Code: B-CONS-P -001

BONGKOT CONSTRUCTION PROCEDURE

Revision No: 00

Flanged Joint Tightening Procedure- Hand Torque Effective Date: January 2011

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B-CONS-P- 001
Flanged Joint Tightening Procedure - Hand Torque
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REVIEW AND APPROVAL SHEET

Prepared by: (DBF/N) Reviewed by: (DBF) Reviewed by: (CSH) Approved by: (DBA)

Name: Denchai A. Name: Y.Pinol / Name: Jirapong D. Name: Nawee A.

/Yospong Dittapon S.

Signature: Signature: Signature: Signature:

Date: Date: Date: Date:

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CONTENTS

1 PURPOSE ............................................................................................................................. 4

2 SCOPE .................................................................................................................................. 4

3 APPLICATION ...................................................................................................................... 4

4 DEFINITIONS........................................................................................................................ 4

5 RELATED DOCUMENT/REFERENCES ............................................................................. 5

6 APPROVED OPERATORS ................................................................................................. 5

7 SAFETY ................................................................................................................................ 5

8 PRE-JOB-CHECK ................................................................................................................ 5

9 JOB-SPECIFIC CHECKS ..................................................................................................... 6

10 EQUIPMENT ......................................................................................................................... 6

11 CALIBRATION...................................................................................................................... 6

12 LUBRICATION OF NUT/BOLT ASSEMBLIES ................................................................. 6

13 RECOMMENDED BOLT TIGHTENING PROCEDURE ...................................................... 7

14 TOOL FITTING & OPERATION .......................................................................................... 8

15 SAFETY REQUIREMENTS ................................................................................................. 8

16 TORQUE TIGHTENING - DO'S AND DON'T'S ................................................................... 9

17 PINCH POINTS AND CORRECT REACTION METHODS .............................................. 9

18 SUMMARY OF WRENCH SAFETY POINTS .................................................................... 10

19 TORQUE TABLE - GUIDELINE ........................................................................................ 11

20 FORMAT ........................................................................................................................... 14

21 ANNEX .............................................................................................................................. 15
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1. PURPOSE

The purpose of this Bongkot Construction Procedure (BCP) is to ensure that all operations can be done
as BKT - Bolt Joint Integrity Management.

2. SCOPE

This procedure covers the hand tool torque for flange tightening by means of conventional or
multiplier hand torque wrench and should be used as the best practice internal procedure to
follow. It is the objective of the procedure to provide a sealed flange first time in a safe
manner whenever applied.
Only the surface facility process piping to be employed in this scope.

3. APPLICATION

This procedure applies to any flanges, which have been assembled to be torque tightening.

4. DEFINITIONS

Flange alignment Final position in the accepted critical/Left-Right & Up

Methods/procedure to assembly flanges for the -Down

Applied Torque Torque applies to a nut/bolt assembly by means of a

calibrated Torque Wrench

JIMS & JDMS /Others Software used for planning, managing and implementing
Joint Integrity Assurance

Boltup & Informate /Others Bolt load calculation software that tightening
Methods, tooling selection, torque and tension values.

Joint Completion Certificate A Report completed giving details of the tightened joint.

Tag Tag, which is affixed to the flange before & after

tightening to detail joint status for quick verification and
traceability.

Witnessed Joint Certificate A Report completed giving details of the witness joint.

Hand Torque Wrench Manual wrench /ratchet design torque wrench with
Interchangeable square drive and hexagon cassettes
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5. RELATED DOCUMENTS/REFERENCES

5.1. ASME B16.5

5.2. ASME B46.1
5.3. ASME B16.20
5.4. ASME-PPC-1-2000
5.5. TOTAL
5.6. GS PVV 146
5.7. GS PVV 171
5.8. ECITB NSDS PF019 Assembly and Tightening of Bolted Connections.
5.9. Manufacturer manual - Tools /Equipment
5.10. BS 2092-2.

6. APPROVED OPERATORS

Required person to operate this type of tools to be trained and understand how to operate/set-
up. BCT1 card will be issued for person after training this module and capability to operate
this type of tools as defined scope or the person/contractors shown that his/her have a
experience/training with this type of tools.

7. SAFETY FIRST

Manual / Multiplier tools enable the user to more easily accomplish bolting tasks with increased accuracy
and efficiency. However, the user must accept the primary responsibility of safety when using tools by
Carrying out site related risk assessments, reading, understanding, and complying with all
Operating instructions prior to and during operation.
In a commitment to facilitate user understanding of all operating instructions.
This procedure and additional safety related sections contained towards the end of this document
are designed to assist in the proper instruction for use and care of tools and play a major
role in preventing accidents and increasing safety.

8. PRE-JOB-CHECKS

8.1 Scope of Work has been identified

8.2 On-site Technical Procedure has been read and understood
8.3 Pipeline or vessel is free of pressure - if not STOP until a specific risk assessment is
carried out and Safe method approved.
8.4 Site specific Permit to Work is in place
8.5 Generic Risk Assessment has been read and understood
8.6 Job specific Risk Assessment has been carried out
8.7 All members of the work party have read, understood and signed:
8.8 Permit to Work
8.9 Job Specific Risk Assessment
8.10 PPE is suitable and sufficient for the task
8.11 Equipment is suitable for the task, tested and in serviceable condition
8.12 Access and egress to the work site is adequate and scaffold fit for purpose,
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9. JOB-SPECIFIC-CHECKS

9.1. Check that the torque values to be applied have been recommended by the manufacturer,
Client or bolt load calculation software and are applicable to the tools being
used and for the flange and bolt material being tightened.
9.2. Check the flange is correctly assembled and all nuts and bolts are correctly set for
protrusion, with nut stampings visible and not against the flange face.
9.3. If any check falls out of limit then the Technical Authority is to be informed for rectification.
If rectification is not carried out, details are to be included on the Joint Completion
Certificate or recorded in JIMS/JDMS.
9.4. Select a wrench that will complete the tightening operation within 75% of maximum output

10. EQUIPMENT

Torque Wrenches have different size square drive or direct fit hexagon cassettes that
Output various torque loads. Square drive vs. torque output data can be found in operating
Manuals or technical data spec sheets.

11. CALIBRATION

The tool must have a Calibration Certificate valid for the date of the task. If the tool has no
Valid certificate, it should be re-calibrated or changed.

12. LUBRICATION OF NUT/BOLT ASSEMBLIES

If a lubricant is to be used, the following must be adhered to: -

12.1. Only approved lubricant will be used.

12.2. Never lubricate bolts with compounds that cannot be identified or where its coefficient of friction is not
known.
12.3. All instructions for Torque Tightening should specify a Torque Value to be used with the specific
lubricant. If not, consult with the Engineer responsible for the job or your consultant/vendor.
12.4. If the nut/bolt assemblies have been lubricated, check if it has been completed correctly and that
(12.1) and (12.2) above are known.
12.5. If a lubricant needs to be applied, the correct procedure should be followed.
12.6. The lubricant must be applied to the nut seating face and the portion of bolt that the nut will be turning
around the end to be tightened only. Apply the lubricant to the bolt and rotate the nut up and down the
bolt to spread the lubricant evenly. If possible, do this with the bolt out of the flange to ensure the
lubricant is spread correctly.
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13. RECOMMENDED FLANGE BOLT TIGHTENING PROCEDURE

13.1 Measure the flange gap at a minimum of four points around the flange (larger flanges should be at
eight points)
13.2 The bolt tightening sequence should begin at the point of the largest gap!
13.3 Mark the correct tightening sequence on the studs in a clockwise direction with chalk as per
diagram. For the correct sequence see (ASME-PPC-1-2000).

Criss-Cross Tightening Sequence Examples:

4 - Bolt Flange: 1-3-2-4

8 - Bolt Flange: 1-5-3-7-2-6-4-8
12 - Bolt Flange: 1-5-9-3-7-11-2-6-10-4-8-12
16 - Bolt Flange: 1-9-5-13-3-11-7-15-2-10-6-14-4-12-8-16
20 - Bolt Flange: 1-13-5-17-9-3-15-7-19-11-2-14-6-18-10-4-16-8-20-12
28 - Bolt Flange: 1-13-21-5-17-9-25-3-15-23-7-19-11-27-2-14-22-6-18-10-26-4-16-24-8-20-12-28
32 - Bolt Flange :1-17-9-25-5-21-13-25-3-19-11-31-7-29-15-27-2-18-10-30-6-22-14-26-4-20-12-32-
8-24-16-28

Note: Correct numbering of bolts should result in all odd numbered bolts around one side of the flange and
all even numbered bolts around the other side.

Marked Up 8 Bolt Flange 1st, 2nd, & 3rd Stage 4th & Final Stage

Criss Cross Sequence Adjacent Bolt Sequence

13.4 Determine the Torque Value for the flange and bolt material being tightened as recommended by the
manufacturer, client or others bolt load calculation software and that it is achievable with the tools
being used. Check that the Flange size, class, rating and bolt material match those on the data sheet.
13.5 Visually check that the flange has been correctly assembled and the correct gasket is fitted.
Check Nut Stampings are the correct way around.
13.6 First tightening stage should be limited to a maximum of 30% of the final Torque setting.
13.7 Second tightening stage should be limited to a maximum of 60% of the final Torque setting.
13.8 Third tightening stage should be carried out at the 100% Torque setting.
13.9 On the Fourth and Final tightening stage, change from diagonal tightening to adjacent bolt-to bolt
tightening clockwise using the 100% Torque setting and chase around flange until nuts finally stop
rotating.

Note: First, second and third stages should be tightened using the criss - cross tightening
Sequence and the fourth stage should be tightened using the adjacent clockwise bolt to bolt
Sequence as shown in the diagrams above
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13.10 Using a small hammer tap test each bolt to check the sound of the bolt rings true, dull or
Vibrating bolts should be retightened to the correct value.
13.11 Complete a Flange Tag and attach to the joint.
13.12 Ensure that the work area is left in a safe and tidy condition and that any Permit to Work has been
signed off.
13.13 Record all tightening information on a Joint Completion Certificate and Witnessed Joint Certificate.
13.14 Input all tightening data into JIMS & JDMS or clients Data management system if applicable.

14. TOOL FITTING & OPERATION

Torque wrenches:

Note: Operation by one person is always recommended unless the wrench cannot be handled
Safely. When two personnel are required then communication both verbal and visual must be
Maintained at all times between the tool handler and operator.

14.1 Square Drive Tools Only: Check that the correct size Impact Socket has been selected.
14.2 Check that the Square Drive is in the correct position for tightening operations.
14.3 The torque wrench is operated via a manual by adjusted value at handle. ‘Torque Control Scale’
or as manufacturers recommendation.

Note: Always remove the tool from the flange and place on a surface where reaction will not
be possible when setting/altering or adjusting reaction points!
For two men operation ensures the communication procedure is clear and understood before
proceeding.

14.4 Fit the tool onto the bolt via the nut ensuring that correct and safe reaction is achieved.
Note: Pinch Points are present around all reaction areas and in tight spaces. Hands and
fingers must be kept clear from pinch points at all times.

14.5 To tighten the nut, ****Not allows any addition/extent holder for tightening

Note: If the back nut begins to move while tightening a backing spanner must be fitted to the nut reacting
off the next adjacent nut to prevent turning. Backing spanners must be secured to prevent accidental
release by being tied off or other methods. Backing spanners also introduce pinch points.

14.6 Repeat steps 14.1-14.5 for all bolts/nut to be tightened.

15. SAFETY REQUIREMENTS

Risk Assessments will be undertaken according to Vendor and Operator procedures. This may
result in extra safety requirements. The following list gives minimum requirements.
15.1 Eye protection must be worn BS 2092-2.
15.2 Gloves must be worn.
15.3 Do not exceed maximum force for the tool.
15.4 Wear Safety boots and overalls.
15.5 Observe site-specific safety requirements.
15.6 Observe all equipment operating instructions.
15.7 Observe all safety instructions in the Operation and Maintenance Manual for the specified
Torque Wrench.
15.8 Observe COSHH instructions when using penetrating oils.
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16. TORQUE TIGHTENING DO’S & DON’T’S

Do’s

16.1 Ensure that you are fully conversant with the safe use of the tools and their operating
Procedures.
16.2 Check that the loads stated are applicable for the tools being used and for the
flange or bolt material being tightened.
16.3 Number the studs as an aid for applying the correct criss cross tightening sequence.
16.4 Make sure that the full thread engagement of the nut on the bolt has been achieved.
16.5 Hand tightens the nuts first, ensuring that the correct face of the nut will seat squarely onto the
flange surface.
16.6 Use correct lubricant and identify its co-efficient of friction before use.
16.7 Ensure that the backing spanner, if being used, is engaged correctly and secured.
16.8 Wear suitable protective clothing.
16.9 Observe COSHH instructions when using hydraulic oil or lubricating compounds.

Don’ts

16.10 Never torque damaged or corroded bolts.

16.11 Never stand in line with the bolt axis when tools are tightened.
16.12 Never hold wrenches at their pinch/reaction points when tightening.
16.13 Do not draw the flange up tight on one or two bolts, as this will cause local gasket crushing or
pinching of the gasket.
16.14 Do not over tighten bolts; take particular care with small bolts, i.e. less than 1” diameter.

17. PINCH POINTS AND CORRECT REACTION METHODS

17.1 Pinch Points are present around reaction areas and in tight spaces. Hands and fingers must
be kept clear from pinch points at all times. Examples of common pinch points are detailed
below
17.2 Improper reaction set up and /or incorrect socket size will cause a concentration of stress that
can make the tool, socket, or nut vulnerable to fracture. The common cause of socket
breakage is cocking, a condition when the socket fits over the nut at an angle. Examples of
“how to “ and “how not to” react with and without a reaction arm are detailed below.
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                                                                           Hex  &  Square  Drive  Wrench  Pinch  Points

18. SUMMARY OF WRENCH SAFETY POINTS

General

18.1 Operation by one person is always recommended unless the wrench cannot be handled
safely, then communication both verbal and visual must be maintained at all times between
the tool handler and remote control/pump operator. The tool must not be tightened without
notification from the tool handler.
18.2 Tool must be removed from application at all times and placed in a location where reaction is not
possible.
18.3 Operator must read and understand all operating instructions before using all equipment.
18.4 Incorrect reacting will cause high stresses on the tool and socket, which may result in possible
breakage and injury.
18.5 High hydraulic pressure hazard use with correct protection.
18.6 Keep hands clear from all pinch points.
18.7 Do not strike or modify any equipment.
18.8 Tool must be removed from application at all times for aligning the socket or hexagon with the nut
and reaction point. This operation will be achieved safely by rotating the drive forward manually.
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19. TORQUE TABLE - GUIDELINE

Torque values reference notes

19.1 Always use the torque table guide from vendor/gasket manufacturers - this table is only
basic reference.
19.2 The yield strength to be confirmed for each type of bolt & nut materials prior to tightening
care to be taken for the correct yield strength with proper tightening – clamping force.
19.3 The torque table guide is valid for the below bolt materials for bolt size up to 2-1/2” diameter
• A193 GR B7/A320L7/A320L43/A193 GR B16
• A193 GR B8M CLASS -2 for bolt sizes 0 – ¾” ONLY
First select the lubricant being used on the bolts/nuts and then use the torque values given in the
table under that particular lubricant.
19.4 For the above bolt materials but bolt sizes above 2-1/2” diameter – use 10% lower values than those
given in the chart.
19.5 Bolt materials: A193 GR B7M/A320L7M
Bolt sizes up to 2-1/2” diameter use 20% lower torque values than those given in the torque table
guide.
e.g. for 2” bolt size under lubricant Copper slip coefficient 0.1 the torque value in the Torque
Table Guide shows a value of 3074 ft.lbs.
So torque to be applied = 3047-(0.2x3074) =2459.20 ft.lbs
19.6 For bolt materials A193 GR B8M CLASS-1: Refer the attached torque chart especially for this
material.
19.7 For bolt materials:A193 GRB8M CLASS-2
Bolt sizes: 7/8” to 1-1/4”: use 35% lower torque value than shown in the torque table guide.
Bolt sizes: 1-3/8” to 1-1/2”: use 50% lower torque value than shown in the torque table guide.
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BOLT TENSION & TORQUE TABLE GUIDE

Bolt Material: High Strength alloy steel bolting - e.g. A193/BS4882 Gr.B7
Bolt Stress The table below gives torque values required to achieve an average bolt stress
equivalent to 50% of the bolt yield stress.

CARE SHOULD BE TAKEN TO SELECT THE CORRECT CO-EFFICIENT OF FRICTION

Bolt Bolt YIELD TENSION Moly Copper Nickle Molykote TORQUE

size size psi lbf coeff=0.06 Slip Grease 1000 DRY
(in) (in) lbf.ft coeff=0.1 coeff=0.11 coeff=0.12 coeff=0.2
lbf.ft lbf.ft lbf.ft lbf.ft

½” 0.5 105,000 6,783 28 43 46 50 79

5/8” 0.625 105,000 10,867 55 84 91 98 155
¾” 0.75 105,000 16,222 96 146 158 171 271
7/8” 0.875 105,000 22,522 153 234 254 274 435
1” 1 105,000 29,557 228 348 378 408 647
1-1/8” 1.125 105,000 38,902 331 508 553 597 953
1-1/4” 1.25 105,000 49,560 459 710 773 836 1,338
1-3/8” 1.375 105,000 61,530 616 959 1,044 1,130 1,816
1-1/2” 1.5 105,000 74,760 804 1,258 1,372 1,485 2,393
1-5/8” 1.625 105,000 89,250 1,027 1,614 1,761 1,907 3,081
1-3/4” 1.75 105,000 105,000 1,288 2,031 2,216 2,402 3,888
1-7/8” 1.875 105,000 122,325 1,592 2,519 2,751 2,982 4,836
2” 2 105,000 140,700 1,937 3,074 3,358 3,642 5,914
2-1/4” 2.25 105,000 181,125 2,766 4,411 4,822 5,233 8,521
2-1/2” 2.5 105,000 226,800 3,805 6,091 6,663 7,234 11,806
2-3/4” 2.75 9,500 251,750 4,602 7,392 8,089 8,787 14,367
3” 3 9,500 302,100 5,976 9,627 10,540 11,452 18,753
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BOLT TENSION & TORQUE TABLE GUIDE

BOLT MATERIAL: A193 GRADE B8 CLASS-1

2
Min Yield Stress 30,000 lb/in

Due to the low yield stress of the material we would suggest a maximum achieved bolt stress
2
of 85% minimum yield – 25,000 lb/in

Taking the above into account the following applies;

CARE SHOULD BE TAKEN TO SELECT THE CORRECT CO-EFFICIENT OF FRICTION

Bolt size Bolt size TORQUE VALUE lb.ft TO ACHIEVE 85% OF MIN YIELD
(in) (in) STRESS -30KSI OF A193 B8 CLASS-1
COPPER coeff=0.10 MOLY coeff=0.06 DRY coeff=0.20
lbf.ft lbf.ft lbf.ft

¾” 0.75 67 44 125
7/8” 0.875 108 71 201
1” 1 162 106 301
1-1/8” 1.125 247 160 463
1-1/4” 1.25 345 222 650
1-3/8” 1.375 465 299 882
1-1/2” 1.5 611 320 1,162
1-5/8” 1.625 784 499 1,496
1-3/4” 1.75 986 625 1,888
1-7/8” 1.875 1,223 773 2,348
2” 2 1,493 941 2,872
2-1/4” 2.25 2,142 1,343 4,139
2-1/2” 2.5 2,958 1,848 5,734
2-3/4” 2.75 3,968 2,470 7,712
3” 3 5,168 3,208 10,067

Conversion Factors
Multiply
From To by
lbf.ft Nm 1.3558
lbf.ft Kgm 0.1383
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20. FORMAT

20.1 Format - Control - CONS - 001/Rev.00/17-04-10:

20.2 Format - Control - CONS - 002/Rev.00/17-04-10
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ANNEX : REVISION STATUS

Document Title : Flanged Joint Tightening Procedure - Hand Torque
Code : B-CONS-P - 001
Effective date : August 2009
Date Revision Revision type and description
no.

March 2010 00 1. This document originally issued for “JIMS” BKT – Joint Integrity Management System as
KPI-2010
2. The topic was raised in the BONGKOT SSHE committee meeting in May 2010 to setup
“JIMS”