-2: LEGACY-CROSS-PATTERN TIGHTENING PROCEDURE SUMMARY OF TABLE-1

Steps Install Round 1 Round 2 Round 3 Round 4 Round 5 NOTES

All bolts As per

All bolts All bolts All bolts All bolts circular ASME, this
Legacy All bolts
star or star or star or star or pattern assembly
cross circular
cross cross cross cross until no procedure
pattern pattern
pattern pattern pattern pattern further nut has been
movement successfully
applied
throughout
Percentage industry for
Tight by
of Final 30% 70% 100% 100% 100% all gasket
Hand
Torque styles and
flange types

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 Owner INDIAN OIL CORPORATION LIMITED
Consultant PROJECTS & DEVELOPMENT INDIA LTD
Document
BOLT TENSIONING SPECIFICATION
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Doc. No. VTV-3281-LIT-9511-PP-DOC-052
VTV Job No.: 3281
Date 04-02-2021 Rev. 1

APPENDIX II: ++.cont.

TABLE -3: LEGACY-CROSS-PATTERN TIGHTENING SEQUENCE AND BOLT NUMBERING
SYSTEM USING SINGLE TOOL

No. of Bolts Sequentially Clockwise Sequence (Note 1)

4 1-3-2-4

8 1-5-3-7 2-6-4-8

12 1-7-4-10 2-8-5-11 3-9-6-12

16 1-9-5-13 3-7-11-15 2-10-6-14 4-12-8-16

20 1-11-6-16 3-13-8-18 5-15-10-20 2-12-7-17 4-14-9-19

24 1-13-7-19 4-16-10-22 2-14-8-20 5-17-11-23 3-15-9-21 6-18-12-24

1-15-8-22 4-18-11-25 6-20-13-27 2-16-9-23 5-19-12-26 7-21-14-28

28
3-17-10-24

1-17-9-25 5-21-13-29 3-19-11-27 7-23-15-31 2-18-10-26 6-22-14-30

32
4-20-14-28 8-24-16-32

1-2-3 19-20-21 10-11-12 28-29-30 4-5-6 22-23-24 13-14-15 31-

36
32-33 7-8-9 25-26-27 16-17-18 34-35-36

Note 1: The numbers shown above refer to bolt sequence which must be followed in clockwise
sequence while tightening bolts

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 Owner INDIAN OIL CORPORATION LIMITED
Consultant PROJECTS & DEVELOPMENT INDIA LTD
Document
BOLT TENSIONING SPECIFICATION
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Doc. No. VTV-3281-LIT-9511-PP-DOC-052
VTV Job No.: 3281
Date 04-02-2021 Rev. 1

APPENDIX II: ++.cont.

TABLE 4 - BOLT TORQUE FOR LOW ALLOY STEEL BOLTS BASED ON TARGET
PRESSURE OF 50 KSI (ROOT AREA)

Nominal Bolt BOLT TORQUE (ft-lb)

S.NO
size (in) NON COATED BOLTS COATED BOLTS
1 1/2 60 45
2 5/8 120 90
3 3/4 210 160
4 7/8 350 250
5 1 500 400
6 1 1/8 750 550
7 1 1/4 1050 800
8 1 3/8 1400 1050
9 1 1/2 1800 1400
10 1 5/8 2350 1800
11 1 3/4 2950 2300
12 1 7/8 3650 2800
13 2 4500 3400
14 2 1/4 6500 4900
15 2 1/2 9000 6800
16 2 3/4 12000 9100
17 3 15700 11900
18 3 1/4 20100 15300
19 3 1/2 25300 19100
20 3 3/4 31200 23600
21 4 38000 28800

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 Owner INDIAN OIL CORPORATION LIMITED
Consultant PROJECTS & DEVELOPMENT INDIA LTD
Document
BOLT TENSIONING SPECIFICATION
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Doc. No. VTV-3281-LIT-9511-PP-DOC-052
VTV Job No.: 3281
Date 04-02-2021 Rev. 1

Note-1 The bolt torque value shown above are based on target pressure of 50 ksi (root area). To
circulate Bolt-Torque for different Target Prestress, refer ASME PCC section 12. The above value
based on coarse threads series for bolt size 1 inch and smaller and on 8 pitch threads series for
bolt size 1 1/8 inch and larger.

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 Owner INDIAN OIL CORPORATION LIMITED
Consultant PROJECTS & DEVELOPMENT INDIA LTD
Document
BOLT TENSIONING SPECIFICATION
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Doc. No. VTV-3281-LIT-9511-PP-DOC-052
VTV Job No.: 3281
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