ASME PCC-1-2019 (Revision of ASME PCC-1-2013) Guidelines for Pressure Boundary Bolted Flange Joint Assembly AN AMERICAN NATIONAL STANDARD rs UCR eS aC ae PEEL uae cenceASME PCC-1-2019 ec c acs ie es) Guidelines for Pressure Boundary Bolted Flange Joint Assembly (AN AMERICAN NATIONAL STANDARD DOU RS UEC arDato of issuance: Sepsember 30, 2019 This Standard will be revised when the Society approves the Issuance of a new edition [ASME lsues writen replies to inquirles concerning interpretations of technical aspects cf this Standard. Pesladically certain ‘actions ofthe ASME PLC Committee may be published as Cases, Cases and interpretations are published on the ASME website under the Committee Pages at htcp/cstools asme.oraf as they are issued, Errata tp codes and standards may he ported on the ASME website undar the Committes Pages to provide corrections to ‘correctly published items, arto correct typographical or grammatical erorsin cadas and standards. Such arrata shall be used fon the date posted ‘The Committee Pages can be found at httpiffestools.aeme.org/. There is an option available to automatically receive an e-mail ‘notification when errata are postad to a particular code or standard. This aption can be found on the appropriate Committee Page after selecting “Errata” in the “Publication Infarmation” section, ASAE te the rapistered trademark of The American Seclety of Mechanical Enginears 1 oF standard wassdeveloped under proce Bares accreted ac mating te criteria for Ake can Natl Starla, The Standards omméteethatapprovedthe cede or stendard was balanced 1 assure that ndraduels fem competent andconcerned nterestshave had an ‘oppertunty to participate. The proposed cade or stangara wits made avilable for puie review and comment that previcesan apportunity {or adational public Inaut From industry, acaderia, reulatory agencies. and the publicatlarge ASME dors not "enprove, "rate" or “endorse” any lem, construction, proprietary device, ar acy ‘ASHE does no take ary postion with respect tothe validity of any patent right asarted in connection with ay terns mancione in this document and doesnot undertake to Insure anyone vtizing a standard against aby for infringement of any applicable letters patent noe ‘rume.ny suc lisbllty, Users of rote or standard aremypreasiy echoing that determination of thevalishy of ary such patent ghts, are the tisk of infringement of such rights, ig entirely their owe responstiy Pertiipstion ky federal agency representativels) or person) affliated with industry I not ta be Interpreted a government orinustry endorsement of tis code ar standard ASME accents responsibilty for ani those Interpretations of this document issued la accordance withthe established ASME procedures sand polices, which precludes he asusnee of intrpeetations by intial No part of this document may be repreduced in any form, (ean electron retrieval system or otherwise, without the ptior written permission ofthe publisher ‘The Amerian Seclety ef Mechanical Engineers ‘Two Park Avenue, New York, NY 20016-5990 Copyright © 2019 by ‘THE AMERICAN SOCEETY OF MECHANICAL ENGINEERS All rights esemed Printed in USA. ‘beeraed Lug A. Cardenas. Singh aae ense on Copy neluorng and sharing praiaForeword Commitee Rester . . Correspondence With the PCC Commitee... Summary of Changes ...--.62e eee secre ee eos ween 40 1 R B u 15 16 Appendices a woger nto memmos CONTENTS Seape oo... ese Intraduction Trai Cleaning and Examination af Flang# and Fastener Contact Surfaces «6.6... Alignment of Flanged Joints . Installation of Gasket «++. Lubrleatian of “Working” Sur Installation of Bolts . . Numbering of Bolts <5. 2000+ ‘Tightening of Bolts 22.20... Tightening Sequence « Target Torque Determination Joint Pressure and Tightness Testing... .. Records Joint Disassembly... References... 66ccececc cee Training and Qualification of Bolted Jolat Assembly Personnel .... Description of Comman Terms . Recommended Casket Contact Surface Finish for Various Casket Types «+++ e-s 4 Guldalines for Allowable Gasket Contact Surface Flamess and Defect Dapta .....02+e-+ Flange Joint Alignment Guidelines .......-. 0+. Alternatives ta Legacy Tightening Sequence /Paremn « Use of Contractors Specializing in Bolting Services Bolt Root and Tensile Stress Areas... coe ee eee Interaction During Tightening ..... Calculation of Target Torque .- Nut Factor Galewlation of Target Torque ASME BU65 Flange Bolting Information . 0.22... Washer Usage Guidance and Purchase Specification for Throuigh-Hardened Washers Definitions, Commentary, and Guidelines on the Reuse of Bolts... Assembly Bolt Stress Determination ......... Gnidance on Trout imoting Flange Jat Leakage Incidents ss Leersed to Luig A Candenas Sale wer leensecr Copying set, and sharing poh 19 35 37 aa 43 48 5a 54 él 62 68 85 66 n 7 aFigures DL D2 ba Ds DS BA E2 Ea E4 Fl F2 Fa Fa FS Fe FT Fe FS io Fat PL P2 Pa O51 QEs2 Tables AL ct Considerations for the Use of Powered Equipment ...+sesescerererers Indicator Type Bolting for Through-Bolted foints <6. eeeseeces ¥ Indicator-Type Bolting for Studded Joints ....0.0.c4cececeeeecessseese Example Legacy and Alternative to Legacy Numibering Sequences for 12-Bolt joint « - Example of 48-Bolt Flange Boke Grouping -.....2.0000000ececeeeeesvseeeeteseeee Example Short Assembly Record « Example Medium-Length Assembly Record Example Long Assembly Record Appendix Procedure Flowchart. Flange Circumferential Variation Tolerance, TE... . Flange Radial Variation Tolerance, 72 ..e.2.ccseescssecuss Flange Surface Damage Assessment: Fits and Dents... Flange Surface Damage Assessment: Scratches and Gauges... .- RT} Gasket Seating Surface Assessment ....... Conterline High/LOW . 2.00. .eeeeeeeene ee Excessive Spacing or Gap « Paraleliom 2.25 sence Rotational‘Twa Hole « Legacy Pattern Numbering System - .« Alcernative Assembly Pamtern #1 (Modified Legacy Pattern) .. ‘Alternative Assembly Paitern #2 (Quadrant Pattern) «... Alternative Assembly Pattern #3 (Circular Pattern) + «+++ Alcernative Assembly Pattern #4 (Multible Legacy Partera) ‘Alternative Assembly Pattern #5 (Multibolt Quadrant Pattern) « Alvornative Patera #1: Modified Legacy Pattorn (Single Tool)... 0s+eevveeeceeee ‘Alernative Pattern #24: Quadrant Pattern: Star Sequencing (Single Teal) Alernative Pattern #3: Circular Pattern (Single Tool) «.-+0sessessevsersteesiseeeere Alternative Pattern #4: Sknultaneous Multibolt Pattern (Four Tools)... Alternative Pattern #5; Simultaneous Multibolt Pattern Example (Two Tools) « Tapored-Hub-Type Flange .-.<.csssecevsveseceeseusesneasecce ees of Slip-On-Type Flange se. esecdveesesesicacsee Lap [olne Flange 24-Balt, 24-Taol Example... 24-Bolt, $0% (12-Too!) Example ‘Torque Increments for Legacy Cross-Pattern Tightening Using a Shngle Tool . Recommended Tool, Tightening Methed, and Load-Control Technique Selortion Based on Service Applications... .00....2 LepacyCross-Parern Tightening Sequence and Bot Numbering Systema When Using a Single Teck Aermatv tol gay rose Pattern Tightning or unce andl NunboringSyre When Using Singie Tool Guidance for Work Ste Experience « ‘ Recommended Gasket Contact Surface Finish for Various Gaskat Types ‘beeraed Lug A. Cardenas. Singh aae ense on Copy neluorng and sharing praia 36 100DAM Ma 422 Pa P2 Pa Pa PS Forms Aq Pad Flange Seating Face Flatness Tolerances (Metrit] «s+ 2+ ecetserreeeevenensereraens Flange Seating Face Flamess Tolerances (US. Customary) - Allowable Defect Depth vs. Width Across Face (Metric) : Allowable Defect Depth vs. Wideh Across Face (US. Customary) Summary Instruction on the Use of Alternative Assembly Procedures s2.cssceceeses Bolt Root and Tensile Stress Areas (Metric Threads) o2.0 ++ 1+ Bolt Ront and Tensite Stress-Areas (Inch Series) ©. ...-- 0. s00eeceveerrees ASME BLGS Flange Bolting laformation Recommended Washer Temperature Limits «. Chemical Requirements ..-....- Dimensional Requirements tor Metric Washers Dimensional Requirements for US, Customary Washers .-...-- 0. Dimensional Tolerances for Metric Washers... sscceveseseves Dimensional Tolerances for U.S, Customary Washers ..2.4.2005 Sampling... . Reference Values (Target Tarque lade] for Calculating Tayget Tarque Vales far Low-Alloy Steel Bolting Bazed on Unit Prestress of | MPs (Root Area) [Metric Series Threads) . . . A Reference Values (Target Torque Index) for Calculating Target Torque Values for Law-Alloy Stes! Bolting Based on Unit Prestress af 1 kst (Root Area} (Inch Series Threads) . Pipe Wall Thickness Used for Following Tables (mm) s+. +++ Pipe Wall Thickness Used for Following Tables ([n.) Balt Stress Limit for SA-105 Steel Flanges Using Elastic-Plastic FEA (MPa) Bolt Stress Limit for SA-105 Steol Flanges Using Elastic-Plastic FEA (ksi) . Flange Reston for A105 Stel anger Loaded Tala 0-41-26 Table 0-4-2 Bat Some Using Elastic-Plastic FEA (deg) « Bolt Stress Limit for SA-208 Steet Fanges Using Elastic Closed Form Analysis (MPa) . Bolt Stress Llmie for SA-105 Steel Flanges Using Elastic Closed Form Analysis (kei) ..... Flange Rotation for $A-105 Steel Flanges Loaded to Table O-4:1-4M /Table 0-4.1 4 Bolt Stress Using Elastic Closed Form Analysis (deg) . . Bolt Stress Limit for SA-182 F304 Steel Flanges Using Elastic-Plastic FEA (MPa). .- 3 Bolt Stress Limit for SA-182 F304 Steel Flanges Using Elastic-Plastic FEA (ks)... Hage Reve fo aS aedon Teeth ASM Din Bb Some Using Elastic-Plastic FEA. (deg) ......-- ++ se tigiuanesd Example Bolt Stress for SA-105 Stel Weldneck Flanges, SA-193 B7 Stel Bolts, and Spiral-Wourd Gasket With Inner Ring (ksi) « Example Assombly Bolt Torque fo¥ SA-L05 Steel Walduock Flanges, 84-193 B7 Steel Bolts, and ‘Spiral-Wound Gasket With [nner Ring (fI0) -...-..00-eyeerevseeeseees Leak Duving Hydro Test (LT) .2..cccccceeeeeeeseee Leak During Hest-Up or Initial Operation (LIQ) Leak Corresponding ta Thermal or Pressure Upset (LCU) ..-.- Leak After Long-Term (Months of) Operation (LEQ) 206.0... Leak During Shutdown (LDS) ....02.2. en Example Reference Sheet... Sample Flange Joint Leak Report « ‘beeraed Lug A. Cardenas. Singh aae ense on Copy neluorng and sharing praia 2 3 49 40 59 6 65 90 68 9 70 70 70 7 78 2 9 80 80 aL BL a2 az 83 83 a 85 86. 93 oF 95 95 95 24 89FOREWORD ASME formed an Ad Hoe Taaik Group on Post Canstyuction in 1993 in response to an increased need fer recognizad and generally accapted engineering standards for the inspaction and maintenance of pressure equipment after it has bean placed in service. at the recommendation of this Task Group, the Board on Pressure Technology Codes and Standards {BPTCS) formed the Past Construction Committee (PCC) in 1995, The scope of this committee was to develop and ‘maintain standards addressing common issues and technologies related to post-construction activities and to work with other consensus committees in the development of separate, product-specific cades and standards addressing Issues encountered after initial construction for equipment and piping covered by Pressure Technology Codes and Standards The BPTCS covers non-nuclear boilers, pressure vessels (including heat exchangers). piping and piping components, pipelines, and storage tasks. The PECzelects standards o be developed based on identified needsandthe availability of volunteers. The PCC formed ‘the Subcommlttes on uapection Planning and the Subcommittee on FlawEvaluaten in 1995. {n 1998, aTask Geoupunder ‘the PCC began preparation of Guidelines for Pressure Boundary Bolted Flange joint Assembly, and in 1989 the Subcom. mittee on Repatr and Testing was formed, Other topics are under consideration and may be developed into furure guideline documents ‘The subcommittees were charged vrith preparing standards dealing with several aspects ef the in-service Inspection and maintenance of pressure equipment and piping, ASME PCC: , Guidelines for Pressure Boundary Bolted Flange Joint ‘Assembly, provides guldance and ts applicable to both new and in-service bolted flange joint assemblies, ASME PCC-3, Inspection Planning Using Risk-Based Methods, provides guidance on the preparation of a risk-based inspection plan Imperfections found at any stage of assembly, installation, inspection, operation, ar maintenance are than avaluated, When appropriate, usiag the procedures provided in API'S79-1/ASME FFS-1, Fimess-for-Sevvice, IF is determined that repairs are required, guidance an repair procedures is provided in the appropriate portion of ASME PCC-2, Repair of Freasure Equipment and Piping. To provide all srakehalders invelved in pressure equipment with « guide to identity [publications related to pressure equipment integrity, ASME PTB-2, Guide to Life Cycle Management of Pressure Equip- ‘ment Integrity, has been prepared. Noneof these documentsareCodes They provide recognized and generally accepted good practicesthat may beusedin conjunction with past-construction codes, such as API 510, API570, and NEB! NB-23, and with jurisdictional require meats. The first adition of ASME PCC-1 was approved for publication in 2000. The 2010 revision was appraved by the Amer- ican National Standards Institute (ANSI) as an American National Standard on January 14, 2019, The 2013 revision included many updaces and a majar naw Appendix A tiled "Training and Qualification af Bolted Joint Assembly Per- sonnel” and was approved by ANSIas an American National Standard on August 12, 2013, This 2019 revision contains a number of updates. The most notable ofthese updates aretheremovalof thereferencetorquetables (Tables 1M and 1) for similar tables in Appendix O intraducing the Target Torque Index andthe insertion of a new Appendix Q titled "Consid- cations for the Use of Powered Equipmenc’ This revision was approved by ANSI as an American National Standard on Tanwary 17, 2019. Leersed to Luig A Candenas Sale wer leensecr Copying set, and sharing pohASME PRESSURE TECHNOLOGY POST CONSTRUCTION COMMITTEE (the fltonong fe the renter ofthe Commitee a te ime of approval ef the: Standard) STANDARDS COMMITTEE OFFICERS Becht IV, cha © D Rodery, ice Choir S.J, Ross, Seersion STANDARDS COMMITTEE PERSONNEL J-Amold, Nianse Bay Engimeorng. LAC 5 J Roce, The Amarican Society of Machanucal Engiueses Becht IV, Becht Engineering Coy Is. 1 Roux, Ras Ensinosring DL Berger, Consutast (€.W. Rowley. The Wesley Corp ML Boring Mista © Ausclates, In, [Taagepora,chavsen Enorgy Tse W, Brown, [atesrty Engineering Solutions 6M, Tanner. MAM N Faransso, HER 1 Oyamada, Delagors High Preseute Gat Elotyinciate of Japan val Eugy Core ‘T Tahara, Slepate TST Teehulogy King. Furmantte Aries, I LE. Batey, Cononburing Mentor Consutant BLE. Lay, Hynere (0. Caufar, continuing Mamber, Contur Coneuling D, Peters. Structural Integrity Associates E Michalopoulos, Corribusing Meriter, Minis of Economics af Ray, Marathon Futrleats Ca. LP ‘cxeseo 7. Reymelds, latartak Moody ‘KMoldhtartan, Coneibutag Memes, Mckhtarae Coosuling| LLC .€ Raters, Shall Global Eslmone (U5. Ene HR. Sinws, Conerborny Member. Bache Enginaecing Ca, Ine DB, Rodery, CA Technology, LEE POST CONSTRUCTION SUBCOMMITTEE ON FLANGE JOINT ASSEMBLY (PCC) ‘Teehastogy. LLC Mine, The Festalie creep fmezrity Eegineering Soltis M. Ruffin Chevron Eoeray Technology to Bp Barron, Nouport ous shighulang J Barnard, Contributing Somber siydeaight Le Garpenter. 22 € cary, Dow cherteal co SS Haul, sex Technatigy LE Batey, Honorary tena, Conzuleane B.Hanez, Valero Eoerze Corn, 6.6 Neely Honorary Memier. Consuant vil Licence Lug A Cardenas Srigl-unr beens on seb, and shang poked‘CORRESPONDENCE WITH THE PCC COMMITTEE General, ASME Standards are developed and maintained with the intent to represent the consensus of concerned interests. As such, users of this Standard may interact with the Committee by requesting interpretations, proposing, revisions or a casa, and attending Committee meetings. Correspondence should be addressed to: Secrotary, PCC Standards Committee ‘The american Society of Mechanical Engineers Two Park Avenue New York, NY 10016-5990, hitp://e0 asme.org/lnquiry Proposing Revisions. Revisions are made periodically to the Standard taincorporate changes that appear necessary ‘or desirable, as demonstrated by the experience galned frou the application of the Standard, Appyoved revisions will be published periodically, The Committee welcomes proposals for revisions te this Standard. Such proposale should be as specific as possible, citing the paragraph aumber(s), the propesad wording, and a detailed description of the reasons for the proposal, including any pertinent documentation, ProposingaCase. Cases may be issued to-provide alternative rules when justified, ta permit easly implementation of amapproved revision when the need ie urgent, or to provide rules not covered by existing provisions. Cases are effective immediately upon ASME approval and shall be posted on the ASME Committe web page Requests for Cases shall provide a Statement of Need and Background Information. The request should identify che Standard and the paragraph. figure, or table number(s), and be written asa Question and Reply in the same format as ‘existing Cases, Requests for Cases should alsa indicate the applicable editian(s) ofthe Standard to which the propased Case applies Interpretations. Upon request the PCC Standards Committee will cender an interpretation of any requirement ofthe Standard, Interpretations can only berendered in responseto awritten request sent ta the Secretary afthe PCCStandayds Committee Requaste for intarprecation should preferably be submitted through the online Interpretation Submital Farm. The forms accessible at http / /go.asme.orgyTrnerpretationRequest, Upon submittal ofthe form, the Inquirer wil receive an automatic e-mail confirming receipt. Ii the Inquirer is unable to use the online form, he/she may mail the request to the Secretary of the PCC Standards Committee at the above address. The request for an interpretation should be clear and unambiguous It is further rec ‘ommended that the Inquirer submit his/ker request in the following format: Subject: Cire the applicable paragraph number(s) and the topic of the inqulry ia ane or twa words Edition: Cite the applicable edition of the Standard for which the interpretation isbeing requested. Question: Phrage the questien as a request for an interpretation ofa specific requirement suitable for general understanding and use, not asarequestfor an approval f a proprietary design. or situation. Please pravide acondensed and precise question, composed insuch away thaca “yes” or “no” reply is acceprable Propased Reply(ies)- Provide a proposed reply(ies} In the form of "Yes" or “No” with explanation as needed If entering replies to more than ene question, please number the questions and replies. Rackground Information! Provide the Committee with any background information that will assist the Committea in ‘understanding che Inquiry. The Inquirer may also include any plans or dravings that are necessary to-explain the question; havrever, they should not contain proprietary namesor information, Leersed to Luig A Candenas Sale wer leensecr Copying set, and sharing pohRequests thatare notin the format described above may be rewritten in the appropriate format by the Gommittes prier to boing answered, which may jasdvertentiy change the Intent of the original request. Moreover, ASME does not act as a consultant for specific engineering problems or for the general application or understanding of the Standard requiements. if, based on the inquiry Information submitted, It is the opinion of the Committee that the Inquirer should seek assistance, the inquiry will be returned with the recommendation that such assistance be obtained. ASME procedures provide for reconsideration of any interpretation when or ifadditional information that mightaffect aan interpretation ig available, Further, persons aggrieved by an Interpretation may appeal to the cognizant ASME Committee orSuscommittes, ASME does not "apprave;”“certiy, or endorse” any item, construction, proprietary device, af activity. Attending Committee Meetings. Tho POC Standards Committee regularly holds meetings and/or telephone canfer- enges thatareopen tothe public Persons wishingto attend ay meeting and/or telephone conference should covtact the Secretary of the PCC Standards Committee. is ‘beeraed Lug A. Cardenas. Singh aae ense on Copy neluorng and sharing praiaASME PCC-1-2019 SUMMARY OF CHANGES Following approvalby the ASME PCC Committee and ASME, and after public review, ASME PCC-1-2019.was approved by ‘the American National Standards Insticute on January 17, 2019. ASME PCC-1-2019 includes the following changes identified by a margin note, (19). Poge 1 1 Location 1 4 82 9a w Table 2 2 1B 142 Table 3:1 15 154 162 163 164 165 165 167 168 16.10 16.1 16.12 16.13 16.15 16.16 Ata Aqa1 change First paragraph editorially revised (2) Subparagropt (3), (2)(2), (8), (2s aad (@)(2) seven (2) Tables 1M and 1 deloted and subsequent rabies redesignated (1) Second paragraph and subparas, (b} and (d) revised (2) Subparagrapns (e) and (1) deleted and subpara. (2) roviosignated 3¢ (3) (1) Revised (2) Footnote 6 added and subsequent footnotes redesignated Edivorially revised Note deleted Formeriy Table 3, Noes editorially revised Revised in its entirecy Final pavagraph revised Suvpazagza ad ms paragraph olowing bp.) Formerly Table 4.1, General Nete added ‘Tire an final paragraph rovisoe Revised init entirery Revised Revised Revised Rovised Address of AWS upulated Revised Revised Revised Revised Revised ‘Added an subsequent paragraphs redesignated Formeriy 16.16, rovised Formeriy 16.5, revised Definition of sentar boicing assembler maved for alphabetical onder Revised Leersed to Luig A Candenas Sale wer leensecr Copying set, and sharing pohPage 22 22 Ey 29 2 32 33 30 38 38 2 45 46 49 50 51 52 53 54 56 58 oa ot 66 06 67 87 67 87 68 68 68 m0 nA 73 3 rr Py Lecation Aa? ALBa AL3S Ate AZAL AAS. ASo4 Ba DA Figure D-L Figure D-5 Fa Table Fel Figure F-3 Fas Figure F-6 Figure F-7 Figure FB Figure F-9 Figure Fei Appendix G Appendix H “Appendix K M41 ‘Table M-L M16 M242 M232 M25 M292 M2102 Table M-2 Table M5 Change Revised Revised Revised Editarially revised Subparazraph (a)(2} revised Subparagrapt (c) revised Revised Added (1) Revised (2) Feomote 1 revised Revised Revised Note revised Revised General Notes editorially revised to mumbered Notes Subparagraphs (a) and (b) revised General Notes (3) and {b) revised Page 1a and Pass 1h revised Pass 1a and Pass 1b revised, Pass La and Pass 1b revised, Pace 1a and Pass 1h revised Deleted Revised in its entirety: Paragraph following nomenclarute revised Revised (2) Title anid Notes (1) and (2) revised (2) Note (3) added Revised Subparagraph (e) added (2) Revised (2) Footnote 1 added Revised In its entirety Revised Revised (2) Note (2) deleted and subsequent Notes redesignated (2) Notes (2) and (3) [formerly (3) and (4)] revised (3) Note (4) added Revised ‘Sabparagraph (k)(5} revised in its entirety Second paragraph added T, added to nomenclazure [1) Tero paragraphs followring aq. (0-2) added (2) Third paragraph following 29, (0-2), and eg. (0-2) revised (1) Subparagraph (c) sevived si ‘beeraed Lug A. Cardenas. Singh aae ense on Copy neluorng and sharing praiaPoge 7 18 13 7 a Py 85 86 8 8 oeation Table 0-2.2-.1M Table 0-3.2-2 0-42 0-43 Table 0-413 Table 0-41-7 Table 042-1 Table 0-4.2-2 Table Pe Appendix @ henge (2) Tables 0-1M through 0-7 redesignated as Tables O-4.1-1M. ‘through 0-4.1-7 Added Added (1) Numerator in eq. (0-8) revised (2) Tables 0-8 and 0-9 vedes\gnatadasTables0-4,2-Land 0-4.2-2 Revised Formerly Table 0-2, ttle revised Formerly Table 0-7, title revised Formerly Table 0-8, tite revised Formerly Table 0-9, title revised Revised Added sil ‘beeraed Lug A. Cardenas. Singh aae ense on Copy neluorng and sharing praiaus) GUIDELINES FOR PRESSURE BOUNDARY BOLTED FLANGE JOINT ASSEMBLY 1 SCOPE ‘These guidelines for bolted flange joint assemblies (BFIAs) apply principally to pressure-boundary flanged jolts with ring-type gaskets that are entively within, the circle enclosed by the bolt holes and with no contact outside this arcle + These guldelines may be sele tively applied to other joint geometries, By selection of those features suitable to the specific service ar need, these guidelines may be used to develop effective joint asoambly procedures for the broad range af sizas and. service conditions normally encountered in industry. Users are cautioned that the guidelines contalned in. ASMEPCC-1 have been developed generically and arerec- ommended far general applications. They may not neoes sarily be suitable for all applications. Precautionary considerations are provided in some cases but should not Be catisidered as all-inclusive. Sound engineering practices and judgment should be used to determine the applicability of a specific method or part of a method ta a specific application. Each joint assembly procedure should be subject to an appropriate review: by qualified personnel. While this guideline covers joint assembly within the scope of ASME Pressure Tech- nology Codes and Standards, itmay be used on equipment constructed in accordance with other cades and stan Garis, Guidance on toubleshooting BFIAs not providing lea tight pertormance is alse provided in this document (see Appendix 2 INTRODUCTION ABFIA‘sa complexmechanical device therefore, BFIAS that provide leak-freesserviceare the result of many selec- tons/activities having been made/pevformed within 4 relatively narrow band of acceptable limits, One of the activities easential to leak-frae performance [2 tha joint assembly process, The guidelines outlined in this docu mnt cover the assembly elements essential for 2 high levol af leak-tightness integrity of otherwise praperly designed constructed BF)As. It is recommended that written procedures, incorporating the fearures of these ‘uidelines that are deemed suitable te the specific appl cation under consideration, be developed far use by the Rule ar aanige ereoad eaages wien sng.rype gaiate ae exuead ln Mandutary Azpendis 2 of ASME Bollar and Prescure swe ‘Ile Dison 1, Nenmandatery Append sation fx bolted Ranges that aresiel ia the Signer ofAppatdla2. ‘anges joint assemblers: Alternative features and methods for ‘specific applications may he used subject ta endorsement by the user, NOTE: within the context of this Guideline, the term “user” Jncludes the user and their authortaed agent. as recarded In either the contract documents or the written arsembly proce dures (s0e para 14.1) 3 TRAINING AND QUALIFICATION OF BOLTED JOINT ASSEMBLY PERSONNEL Ik is recommended that the user provide, or arrange to have provided, as appropriate, essential taining and qualification in accordance with Appendix A of the bolted jolnt assembly personnel who will be expected to follow procedures developed from this Guideline, See section F-2 of Appendix F for comments on ‘accepting flange joint assembly procedures not currently listed in these guidelines, The qualification of assemblers in accordance with Appendix A may be considered portable subject to the guidance in para. A, 4 CLEANING AND EXAMINATION OF FLANGE AND (15) FASTENER CONTACT SURFACES Before assembly Is started, clean and examina Range ‘and fastener contact surfaces as described in this section. Wich one exception, remove all indications of the previous gasket installation from the gasket contact, surfaces; use approved solvents and/oz saft-wire brushes, if required, for cleaning to prevent surface contamination and damage to existing surface finish. Avoid using carbon steel brushes on stalniees steel flanges, The exception based on experience is resicual exible graphite tat may remain In the surface Nnlsh grooves When either a flaxible graphite clad or a spiral-waund ‘gasket with Newbie graphite filler Isto be used as the re placement gasket (2) Examine the gasket contact surface ef woth mating joint Manges for compliance with recommended surface finish (see Appendix C) and for damage to suriace finish such as scratches, nicks, gouges, and burrs. Indica Tons running radially across the facing are of particular ‘concern. Refer to sections D-2 and D-2 of Appendix D for guidelines covering recommended limits on gasket ‘contact surface imperfections and their locations. (1) le is recommended that surface-finish compatator gages be available to joint assembly person- el. Leersed to Luig A Candenas Sale wer leensecr Copying set, and sharing poh(2) Report any questionable imperfections for appropriate disposition. If machining ar weld rapaly of imperfections is deemed a be raquirad, soo ASME PCC-2, article 305 for repair considerations. “Appendis C provides recommended final surface finishes. (2) When-wosking with problematic or critical service [soe Note (1) of Table 2] anges oflargediameter with leak Iistarles ar suspect fabvication, it is recommended to ‘check gasket contact surfaces ofboth joint flanges for fat- zneas, both radially and circumferentially. This may be accomplished in some cases using a machinists straight fedge,nd fecier gages, butusing ether a securely mounted run-out/flatmess gage ar fleld machining equipment capable of providing accurate total indicatar readings isrecommendad Section‘i-1 of AppendixD provides fat- ness tolerance recommendations Ifmachining or weld vepair isdeemed to be required to achieve the required fatness, see ASME PCC. 2, Article 305 {or repair considerations, appendix © provides recou- ‘mended final surface finishes. {) Examine bott® and nut threads and washer faces of nuts for damage such as rust, corrosion, and burrs; replace/correct any damaged components. Likewise bolt/nut combinations for which the wuts will not tura freely by hand past where they will come to rest after tightening should be replaced /corrected: this includes tapped hole threads. (See ASME PCC-2, Article 303, which covers repair of damaged tappad hole threads) Ifsepavate washers are scored of cupped from previous use, replace with new throwgh-hardened washers? (surlace-hardened washers are not sultable). The condi tion of previously used bolts nutshasa large‘influenceon the performance af a bolted join assembly. The follavring guidelines relating to the reuse of bolts/auts are offered for consideration: (1) When using bolts and nuts of common grade as fasteners, the use af new alts and nuts upto M30 (1% ln.) diameter is recommended when bait load-contral ‘methods such as torque or tension are deemed necessary {see Appencliy K). For larger boit diameters, its recom. ‘monded that the east of cleaning, deburring, and recor ditioning be compared to the replacement cost and considered in the assessment of critical issues of the assembly. When assessing the cost, consider that working with and reconditioning fasteners in the field may be more expensive than replacement and that the resulis of reconditioning cant be unpredictable, When coated bolts are used, the renaining corrosion protection and self lubricating functions are additional consitera tons with respect fo continued use oF replacement. BFA pura 2 abate eh ud bl, "Use ef washers i prion However te generally recognized that the noe of threugh-fardensd ses wannees el improvs the transi feargueipuslatocanlctent bolt sesh, Seapprndls MorasulaBle Sarougpcundoned washer specinceion gulceane (2) Strong consideration should be given to repla lng bolts of any aize should it be found that they have been abused oF nonlubricated during previous assem- blies. (3) Thread dies generally do not resuh in a smooth, reconditioned surface; therefore, turning bolt threads ina lathe is the preferred method to recondition costly fasteners. The process will removethread material: there fore, the user is cautioned to ensure the tolerance imits.of ASME B1.1 for the orlginal class af fit specified are not exceeded. Any fastener with thread dimensions tess than the minimum major diameter or the minimum pitch dlameter should he replaced. (4) Nuts are generally replaced rather than recondi- toned. “Appendix N provides supplementary information on the bolt reuse topie. (2) Examine nut-bearingor washer tearing surfacesof flangestor coating scores, burvs, visual evidencect out-of -squareness (indicated by unever wear), ete. Coatings over approximately 0.13 mm (0,005 ln.) thick should be either removed or reduced in thickness; remove all coating for critical joints, Roughness, gouges, and protrusions should be removed from these surfaces, On severely damaged flanges, machining this area may be required, in which ‘case the minimum acceptable residual flange thickness must be considered. The use of through-hardened, flat washers’ may be appropriate to provide smooth and square nut-bearing surfaces, 5 ALIGNMENT OF FLANGED JOINTS Proper alignment of all joint nsembers is the essential element of flange joint assembly: ft results in maximum seallng surface contact, maximum opportunity for ‘uniform and design-levelzasket loading, and reduced fric- ‘tion between the nutand the flange, Guidelines forallgning flanged joints are provided in Appendix £ 6 INSTALLATION OF GASKET Place a new gasket in position after determining the absence of for having made correction for) unacceptable gasket sealing surface imperfections and flatness toler- ‘ance deviations, a3 well aa jolnt alignment considerations (see Appendices D and £). Reuse of 3 gasket is net recommended However, the substrates of grooved metal gaskets with facing layers may be reused after having been reconditioned and refaced in a manner consistent with the eriginal product spacification, The reinstallation ef gaskets so “Fla eashere protect the aut-contac srtace of tie ange from smethogs (either manual er hyrauiey ara used for bole nizhtening Flat washers also promote improved lend atstribution Sa Appsndls Bt fra uleable rough hardaued washer putcae speci ‘ton gticeine ‘beeraed Lug A. Cardenas. Singh aae ense on Copy neluorng and sharing praiaay) refurbished is not considered gasket reuse since the sealing performance of the gasket has been restored. For other gasket types, experience has dearly shown thaconly a new gasket will reliably provide the necessary plastic deformation and elastic recovery characteristics essential to achieve an effective seal, Visual or physical inspection of a used gasket for apparent damage is not sufficient ta detect such sealing surface factors as ‘work hardening britieness,orthe effects ofheat or inter- action with the serviee fui 2) Verity tuat the gasket complies with the dimen sional (O.D, LD, thickness) and matestal specifications. (2) Position the gaskarto be concentec with the flange LD,, taking suitable measures to ensure that it is adequately supported during the positioning process. Xa portion ofthe gasket should project into the ow pati. 6) Ensure that the gasket will remain in place during, the joint assembly process; avery light dusting of spray adhesiveon the gasket not the flange) may be used. Part cular care should be taken to avoid adhesive chemistry ‘Hat Lg Incompatible with the process fluid or could regult in stress corrosion cracking or pitting of the flange surfaces. Do not use tape strips radially across the gasket ¢o hold fc in pasition. Do not use grease 7 LUBRICATION OF "WORKING" SURFACES? Lubrication reduces the coefficient of friction and results i less required torque to achieve a given. tension, improves the consistency of achieved load ‘from belt to bolt wichin the joint, and alds in the auboe- quent disascambly of the fasteners. When reusing bolts or if lubricant is applied Ineansie~ tently, the nut factor will change and therefore the torque values should be adjusted accordingly (refer to Appendix K). (a) Ensure that the lubricant ts cheruically compatible swith the bolt/nut/washer materials and the process fluid Particular care should be taken co avoid lubvicant chem- istry that could contribute to stress corrosion cracking, galvanic corrosion, oxygen auto-ignition, etc. (®) Ensute thar the lubricant has proven ta besiitable for the expected range af application temperatures) and antiseize requirements (c) Before lubricant is applied to the bolt and nut ‘threads, nuts must run freely by hand past where they will come to rest after tightening, If nuts will not turn freely by hand, check far cause and make necessary corrections/replacements (@) Apply lubricant Liberally and completely te the nut contact fices and to the threads on both ends of the bolts: past where the nuts will come to rest after tightening: the lubricant should be applied after the bolrs are inserted The term working” mrfeere elers to thoge interfices between festansr cempasensa and/er fastonara and flanges that alae me anethor urtagtphtning oF lesvcing ‘through the Hange bolt holes te-avsid possible contamina- ‘on with Solid particlas that cauld create unwanted reac- tion tarque, Lubrication should be applied irrespective of the tightening method used_ (e) Do not apply either approved lubricant or unap- proved compounds to the gasket or gasket-contact surfaces; pratect against inadvertent application to these surfaces, 8 INSTALLATION OF BOLTS Inatall bolts and mute 20 they are hand-tight with the ‘marked ends of the bolts and nuts located on the same side ofthe joint and facing ourward to facilitate inspection; then snug up to 15 Nem (10 fe-1b} to 30.Nim (20-1), but notto exceed 20% of the Target Torque (see section 12).IF nuts de not hand tighten, check for cause and make nec- essary corrections, 8.1 Bolt/Nut Specifications Verify compliance with bolt and nut specifications [materials, diamoter, length of bolts, tread pitch, and hut thickness equal to the nominal bolt diameter heavy hex series nuts)) 8.2 Bolt Lengths Check bolts for adequate length. This length should consideythepresence of washers, nut height, and required {thread protrusion. The requirements in tite neve construc- tion cores are basedon complete thread engagement fer ‘he full depth of the nur. However, ir has beea shaven that ‘the full strength im a threaded fastener can be developed ‘with one thread lege than complate thread engagement {see para. 16.15 references), a potential consideration in careain past-construction situations. The use of belt tensioners requires that the threaded portion of the bolt extend at least one bolt dlameter beyond the ‘outside nut face on the tensioner side of the joint. Galva- nized or coated bolts may require special tensioney puller sleeves, 8.2.1 Excess thread protrusion can hinder joint disas- ‘sembly due to corrosion, paint, or damage. A practice that facilitates joint disassenibly (see section 15) 1s to fully ‘engage the nut on one end (no bolt projection beyond the nut) so that all excess threads are located en the appo- site end, Escess thread protrusion beyond the nut should ‘be minimized. 8.2.2 When the affective stretching length (Leer see para. 10.2) is short,’ the total initial bolt slongation [AL; see para 10.2) resulting from the determined Targot Bolt Stress (see section 12) will be a 7 Toreid engagement covered in UG-L3 of ASME BPC Section YL Djviton Lond para 1523-91 ASME BSL TA bolt having aa secre Bengt shorter amet is peoeray couldared to be “shor wan § Haass wad Leersed to Luig A Candenas Sale wer leensecr Copying set, and sharing poh (a)aaa cua proportionately small value, thereby resulting in a signif- icant percentage reduction in the past-assembly bolt stross due to normal gasket creep, embedment losses, and joint heat-up. The sensitivity ta this occurrence shauld be given careful attention along with other joint considerations when selecting the level of Target Bolt Stress ‘9 NUMBERING OF BOLTS 9.1 Numbering of Botts When.a Single Toot Is Used When either the Legacy or Modified Legacy mathod is used, the corresponding bolt-nurbering systems are as fellows: (@) A system wheveby each bolt location, starting wate ‘number Land continuing through ¥ (where 1Vis the total ‘number of baits inthe jolne), ts numbered sequentially on ‘the flange in.a clockwise manner, This system was used in. ASME PCC-1-2000. It has been retained (and thereforele referenced as the Legacy method), The crass-pattern passes are completed using the pattern autlined in Table 3. This numbering system allows, for example, the quick identification of bolt number 20 in a 40-bolt flange but requires 3 reference table such 35 Table 3 {or the tightening sequence during the tightening process. (@) Am alwernative numbering system for the Legacy method (see Table 3.1) is dasigned so that che number assigned at aach bolt location represents the sequential ‘order for tightening that bole; in other words, the cross- pattern tightening sequence is identified by the assigned bolt number and, therefore, a separate reference table is not required during the tightening process. For the purposes of joint assembly, the Table 3 and Table 3.1 numbering systems are considered equivalent, See Appendix F for ont assembly patterns andl torque. Increment combinations that raquive less assembly effort than the Table 3 and the Table 3.2 methods, 9.2 Numbering of Bolts When Multiple Toots Are Used Seo Appendix F (Alternative Parterng #4 and 45), 10 TIGHTENING OF BOLTS Using the selected tightening methad/load-control technique (see pars, 10.{), tighten the joint using either the torque increment rounds shown ix Table 1 and either the companion Table 3 or Table 3.1 cross- pattern tightening sequences when using a single teal as described in saction 11, of one ofthe alternative right- ‘ening procedures shown in Alternatives #1, #2, and #3 of Appendix F, Alternatives #4 and 45 Ulustrate alternative group numbering systems and tightening sequences when simultaneously using multiple tools. Iris recognized by Nonmandatory Appendix § of ASME BPVC, Section Vil, Division 1 that the initial ightening of ‘the bolts in a joint comprising flanges designed in accor- dance with Mandatory Appendix 2 of that Division isa prestressing operation and that the level of required ‘Target Holt Prestress can vary considerably above the Gode-tabulated design-stress value, This isan acceptable and usually requized practice. Appendix States that". a1 initial bolt stress higher than the design value may, and in most cases, must, ba developed in the tightening epera ton, and itis the intentof this Diststen thatsuch apractice {is permissible, provided it includes necessary and appro- plata pravision to ensure against excessive lange distor- tion and gross crushing of the gasket” For joins custom designed in accordance with Appendix?, acammon range (of Target Bolt Prestress that is often found acceptable is around 40% t0 70% of the specified minimum yield strength ofthe bolt material [see also pars.0.2.2 regarding the effect of short bolts onthe determination of the Target Torque value), This range i normally only exeseded in ‘exceptional cases that have been assessed by a qualifled ongineer. However, any maximum Target Bolt Prestress must be selectad to ensure thar all three of the jolnt components — bolts, flange, and gasket — are stressed within acceptable limits. (See also para. G-1.2) Seclion 12 provides guidance on the determination of the assembly Target Torque value Appendix O outlines a method to determine the assembly balt stress for a given flange jolut (bolt, flange, gasket assembly), The method is bared on 3 formula and flange strege lita that are supported by and consistent with elastic-plastic FEAWwork. Acalculation is provided that uses an example-specitic maximum allow. able gasket stress; however, the user must provide this information. Tables for maximum bolt load limits are provided for ASME B16.5/B16.47 Series 4 flanges and the method ta calculate the assemily bolt load for ‘other standard and nonstandard flanges is outlined, 10.1 Tightening Method/Load-Controt Technique (2) Several tightening methods are available such as hand wrench, slug/hand wrench, Impact wrench, tarque tools, and tension tools. Also, several load- control techniques are available. Thus, several combina- tions of specific joint assembly methods/techniques are available for consideration. @) Four such combinations that are commonly used are listed a3 follows in ascending order of bolt-load control accuracy; however, the implied belt-load soutrel accuracy is dependent on assembly procedures, specific material properties, and operator training and competency: (J) tightening with hand or impact wrenches. Hand wrenches are practical oaly for bolts approximately 25 mum (1 in} in diameter and smaller. Leersed to Luig A Candenas Sale wer leensecr Copying set, and sharing poh‘Table 1 Torque Increments for Legacy Cross-Pattern Tightening Using a Single Toot Hand Sheen. thea amegup"w 15 Nanfa0 li} 908-r{20 fb) (motto exceed 20% of Target Torque. Check Mange gap around ‘arcuferanco fr utaformy. fo gap atound the circunerence's not reasonably warm, maka the appropriate adjuctmasts by ap aroundclncumnference fer uniformity Itbewap around he ‘cteurdorence tot Yezconably uniform mas ho approprata adjusts by selective ughteug/Ioocenig bofare proceed. seoundeticumforones fy uniformity the gop atoundthe ‘rcarferepce i oe reasensbly uniform make the sppropriateadjurcnactrby selective tightwning/looreningbefae proceeding ye foe nection 12). Check Mange gxp around eicumforence fr uniform: Ite gup aout 2 lg uct restcaahlyuslform mks the appropriate adjutnastysslectvetighilngdlooeacag bers pce the Conczus nghtontng he bal hus on acireular clockwise pattaen uote further nut rotation cceursat the Round 3 Target Toraue waive Porandicaor belting. higten Gots te tpdrator rod retacticn reading Fra it are within the spaced ange Step Lending install lective tightening before proceeding Round 1 Tighten 2036t0 3044 of Target Taraue fate section 12] Aheck fs Aswad 2 ‘Tghtunte 0354070} of Target Tanya ete zeein 12). ches ang ‘Roueal 3 Tighe to L000 Tange Te ‘eeu Round 6 Round § Thos permitting watts minimum of hand repent Roundl4s thi wil cetore the short tarm creep eelazaticn/embedment nezes If ‘he lage subjected to suhsequant test pressura higher than is atiag ttray be desirable to repaatches round ater tha tas sm etek (2) tightening with hand-operated or auxiliary- powered tools with torque measurement. Hand-operated. torque wrenchesare practical only for bolts with assembly. torque less thaa apprasimately 700 N-m (S00 fla). (2) tightening with tensioning tools that apply an axial load to the bolt with force measurement, (4) any tightening method used with bolt elongation (ctretch) oF load-contrel measurement, Bolt materials and properties vary within bolt types and this must be accounted for vihen using these methods. (c) The selection of the tightening method/laad~ contrel technique fer the joint under consideration should be made based on past experience with similar joints and full consideration af the risks (safety, envivon mental, finan) associated with potential leaks for the service conditions under consideration. For example, itis Widely racoguized that the mast accurate halt prelaad. control method (#103 ar less) is direct measurement of residual bolt elongation (stretch) after tightening (see para, 10.2), whereas large bolt load variations are possible when any tightening method alone, not followed by stretch/load verification, is used. Use of hydraulic bolt tensioners results in accurate application of initial axial Toad to the bolts; however, this initial load is decreased due ta transfer-load losses when the lad ftom the hydraulic bolt tensioner is transferred to the nut on. the tensioner aide of the joint. Therefore, if wexsioners are employed ta obtain the target residual preload, use the procedure recommended by personnel who are experienced and qualified in controlled bolting services. Mast tensioning tools require additional bolt length. (4) Regarding direct measurement of residual bolt elongation, it should be recognized that, If ultrasenic ‘or micrometer elongation control is used, initial bolt Jength reackngs must be obtained sud documented for each bolt for which bolt elongation is to be determined: additionally, compensation must be made fortemmperature ‘changes in the bolt after the initial length measurement For accuracy, the Instrument sould be calibrated taprap- erly read the bolts being tightened. Information stared in the instrument or tabled values may be too generic ta produce the desired level of accuracy. For belts con- structed with a centerline indicator (gage) rod as shown in Figures 1 and 2, nelther inital length measure- ‘ments nor temperature compensationis required, thereby allowing direct determination of the tue belt elongation, {and hence bolt stress) for both initial assembly and trou- blashooting purposes during operation, (@) Peoprietary force-sensing devices that can provide accurate and reliable real-time (increasing and decreasing) bolt tension readings/printouts are available from several manufacturers 10.2 Bolt Elongation (Bott Stretch) Determination When bolt elongation (bolt stretch} measurement is selected as the load-cantrol technique ta be used, the ‘Yequired bolt elongation is computed according to the following equstion (assumes the belt is threaded full (ee) ‘beeraed Lug A. Cardenas. Singh aae ense on Copy neluorng and sharing praiacorny Tame poled Bre ee | — Hee eee =| “ater | ne ae Tig ea ont 6 esate corsets ol eteng nour ~ Iori sea nin naiete-Tye Botina for Tah Bate Jos su ornsmense reac (ren wh ano 8 ets tmnt yea ila SOT ee tna ANAS cram abies sng wera te ne “ina 3 rpms nds eso sae rts fa SE 1) cap name cr orp ema ne fy pes Pil ron wlan Lear art earn Gy ep ein a ary ieFigure 2 incaor-Type Boing for Sued Jone THRE esa Ty | wealth er eat inte | easiee "ShetaeN a seo Ea gaa Seah ak peatli teh \ ‘Shears ener eee Lear art earn Gy ep ein a ary ie(10) Table 2 Recommended Toot, Tightening Method, and Laad-Control Technique Selection Based on Service Applications Service Applications Foe 00 Toots (Nate (201 Tightening Method ‘Load-Conteo! Technique, Mid Service Macual or sualiacrpewered tools Patleen single or multiolt. Gonsislent procedure periaduatry ber pravtree Tightening procedures or torque coual Ietermedine Manual ef auniiwsy-pewered toole or Pater single ar multboit See Note (31 Service torque: er teasies-meararing tole tightening procedures (Grtical Service Torque: or tensior-mearuring tose Patlern single or mutibeltTerque ot tension control with Final bok Tushtening precedures on/ land verification optona [Note (GENERAL NOTE: Sou pata. 104, NOTES. 1) Service Applications should he denignated by the weer and shouls cenmiier governing deign conaitions (presente, temperstute, et), iter gasket type, etc, joins leakage bisory. and fad eereice category ‘mechanical cern fol diameter. flange (a) in enanopo o sk Sari ie Category D lu Se [op Ai natal of atnanetataSarec (Examples of Conca Service include service requicemems a defined br loca ira al requirements (saris for United States ie CFR 3010,128(0SHA PSM rue) lethal estetancn service a deflnad tn SME BPUC, Sacto Vl Diiton or Category MPladSerece ne Catned ASME {2} all sols shall [B) tizeecognansctat provethinsautic are soneideration ofthe Haka ogulary and properly matnamned and callrated ony lee ane vgulary ghtens using pace wrenchas op manual tool with ue prssis laa contro Eopavionce may fr certain applications, but usmaanured rhtenlng enttrecctamen dad for inertondate Service applications without (6) Whereas: practce ith specifcorsmlsr eqaipmectscarrantsorwheretasting/research dates elongation andlosdverscaton miazbe vied, where - AL = root area, mm? (in*). See Appendix H for bolt Aue = tensile stress area, mm" (in). Soe Appendix H for bolt tensile strese areas. modulus of elasticity, MPa (ksi) effective stretching length, nam in.) The conven: tional assumptian is that te effective stretching length in a theough-balted jalut systemn is the distance between mid-thickness of the nuts, whore the nominal thickness of a heavy hex series nut is ene aominal bolt diameter. By the same standard, the effective length of the portion of a bolt that is studded ima a tapped huole is one-half of a nominal bolt diameter. Sy = Target Bolt Stress (root area), MPa (ksi). It is noted that bolt stresses computed in accardance with Mandatory Appendix 2 of Section VII, Divi- sion L of ASME BPVC are based on raot area. If Target Bolt Stress (tensile stress area) is used, drop the 4,/Aq;term from the AJ computation. AL = holt elongation (bolt stretch), mm (In. Select a tolerance on this computed value and include it 1 the Joint assembly procedure Le 10.3 Tightening Method/Load-Controt Technique Selection ‘Table 7 shod an example of an approach to selecting the tools, tightening meted, and load-control technique suitable to the need NOTE: Table 2Isprovided as anillustration: 2ue consideration of specie conditions and factors applicable te the joint under consideration should be given when selecting the appropeiase lightening method load -contrel technique combination for a aghen application 10.4 Start-Up Retorque Onjoints thar are peoblematic, or havebeen determined to have insufficient buffer agalnst leakage in accordance with Appendix 0, start-up retorque may be performedto decreaze the likelihood of Leakage duving operation” Start-up retorque fs performed vrhen the temperature fof the flange or bolts is between 150°C (300*F) and 230°C [450°F) or within 24 h of unit start-up if the jolut temporature remains belaw 150°C (200°F). This temperature range and time window are selected to allow for the maximum amount of gasket relaxation prior to retightening while avoiding significant evapora- ‘lon of lubricating ails from the antiseize product. Lass of Iubricathag oils greatly reduces theaccurary ofthe toque, blowout ar esape my evar at ola other han the woe blag sed Tis ik could ‘BAUlaly Neth eppact to personal a wey otha June ‘beeraed Lug A. Cardenas. Singh aae ense on Copy neluorng and sharing praiaThe applied torque is sometimes adjusted to account for changes in antiselze nut factor ar the average start-up. retorque temperature, Start-up retorque is typically. not recommended for PTFE-based gaskets. Where Start-up retorque is not practical, live tightening at a later stage of operation using turn-of-aut may be used. as an alternative. ‘The start-up retorque Is performed In accordance with, the following procedure (@) The amblon-temperaruee assembly Target Terque value should be adjusted ta account for any change in out {actor with temperatur () Once the unit is brought online and the metal temperature is between 150°C (30°F) and 230°C (450°F) (commence once the flange reaches the lower temperature) or within 24 b of unit start-up if the joint temperature remains below 150°C (300°F), then. proceed ina circular pattern and tighten each bolt The use of multitoel tightening an oppasing bolts is an, acceptable practice, buta ircular pattern should be used fe) Continue rightoning in the circular pattern until the ‘nURS no longer turn, ‘An engineering and risk analysis of the proposed scart- up revorquecoperation shall be carried outro establistrhat the operation can be performed safely. Startup zetorque: should not be considered the same as live tightening erhot bolting (se¢ Appendix). Livenighteningor hot boltingare: post-assembly activities usually undertaken due to leakage ov maintenance requirements and ave covered. further in ASME PCC-2, 11 TIGHTENING SEQUENCE 1L1 Single-Toot Usage Select from the following: {@) The Table 3 Legacy pattarn and numbering system. [B) The Table 3.1 modified Legacy pattern and numbering system, (6) The alternative pattern sequerices shown in Alver~ natives #1,42, and #3 of Appendix F; compliance with the: stated limitations for their application is essential. ‘The torque increment round-tightening information for the Table 3 Legacy pattern is detatled in Table 1 (see Figures 3 and 4 for an llusteation ef the Legacy cress pattern tightening sequence for a 12-bolt flange and 3 48-belt flange, respectively, the latter Illustrating the bolt-grauping concept). Counterpart ilfustrations of certaln alternative pattern sequences are covered in. Appendis F. MOTE: The cros-patiem belt-tightening sequence and multi ‘ound tghtoting are necessary to counter the elas Intaraction ‘hat occurs when tightening bolts See Appendix | for additional information regarding elastic Interaction (or bot cross-tal), ‘11.2 Muttiple-Taol Usage Follow the procedures outlined in alternatives #4 and #5 of Appendix F 11.3 Measurement of Gaps For tite purpose of maintaining parallelism during the initial tightening passes of assembly, take measurements ‘of the gap between flanges around the circumference. Measurements and adjustments are not needed past {his point if the flanges remain parallel. Measure the gap between flanges at elght or more equally spaced laca- tions of good-quality flange surface around the circumfer- ence. Use a measuring device that allows for good comparison between points. Gap measurements are not intended as indicators of gasket stress. Loosen bolts in the vicinity of the low readings (smallest zap between flanges), until rhe gap is uniform te within 25 mm (010 in), IF mecessary, bolts at the location of the highest readings (largast gap between flanges) can be fightenad However, if the difference in torque required to keep the gap uniform is greater than 50%, disassemblethe joint and locate the source ofthe problem. 12 TARGET TORQUE DETERMINATION Guidance on determination of Target Torque is in Appendix 0. 13 JOINT PRESSURE AND TIGHTNESS TESTING Bold joi savemled should We tested tecture Vk tightness, Subject to code/regulatory requirements the ter should establish (a) the type of leak test (e.g, visual, bubble-forming ‘solution, sniffer) () teat fluid (e.g. air, inert gas, watex, service fluid) () test pressure (e.g, low pressure or up to a code- mandated vleual Inspection pressure) (a) acceptance criteria (often simply “no detectable leaks’) The user also cautioned to consider thatthe practice of using “temporary” gaskets for pressure or tightness: testing fystems tat ince bolted lange joint asem- Dissdag resulted in nuinerous incidents of nluryandnear injury to assembly pettonnel ue to blowout flrs of these alternative gasket matarias/types, The uze of suibsinute ensketsduringteringinetexdeftiozedesizned 3: the fina seal forthe joint (snot recammpended Refer ASME PCC-2,Aicie 901 for general good prac tices or pressure ind tightness testing of pressure equip ment Leersed to Luig A Candenas Sale wer leensecr Copying set, and sharing poh 9) (as)Table 3 Legacy Cross-Pattern Tightening Sequence and Bott-Numbering System When Using a Single Toot No of Bolts ‘Tightening Sequence for Cross-Pattern Passes [rvote (1) —B__[trrie seu eee ba [ssitna0 4164009 + 244800 = Surtiay = 518001 7 ETRE 26 [aso = 410-1105 204997 3 2469205 5194226 7.210828 STATA Sa [arses = 521 a9-29 F49-MnDT = 79501 = PLOIOS = G2FIeW = 4900-08 SETTER 36 [28 1920-24-10 44 2 +20-29.50-0456020 2824-018 1 915238 27895-2009 41697 BOUTIN aq engeh=ay ia ab 24192048 6 = 09 98526-5474 1507 B= PRA II POLE $9-94-95-26 = 22RD - — WS [i254 252607 18--33-140516 7G A EEO TTS + aba SOA 49-50-51.52 — 35-26-27-08 + 10-123 — $7-38-39-40 Be ras = s9000392 = teaeist6 = ai42abad = 21 20aS ES BSOGTSES SIDED OOD W [ieeq- massa aware aisle ere sista aaa PEL Ge [eng 290095 36-+371820-00 495081 5) 0-10-3112 = 1-42 B44 35 2627.18 TSEC ASET A] S7NG ud — 24 EES I44 SBSESSSE = 13TEIS TE a ASab4T 48 2690-3490 4 61826384 Ge [bases arse sean 4 srazseat 5 s5sed5ae 5 SugLT Iz sAbeeaT aa 2950313: 4 eFeseTELD inieiete—sravieat + a9avarae -fe7e—4daza~iedeleie ~ ana0eLa2 ~ aeaear8 J seeted GeNERAL NOTES: {a} See Table 31 covering an lternstive tothe Lenacy pattern nmbering sistem. () SesAppeadi Fr Atsnctive #4 (Medlted Legacy) which wserthe ame numb esleg system asthe Lngacynathod (Tabla oe Table 22) but ‘dfcortargus eranent than that Tabs 1 altenaces £2 “able 3 anda ifasent rorgue lncisenent tha that bn Table 23 trom Aypondc Puss otk aciferen patra than hata Table’ of aoe wit katona ef ie apelicasion of these alternates ls (6) Ses AppendlsF for Alteraatives #4 and #5 for altrnative graup numbering and tighten sequence when lultanaculy using multiple NOTE) (1) See Figure and forillneraomsotLagaey enone patarstihteningeequensee sid bslt- suman miter whenumingsei te 14 RECORDS Consideration should te given to the preparation of a Joint assembly vecard far each assewbled joint, particu- larly those that are deemed to be an erttical service or deemed to be prone ta leakage. 14.1 Documentation of Authorized Agent AAs described Inthe Note atthe end of section 2,the term ~user” ig understaod to include the user ar their author- aed agent. Such authorization chould be recorded in ‘either the contract documents or the written assembly procedures 19 14.2 Joint Assembly Records Joint assembly records may incude the following infor- mation: (2) foint location or identification (2) joint class and size (@) specifications and conditions of flanges, fasteners, washers [including nut-o washer-hoaring surfaces), and gaskets (4) date of activity (assembly, disaesembly, pressure test, etc) (@) names of assemblers/workers @) name of inspector or responsible person (@) disassembly method (hy) adverse dissssembly conditions, such as the pres- ‘once of nut selaing er thread galling ‘beeraed Lug A. Cardenas. Singh aae ense on Copy neluorng and sharing praia 19)(ay) Table 3.1 Alternative to Legacy Cross-Pattern Tightening Sequence and Bott-Numbering System When Using aSingle ‘Toot wa. of Bolts Bol-Numbering Sequence (a fe Marked Clorkwise on Flage [Note Ci] 3 jzaae 5 esaranae Feereee se eee reer) te [5518541715 210,618 412 8 1e 20 [47559331918 7,18, 2 18 m6 18 aoe De de [217.9598 3, 8,29,20 7,15, 23,3, 18 10,6 14 22, 4 20 38 |[3.35.17, 9.5, 15 28.8.37, 19, £2 7.15, 25,2 36,18 106,14, 22 9 28,2012 Be 28 32 [225 17 95, 15 28 25.377, 19 117.18 23 31 2.26 36 106 14 72 30.420 012g le 28 SE 36 8.26, 18.10 0 234,26, 18 106, 44 | aa, 35 25.47,9,5,08,21,20,97.5,45,26,27. 05,21, 7.15.25,44, 39,2 42.36,26, 18.10.6142, 20,98.6,44, 36 28,2012.8,16 24,92,40 oe | an.as. 28.1709 5 18.21,00,97.05 5 48 9507 1 91,715 09,91,99.47 2 LIA ISTE 18790 IE AB HEE IE Rete 24g4ae _ - Sp [ies.a133.25.i7,9.5.1521.05.57.45 351,03 3527 1911752551 39.07 2 5042 3026381081022, 30.38 48652 45,36, 26 20,12 8 16 24.92.40, 48 G6 | h.49.an $9.25,19.955 08,21, 29,97 45,59 582 99,95, 27 10.05, 7 Abas oe, 39,47, 55, 250 OE 26 THIN IRIN, 45.54 4.52 44, 36,26 20.12. 16, 24 52 40, 45 $6 eo | isi.as,41,33.25.17.9 5,13, 11.26.97,45,53,3.58,51,05.35,27, 16.21,7 1,73 31,38 a7 85,288 50 42 36 26,18 1006,14 22.30, 36. 46, 54 4 60, 52.44 36,28 20,12 B16 24 92.49, 48, Se G+ /a59,48,42.98.25,07.9,5 25.21 25,59,45.58 60, 8.58 $1,45,55,27,19.11,7.25,03,51.98.47, 55 68. 258 50 4E TRIG 1810, 14,22, 30,38, 46 54.62, 4 60 52.44, 36 26 20 12 Je, 24 32 a 4, 56, 6a ee | E685, ¢0.41,38,25 17.9.5 43,21,25,27,95 59,61 3 67 59,51, 43,25,27,15,11,7,15.08.38 95 475568 266585042, 26,16, 10, 6,14 22 30, 36,46, 596 62.4, 68, 60, 52, #4 36.24, 20,12, 8, 16, 24 30.40, 4, 96.08 TE | 05,57 49.41, 88,25 17,9.5,13,21,00, 97.45 59,61, 69.8,67 58,51, 45 95,27, 19,11,7,15,28, 81 90.47.55 63 7A Leh SH 0 4B.34 26 1B 10.6 14 32, 16, 35, 46,54, 62 70.4 65, 60,52, 4, 36,26, 20,12 5 16 24 32,40, 48 58.64, 72 Fe [ivs.e5S7.45,ai,33 25 17,5,5.13,21,25 37 45,55 60 69,875, o7,59.51,43,38.77 29,017, 15 23 34 S547 95087274 (6,58, 80,42) 84,26, 18,20, 14.22, $0, $646, $5,632, 70,4 76,68, 60, 59,49. 34, 28 20,17, 6 26, 24.92.40, 48,56, 68,72 G0 |8,79,66,57 49.43.9925 17)9,5.13.24 29,97, 4555%.61,69,77. 9.95.60, $0/51,4595.27, 19.14, 7.25,29,31, 90, 97,55, 63.71.79, 2.78 6,50, 50,42. 34,26 18,10.6.26 22,30, 38,46. 58, 62.70, 784 76.65.60 52, $4 36,28,20-22.8,16,28 92,40,48, 5606 72, ey [51,7305 67 99,41,95.25 17.5.5 15 21,28,37,45,6361,09,77.3.88 75.67.95 5140 95 27.05,127.15 259828 97.85.83, 71,39,2.63,74 66,58, 5042.34 26,18, 10,6 16 22 30,38 46,54.62.70,76,4 88, 16,06.60,52 44, 36.20,20.12.6.16,1432.40, 1454, 73,55 57,48, 41, 15,28,17.9,5 13 20,29, 97, 48,8561 68,07,05,5.08,75 67,69 $1,45,38,29.19,01,7,15 98.31, 1947.85, 63.75.79.67.2.02.74.66:50,50 42,3426 10.10 6 14 22 30, 38,46 54.02 70,70 a6 4 04, 76 00.66, 52.44.56,26,20.12.6,10, 34,33, 40, 48, 56 4, 73,00, 98 GENERAL NOTE: See serion 0 NOTE: [1] The momber-amipned st exch bot Inenton reprarens the sequential ser for tightens the alt ul ‘beeraed Lug A. Cardenas. Singh aae ense on Copy neluorng and sharing praiaFigure 3 Example Legacy and Atternative to Legacy Numbering Sequences for 12-Bott Joint (a) Lesaey (see Table 31 (9 leak history G) bolts, muts, and washers used (k) flatness measurements, when made (see Appendix 0) ( assembly procedure and tightening method used, including applicable Target Prestvess values as per he indicated tightening methed (m) unanticipared problems and thelr solutions (2) twoldata such as type, modal, pressure setting, and calibration identification (2) tool access or safery issues (®) recommendations for future assembly pracedures and joint maintenance and repairs Exaniples of three different types of jolne assembly records are shovrn in Figures 5 through 7. An example ‘of a joint leakage record is showm in Form P-3.4, Often, the tlest step in maintaining joint assembly records is to uniquely identify each joint. Theunique idan- tifler should ideally be permanently fixedto theJolntucing a marking or tag system that enables an assembler to verify that they have the carrect joint prier te working on it. Such a system enables storage of joint assembly records against the unique joint identifier and minimizes the patential hazard associated with disassembly of the \wvong joint. Joint assembly records have the following two purposes: = Thay facilitate joint assembly quality control by recarding the individual responsible for a particular portion of the joint assembly process ~ They provide a recard of the joint assembly para meters that were used and the lessans learned. 2 [by Alternative to Legacy [see Table 3:1) ‘The first purposeis achieved by increasing the respon- slbllty of the Individual invalved in assembling the joint bby maintaining a record of their actions and identity. The second purpase Is achieved by documenting the actual parameters used and observations made during joint assembly, This {ufarmation will be useful if the joint leaks during operation, or for euidance during future ascombly of tae joint. [Cla eogentual that any deviations, comments, observations, or changes to the assembly procedure are fed back into che joint assembly record system, such that the assembly procedure may be updated prior to the next joint maintenance activity. Users shauld decide what level ofcetail torecord based ‘on their awn needs and resources, Due to the large numbers of pressure-boundaty bated Jolnts assembled during construction and maintenance activities, it may not ba praetical fo malntalit a¥ecord of al joint assembly parameters (ie, the example record shown in Figure 7]. ‘Therefore, this sort of record is aften completed and archived only until the next assembly for joints that are the most critical or most likely to leak. The shortened racord (Le, theexamplerecordsshown inFigures5 and) ‘prpically does not include all the joint assembly para meters or observations and is typically discarded after the unit start-up, This means that the second purpose is not achieved, but the more important effect of improving joint assembly quality central is tll actained. There is typically also a register of joints that is main. tained, in addition to the joint assembly records, which tracks the progress of each joint, whether there is an assembly record or not. The register may Incorporate the use of the joint assembly records by requiring Leersed to Luig A Candenas Sale wer leensecr Copying set, and sharing poham Figure 4 Example of 48-Bott Flange Bott Grouping Group 7 V234 2 Bera 2 Bioitie a 13261516 5 aBte20 6 nerazsza 7 25.26.2778 a maoatK 9 saab | sPaaaaaa " anapasaa 12 4546-47-40 Tightening sequence for 2 groups: 410 zesn a 59-612 [Tne 12-group sequence isthe samens a 12 bolt saquence: roe Figure) GENERAL NOTE: This igure ison lostratioa of hows bolte may be groupe for righting, Bole may be grouped and tightened eating acl: [Fup ae one sit nthe tightening sequence A suggested numberof bate Sra groupie tee meaner contined uthin# 30 dag ae, Hewemeer iat gasket damage or Aange rsaliecent soa visualconfirmation ofa completed record prior tothe joint vegister being updated ta shaw tat the jelut may be returned to.servics, {An additional nate of guidance is that the tendency x0 provide or request roo much information on the joint assembly record should be avoided. It should not be: considered a substitute for written assembly procedures: or assembler qualification. 15 JOINT DISASSEMBLY Before any joint is disassembled, itis essential that asgurance he obtained from personnel In responsible charge of the management of the eystam that al pressure, lnicluding chardueto aliquid head, has been removed irom. the system and that proper procedures have been followed to ensure that [oints may be safely opened. A sufficient number of loosened nuts should be left in place until all tension has been relieved, to guard against falling compenents, pipe spring, or other unanticipated a te comsideced when bolts are erauped. movement. Dus to the possibility of residual liquid in the pipe along with any unrelieved pressure, the first bolts lonsened should be in-a location that will direct any pressure roleaso away from the assembler. Generally, {or joints inthe vertical plane, this will be atthe tap af the joint and then at the bottom to drain the liquid When significant numbers of bolts are loosened, the fatic recavery ofthe clamped parts can result in exces sive laads on the relatively fewr remaining bolts, naking further disassembly difficult and sometimes causing galling’ between the nut and bolt sufficient to result in torsional failure of the holt as further loosening is attompted. The reported incidents of disassembly dffcul- tia have typically involved (a) flanges larger chan DN 660 (NPS 24) (@) Mange thicknesses greater than 125 mm (5 in) Vieparenes tar sen $3-193 Ge BF boler are mae toe alg Incidents eax aveldad 4y using higher strength SAI Gr 4 ‘beeraed Lug A. Cardenas. Singh aae ense on Copy neluorng and sharing praiaca Figure 5 Exampte Short Assembly Record oO Dace ot instalation: Gaskot description: Final torque used Joint accembied pected Notes/Problems: (¢) bole diameters M45 (144 in} and langer Accordingly, use of a joint disassembly pracedure may be desirable for joints inveling components mestng all ‘the criteria of (a) through (¢) aboveorwhere galling ofthe bok hss been aris found r be problematic. Also, seofa Joint dlssseenbly procedure may be piudent for jolts involving components for which high local trains could be detrimental (eg, glaae lived equipment, lens ring joints) or joints where the gasket is to be removed for analysis 15.1 Disassembly Load Controt 15.1 When a joint disassembly load-contral prace- dure is deemed appropriate, start by loosening one bolt completely, while moting the amount of nut turn it takes to fully relfeve the bolt load from assembled to the flager-tight condition, 15.12. Retighten the loose boit to approximately “ of the rutn tofullrxelieve the load (e.g, ifthe nut comes loose after two flats of movement, then retighten by turning the nut % flats from finger Cght, Le, toa position af a faz Jess than the eriginal amount of nut turn), ISLE Proceed in a circular pattern axound the joint andloosen each tok by approximately “of te turn of mut required to fully relleve the load (e.g, if the wut comes loose after two flate of movement, then loosen each aut by % of a Nat. 15.1.4 For particularly problematic jolnts, continuo to proceed in cireular pattern around the joint and loasen sachbolt by afurther 4 of therura.of aut required tofully relieve theload (eg, inthe aboveexample, further*4ofa fa) 4 15.1.5 Proceed with bolt loosening and mut removal ina ‘ular pattern, remembering tareatficmchar all pressure ‘on the joint has been released and that the joint has sepa sated prlor ra removing all bolts and auts ‘An aid such as a hydraulic or manual flange spreader aay be used if necessary fo separate the joint 15.1.5 Ifthe boits start galling during final disassembly (Le, when performing the step in para. 15.1.5), then retighten all loosened bolts {if possible) to the position sbtainad after performing the step to para. 15.1.3 of para. 15.1.4 and then recommence at the step in para 151 16 REFERENCES 16.1 General, ‘The following is a ist of publications referenced in this Guideline. 16.2 API Publications API Standard 660, Shell-and-Tube Heat Exchangers AP] Recommended Practice 686, Recommended Practice for Machiwery Installation and Installation Design Publisher; American Petroleum Institute (API), 200 ‘Massachusetts Avenue NW, Suite 1100, Washington, DC 20001-5571 (www.aphorg) 16.3 ASME Publications ASME Bi, Unified Inch Screw Thieads (UN and UNR ‘Thread Form) ASME B1:13M, Metric Screw Threads: M Profile ASME B16, Pipe Flanges and Flanged Fittings: NPS ‘Through NPS 24 Metvic/lnch Standard ASME B1620, Metalltc Gaskets for Pipe Flanges: Ri Joint, Spisal-Wound, and Jacketad ASME B16.47, Large Diameter Steal Flanges: NPS 26 ‘Through NPS 60 Metric/lnch Standard ASME 831.3, Process Piping ASME B46 1, Surface Texture (Surface Roughness, Wavi- ness, and Lay)) ASME PCC-2, Repair of Pressure Equipment and Piping Publisher: The American Sacleny of Mechanical Engineers {ASME}, Two Park Avenue, New York, NY 10016-5999 (wwwasmeorg) 16.4. ASME Boiler and Pressure Vessel Code Soction Il, Part A'— Ferrous Material Specifications: $A-1045/SA-105M, Speesfication for Carbon Steel Forgings for Piping Applications SA-182/SA-182M, Specification for Forged or Rolled Alloy ‘and Stainless Steel Pipe Flanges, Farged Fittings. and Valves and Parts for High-Temperature Service Leersed to Luig A Candenas Sale wer leensecr Copying set, and sharing pohFigure 6 Example Meaium-Length Assembly Record FRONT O Joint dentitcation: Plont name: EquipmentiOwa. na. Joint descriotion no. Joint Description: Diameter: Pressure rating: Gest typets Bott specificstion: Bott size and lena: Washer descrint ‘Ascambly Pararnators: Assembly metio Assambily bot stress: Lubricant weed! Assembly torque: Pump pressure Too! Mtantiieation: LUst twol calibration isentiions: $A-193/SA-193M, Specification for Alloy-Steel and Stain less Steel Bolting for High-Temperature or High Pres sure Service and Other Special Purpose Applications 58-194/SA-194M, Specification for Carbon and Alloy Steet Nuts for Bolts for High-Pressure or High-Temperature Servis, or Both 5A-453/SA-453M, Specification for High-Temperarure Bolting, With Expansion Coofficients Comparable to Austenitic Stainless Steels $A-540/SA-540M, Specification for Alloy-Steel Belting Materials for Special Applications 5A-693, Specification for Precipitation-Hardening Stain ess and Hear-Resisting Steel Plate. Sheet, and Strip Section Il, Part B — Nonferraus Material Specification: SB-627, Specification for Precipitation-Hardening Nickel Alloy Bars, Forgings, and Forging Stock for High ‘Temperature Service NOTE: ASME $A and 38 matertal specifications are used in ASME PCC-.ASTM material specifications may.isa beused artaken to apply, as allowed by the applicable cada of construction, forthe fant being considered. Section VILI, Division 1 — Rules for Construction of Pres- sure Vessels ack oO Joint Assembly Sign-OMt {11 Disassombtod Range inspoctod (2) Gaskot inspected pro instalation (3) Bolt pro-instatree-runningh By, Siah Jone wigned By__ Bots lubricated By, Siar oine sng tightened By, Siay Joint 190% assembled By, Siar one leak tested (pressure By, Siar Final OC sign ot (5) tsi 7 Publisher: The American Soclety of Mechanical Engineers (ASME). Two Park Avenue, New York NY 10016-5950 (wow.asmeorg) 16.5 ASTM Publications ASTM A240/A240M, Specification for Chromium and Chramium-Nickel Stainless Stael Plate, Suet, and Strip for Pressure Vessels and for General Applications ASTM A829/AB29M, Standard Specification for Alloy Seructural Steel Plates ASTM F436/P436M, Standard Specification for Hardened Steel Washers Inch and Metric Dimensions ASTM F606 /P606M, Standard Test Methods for Deter- mining the Mechanical Properties of Externally and Internally Threaded Fasteners, Washers, Direct Tension Indicators, and Rivets Publisher American Society far Testing and Materlala (ASTM International), 100 Barr Harbar Drive, P.O Box C700, West Conshohocken, PA 19428-2959 (wvew.astm.org] 15 Leersed to Luig A Candenas Sale wer leensecr Copying set, and sharing pohFigure 7 Example Long Assembly Record Joint Identification: Plant naene: Joint desceiptioninumbe Joint Descriotion: Diametee Gastot type and material Gasket size (0.D. 1D, and thickness Boivint spacitiation: ‘Washer dsscripciow ‘Assembly Description Disossembly procedure required? ‘Yes/No ‘Assembly method to be used: Target assembly bot sree ‘orava or tension setting required: Assembly ee-taraue required? Yes No Lubricant to be used ‘ther special instruction ‘oo! identitication Equipment’Dveg. no, Prossure retina: Botts Bort length Keep tailed gasket? Yes/No Re-torque torque value List 00! and pump if applicable! unique calibration identifiers Joint Assembly Sign- OF, |i) Disassembled Flange inspacted (2) Gasket inepected pre-insall (9) Bolt preinstall (free-running! By: Sign (4) doint alignment 2 (S) Bolts lubricated 2 Sign. Joint srum tightened ‘Sign (7) doin 100% assembled Sign. (6 gre (i) doint teaketested 2 Sign. (9) Final OF sign-off Sion: Date: Notea/Probtens: Joint Assembly Parameter Racords: Nutiwasher besting surface condition: Flange finish and fines fal defect: Defect dep Max. ware: Mae Ji alignment: Mae aid Joint in-process alignment: Max. pap ference @ snug __ Max. pap diferenc @ tights ———__ Final pump pressure use: Joint leak tet: Test pressure ‘Action taken if leaked! Leak: Yes/No ‘Return completed record to iiemel 16 Leersed to Luig A Candenas Sale wer leensecr Copying set, and sharing pohus) ay) ay) aay) 16,6 AWS Publication AWS AS.14/A5-14M:2011, Specification for Nickel and Nickel-Alloy Bare Welding Blectrodes and Reds — 20th edition Publisher, American Welding Society (AWS), 8569 NW 36 Suet, Ne. 130, Miami, FL 33169 (wwwawsorg) 16.7 European Committee for Standardization Publication EN 1591-1, Flanges and thetr joints — Design rules for gasketed circalar ange connections — Part 4: Caleulz- fan Publishér: European Committee for Standardization (CEN), Avenue Marnix 17, B-1000 Brussels, Belgium (onwcenen) 16.8 ISO Publications 180 6789-2, Assembly tools for serews and fits — Hand torque tools — Fart 2: Requirements for calibration and determination of measurement uncertainty 180 7005-1, Pips flanges — Part 1: Steel flanges for indus- twial and general service piping systems ISO 27509, Petroleum and natural gas industries — Compact flanged connections with IX geal riag Publisher: International Organization for Standardization (150). Central Secretariat, Chemin de Blandonnet8, Case Postale 401, 1214 Vernier, Geneva, Switzerland, (wvrwitso org) 16.9 U.S. Department of Labor/Occupational Safety and Health Administration Publication 29 CFR 1910.19, Pracess Safety Management of Highly Hazardous Chemicals Publisher: Occupational Safety & Health Administration (OSHA, US. Department of Labor, 209 Constitution, Avenue, Washington, DC 20210 [wwwioskagav} 16.10 Japanese Standards Association Publication JSA /1S 8 2251, Bolt Tightening Procedure for Pressure: Boundary Flanged Joint Assembly Publisher: Japanaca Standards Assoslation (JSA), 41-24 Akasaka Minato-ku, Tokyo 107-8440 Japan. (www sa0rip) 16.11 MSS Publication MSS SP-9, Spot Facing for Bronze, Iron and Steel Flanges aw cence fo Lug A Cardenas Srigle-uer eens on Publisher: Manufacturers Standardization Society of the Valve and Fittings Industry, Ine. (MSS), 127 ParkeStenet, NE, Vienna, VA 22180 (www.mss-hg.org) 16.12 PIP Publication PIP VESV1002, Fabrication Specification for Vessels: ASME Goce Section VIIl, Divisions 1 and 2 Publisher: Process Industry Practices (PIP), Construction Industry Institute, The University of Texas at Austin, 4925 West Braker Lane (R4500), Austia, TX 78759 (wew pip-org) 16.13 TEMA Publication Standards of the Tubular Exchanger Manufacturers Asso- ciation Publisher: Tubular Exchanger Manufacturers Assoclation Inc. (TEMA), 25 North Braadway, Tarrytown, NY 10591 (wwwremnacrg) 16.14 WRC Publications ‘WRC Bulletin 449, Guidelines far the Design and installa tion of Pump Piping Systems WRC Bulletin 538, Determination of Pressure Boundary Joint Assembly Bolt Load Publisher: Welding Research Council (WRC), P.0. Box 201547, Shaker Heights, OH 44120 (worw forengineers.org/welding-research-counctl) 16.15 VDI Publication ‘¥DI2230, Systematic calculation ofhigh duty bolted joints — Joints with one cylindrical bale Publisher: Verain Deutscher Ingenicure (VDI), P.0.Box 10 1139, 40002 Dusseldorf, Germany (www .vdl.de) 16.16 Other Publications Bickford, |, HvAn Introduction to the Design and Behavior of Boited Joints, Marcel Dekier, inc, New Yorke (1995) Bickford, JH, and Nassar, §, eds, Handbook of Bolts and Boited Jounts, Marcel Dekker, inc, New York (1998) Brown, W.. “Hydraulic Tensioner Assembiy: Load Loss Factors and Target Stress Llmito” ASME 2014 Pressure Vessels and Piping Conference, PYE2014-28685, Anaheim, CA, USA, July 20-24, 2014, BOL: 10.1135/ PYP2014-28685 (tp: /proceedings asmedisitalcollectionasmeorg/ proceeding.aspx articleid=1937878) Brown, W.,and Long. S. "Acceptable Levelsof Corvoston for Pressure Boundary Bolted [oints” ASME 2017 Pressure Vessels and Piplug Conference, PVP2017-65507, Copying nelvevrg and sharing praia (as) 9) (ay)Waikoloa, Hl, USA, July 16-20, 2017, Dol: 19.1115/ PVP2017-65507 (http /proceedings asmedigitalcollectionasmantg/ proceeding aspx?articleid=2660404) Kikuchi, 7, Omiya,¥, andSawa,T."Effectsof Nut Thinning Due to Corrosion on the Swength Characteristics and the Sealing Performance of Bolted Flange Joints Under Internal Pressure” ASME 2011 Pressure Vessels and Piping Conference, Volume 2: Computer Technology and Bolted Joints, PVP2011.57445, pp. 39-41, Baltimore, MD, USA, [uly 17-21, 2021, DOI: 10.1115/PVP2011-57445, (ittpy/ /proceedings asmedigitalcollectionasmeorg/ proceeding aspx7articleid=1627803) Kilurchi, T, and Sawa, T, "Effects of Nut Thinsting on the Bolt Load Reduction in Bolted Flange oints Under Internal Pressure and Bending Moments," ASME 2013 Pressure Vessels and Piping Canference, PVP2013-97191, Paris, France, July 14-18, 2013, 18 DOL 10.1115/P¥P2013-97191 (httpy//praccedings asmedigitalcallection.asme.ceg, proceeding aspy7articleid=1815358) Kovas, W. |, “Design for Leakage In Flange Joints Under External Loads” ASME 2005 Pressure Vessels and Piping Conference, Vol. 2: Computer Technology, PYP2005-71254, pp. 53-58, Denver, CO, USA, Tuly 17-21, 2005, DOL; 10.1115/PVP2005-71254 (hetpy//proceedings asmedigitalcollection.asme.org/ Proceading asp 7articletd=1574219) Payne, |. Rand Schneider, R.S, "On the Operating Tight: ness of H16.5 Flanged Joints, ASME 2008 Pressure Vessels and Piping Conference, Vol. 2: Computer Appl. «ations Technology and Bolted joints, PVF2008.61501, pp. 115-124, Chicago, [L, USA, DOL: 10.1115/PVE2008- 61561 (http://praceedingsasmedigitalcollection asme.oeg/ proceeding,aspx7articlesd=1634570) ‘beeraed Lug A. Cardenas. Singh aae ense on Copy neluorng and sharing praiaAPPENDIX A TRAINING AND QUALIFICATION OF BOLTED JOINT ASSEMBLY PERSONNEL A- INTRODUCTION AcL1 Scope A-LdLd Background. This Appendix was developed in response to 2 need expressed by some in the bolting services industry. It provides guidlines for establishing uniform criteria for training and qualifying baited joint assembly personnel. [t also provides guidelines for quality control of the program. The recommendations autiined in this Appendix are intended as a guidetine, and they may be applied aifferency by diferent user orga nizations, The judgment either to apply or to not apply these guidelines vests entirely with the user. A user or ganization may use its in-house, company-specific program thar is managed, audited, and maintained by ‘a in-house qualified employee, The organization may for may not use the services of an Appendix A~Cualifled Bolting Specialist User organizations who choose to use provisionsof this Appendix should specify the level of qualification required, Examples include the follawing, (2) An organigation may require only ane Appendix A~ (Qualified Botting Specialist who works with a number of bolting assemblers. (®) An organization may require that 2 group of Appendix A-Qualtied Bolting Specialists work in the or- ‘ganization (6) An organization may require each assembly team ‘working in aplantto be.as aminimum,ledby anindividual Who is an Appendiz A-Quslified Senior Bolting Specialist See also para, ALLA, A-1.1.2 Qualified Botting Spectallsts, Qualified Senior Bolting Specialists, and Qualified Bolting Specialist Instructors (a) This Appendix includes requirements for the training. qualification, duties, and responsibilities of (Qualified Batting Spectatists, Qualified Seniar Batting Spe— cialists, and Qualified Bolting Specialist Instructors: engaged in the assembly and disassembly, including, inspection and quality assurance, of (1) pressure vessel pressure-houndary bolted joints (2) piping pressure-boundary bolted (3) storage tank pressure-boundary bolted joints 19 (@) Additional supplemental qualifications may be ‘obtained on the basic training toextend the qualifications, duties, and responsibilities to include (1) powered equipment (2) heat exchanger pressure-boundary bolted joitts (3) special pressure-boundary bolted [olnts The process for obtaining the various levels of qualifi- cation ave outlined, for information, 1a Figure A-1. A-L.1.3 Quallfication. ASME PCC-1, section 3 recom- ends that jolnt assemblers and supervisors be qualified bby an organization in arenrdance with the requirements ‘contained in this Appendix Inthe qualification process, the Qualifying Organization conducts training, demansteations, and. practical and ‘written examinations to determine person's general -nowrledge of bolted join: assembly and related technical areas. No determination ismadeof an individual's capabil- ieies in applying that knowledge within a specific work ‘environment or under actial working conditions. tremains the sole respoasibllity ofthe employer of the individual to determine the individual's competency for the task assigned. A-LLA Covered Assembly Activitles. This Appendix can be applied to any person who is invalved in the assembly/disassembly or quality assurance activities concerned with pressure vessel, piping, and tank Yolted joints, It applies to persons typically employed by, but nor limited to, the following: (@) jurisdictional authorities (4) manufacturers, installers, and maintainers of equipment (@) equipment ayers and thelr employees {(@) contract bolted joint assembly personnel (@} labor organizations @) educational institutes A-LLS Exempt Assembly Activities. This Appendix does net caver personnel engaged in the assembly of structural-type bolted joints or pressure-baundary, bady joints on rotating equipment, These types of bolted joints are not covered by the miniaum training curriculum outined in this Appendix, Leersed to Luig A Candenas Sale wer leensecr Copying set, and sharing pohFigure A-1 Appendix Procedure Flowchart ‘Qualifying Organizatian creates # Quslifeation Program that complicw with ASME PCC-1, Appetit A The progrars shall include (a) taining af fundamentats (pars. 8-2-3) (| practics! demonstration and examination ipara. A-2-4) (ec) experience requiremenss (naras. A-22, 43.3, and ded. th (8) maintenance requirements (pares. A-26, 8.3, and 4.2) (o} ality assurance (section AS) ¥ ‘Qualifying Organization should contract sad submit the Qualification Program ta an independent Review Organization Review Organization Uaterrines Yaa the Qualification Program complias with ASME PCC-1, ‘Appendic& + LJ Raviow Organization conducts ‘Qualifying Organization conduets taining — ongoing reviews of tad assessment af individuals Auatitication Program: Yeo Individuat passes? ‘Gualiication Program ‘Qualifying Organization roviows and assesses individual experience and qualification ‘msintanance (reference towers) ldividuat passas? ‘Qualifying Organization collects ant collates user feedback periadically Ipica. A-5.5) Roviow Organization periodically sollatas usor feedback from ‘Qualifying Organizstions (para. A-5.5) 20 Leersed to Luig A Candenas Sale wer leensecr Copying set, and sharing poh(19) A-L2 Definitions ‘Terms used in this Appendix have the meanings specl- fled inthe following definivions. Other terms used havethe meanings specified in section A-3 of thls Appendix. ASME: The American Society of Mechanical Engineers, ‘pokup wrench: thetoolusedto secure the nutor bolt head ‘opposite to the one being turned or torqued. bolting assembler: x person meeting the experience qual fications of para. 4-2.2 who le engaged inthe assembly of bolted joints in accordance with the recommendations: contained in ASME PCC-1 but has not yetreceivedteaining: and qualification from a Qualifying Organization. bolting instructor: 4 person meeting the experience qual! fications of paca. A-+.L who is engaged in the assembly of bolted joints and the training of bolting assemblers in accordance with the recommendations contained in [ASME PCC-1 but has not yer racolved training and qual! fication from a Qualifying Organization, bolting crainee: a person undergoing training to become. Qualified Bolting Specialist current edition: the edition ofthe referenced cade or stan- dard that is specifically cited in ASME PCC-1 or was in effect at the time of publication of this edition of ASME POC, heat exchanger/tubesheor joines: goskated bolted joints that comprise the pressure-boundary closure betvrsen the tubesheet and the mating shell and tuboside girth, flanges and that require special assembly considerations (see para 4-2.3.3). The gaskars for these joints are gener- ally located entirely within the circle enclosed by the bolt hholes, with no contact outside this circle; however, this is not intended to exclude ether configurations, such as Hat faced flanges, from this Appendis, Industry Organization: an organization that rapresents the lntareses of users ef bolted |elnt assemblers. Jocestedition: the larest edition imeffectatthetimect refer Material Safety Bara Sheet (MSDS): data sheet for chems\~ cals that defines important information such as the levels of toxicity, flammability, and first-aid actions required, personal protective equipment (PPE): the safety equipment (safety glasses, satery boots, earplugs, etc) required to perform the assembly task piping jolacs: similar to pressure vascel joints; howaver, considerations relating realignment and external loadings: con the joime can govern design and assembly require- ments. The gaskets for these joints are generally located entirely within the circle enctosed by the balt holes, with no contact outside this circle; however, this is mot Intended to exclude other configurations, such a flat-faced flanges, from this Appendix: a powered equipment) hydraulic or pneumatic joint ‘assembly equipment, such a3 a hydraulic torque ‘wrench, pneumatic torque wrench, ar hydraulic bolt- tensionlag equipment pressure vessel joints: gasketed bolted joints that comprise the pressure boundary closure between two flanges or between a flange and a blind. The goskets for these Joints are generally located entirely within the circle enclosed by the bolt holes, with no contact outside this cece; however, this ig not antended to exclude other configurations such a fat-faced flanges, fromthis Appen- ax, (Quolicatian Manuar: the dacumentacion ofthe Qualifica- ton Program in accordance with para. A-5.2. Qualification Program: a Qualifying Organization's rogram, which is used to qualify bolting assemblers, senior bolting assemblers, and bolting instructors, ‘Qucifed Belting Specialise: & person qualified by @ Quatl- fying Organization as meeting the requirements of sectlon Ac? of this Appendix. ‘Quolifed Boling SpecilieeInsructor: a person qualified bya Qualifving Organization as meeting the requirements of section A-f of this Appendix. ‘Qualified Senior Botting Specialist: a person qualified by a ‘Qualifying Organization as mesting the vequirements of section A-3 of this Appendix, ‘Qualifing Organization. an cepanization that undertakes the training. demenstration, and practical and theoretical ‘examinacions outlined inthla Appendix to quality abolted joint assembler. Review Orgonization: an independent organization that conducts quality conteol reviews of the Qualification Program. Culdance for selection of Review Organizations is provided in pare. A5.3 ring-Diee fo(nts (RTP) anges fitted with metal lag wpe foint gaskets (a5 detailed in ASME B16 20), sonior boiting assembler: person meeting the experience qualifications of para. A-3.1 who is engaged In the assembly of bolted joints in accordance with the recom mendations contained in ASME PCC-1 but has nat vet received training and qualification from « Qualifying Or ganization special joints any site-or process-specific Ranged coninec- ton requiring different or additional instruction or considerations for assembly euchax clamped connectors, valve bonnets, and valve body jolats} subject-matter expert (SME): an individual considered Jmowledgeable in the field of bolted joint assembly. Guid- ance for selection of SMES is given in para. 5.4 ‘beeraed Lug A. Cardenas. Singh aae ense on Copy neluorng and sharing praia10 ‘A-1.2 Reference Documents Where the eferenced standard ercodedoes notinclude aneffective dave and a specific editions notreferenced in ASME PCC-1, the latest edition of the code or standard. should be used. A-L.3.] API Standards API Standard 660, Shell-and Tube Heat Exchangers API Recommended Practice 686/PIP REIE-686, Recom- mended Practice for Machinery Installation and Instal lation Design, Chapter 6, Sections 46 through 4.9 and Figue B+ Publisher: American Petroleum Institute (API), 200 Massachusorta Avenue NW, Suita 1100, Washington, De 20001-5574 (wwvw:api.org) A-1.3.2 ASME Codes and Standards ASME BL, Unified Inch Serew Threads (UN and UNR Thread Fann) ASME BL7, Screw Throads: Nomenclature, Definitions, and Letter Symbols ASME B165, Pipe Flanges and Flanged Fittings: NPS "4 ‘Through NPS 24 Metric/Inch Standard ASME B16.20, Metalic Gaskets for Pipe Flanges: Ring- Joint, Spiral-Wound, and Jacketed ASME B16.4?, Large Diameter Steel Flanges: NPS 26 Through NPS 60 Metric/Inch Standard ASME B31, Process Piping ASME B46.1, Surface Texture (Surface Roughness, Wavi- nose, and Lay) ASME BPVC, Boilerand Pressure Vessel Coda, ction VL Division i, Mandatory Appendix? and Nonmandarory Appendix § ASME PCC-2, Repair of Pressure Equipinent and Piping Articles 303, 305, and 501 Publisher: Tae Aunetican Socety of Mechanical Engineers (ASME), Two Park Avemte, Nev York, WY 10016-5980 {www asnseorg) A-1.3.3 PIP Publication PIP VESV1002, Fabrication Specification for Vessels: ASME Code Section VIM, Divisions 1 and 2 NOTE: GeealseAP! Recommened Practice 60¢ /PIP REIE-96in para a3 Publisher: Process Industry Practices (PIP), Construction Industry Institute, The University of Texas at Austin, 3925 West Braker Lane (R4500), Austin, TX 78759 Gwww.pip-org) 2 A-134 U.S. Federal Regulations 29. CFR 1910119, Process Safety Management of Highly Hazardous Chemicals Publisher: Occupational Safety & Health Administration (OSHA), US. Department of Labsr, 200 Constirution Avenue, Washington, DC 20210 (www.oshageu) 8-135 WRC Publication WRG Bulletin 449, Guidelines for the Design and Installa- ‘on of Pump Piping Systems Publisher: Welding Research Council (WRC), P.O, Box 201547, Shaker Heights, OH 44120 (wnew forongineors arg/welding research-council) £6136 Handbook Bickford, [Hn Intraduction tthe Design and Behavior of Boited joints, Mareal Dekker, Inc, Naw York (1995) A-2 REQUIREMENTS FOR QUALIFIED BOLTING SPECIALISTS A-2.1 Qualifications A Qualified Bolting Spectallor shall have received the training and shall possess practical experience to comply with the requlremants outlined (n this section ‘A Qualified Balting Specialist shall verify that he or she ‘mots the qualifications in paras. 42.2 through A-2.6. A-2.2 Experience ‘The bolking assembler shall have worked in the Feld with the assembly of balted jeints far at least 6 ‘months full time, or the equivalent part-time period as defined in Table A-1, The experience may be obtained prior to the required training and practical examinations asoutlined in para. A-2.3 and para.A-2.4, respectively. The ‘experience shall be sufficiently broad to ensure the indi vidual has had exposure to move than half ef the aspects coveredin the training outlined in para, 4-2.3, Theexperi- fence should be documented by references fram Senior Bolting Assemblers, Qualified Senior Bolting Specialists cor Qualified Belting Specialist Instructors indicating ‘that the field experience obtained meets the requirements ofthis Appendix. An examplereference sheet ls suppliedin Form A-1, Atleast one reference should be from 3 super visarat the individual's current or provious placeof workk An individual may obtain the fleld experience subsequent to comptetion of the taining, in which cage they are not considered qualified until sueh timeas they have sufficient experience to obtain thetr qualification, Leersed to Luig A Candenas Sale wer leensecr Copying set, and sharing poh‘Table A-1 Guidance for Work-Site Experience Equivalent Time ‘Assensed ‘line worked ‘Worksite Experience requ (oto accnebly on a daly anal Tafrequact but with intense Gerlods Hatin wocked cea sesertiy a least & week per monty snd st leat a otal of fie third he tim worked! ta pear) Sporadic Qotnt assembly at mrt time feeguancy lous than tht for ‘worked “infreauect) In the case of an individual with powered equipment, ‘neat exchanger, oF special Jaint supplemental qualifica- tions, the experience shall include at least one-quarter of the time spent working on those stems of equipment. ‘Where the frequency af wrorldng on such equipment is less ‘than this, the tlme period prier to achleving the supple mental qualification shall be extended natil an equivalent period has passed. A-2.3 Training of Fundamentals ‘The Qualified Boltizg Specialist shall have adequate: training on the fundamentals of the assembly, operation, land quality assurance of boltad joints. Practieal and theo. retical examinations shall be given at the end of such waining te ensure, to the satisfaction ef a Qualified. Bolting Specialist Instructor, that the candidate has attained awareness in the topics outlined in (a) through (1) below, The curriculum of this training stall ensure candidates are aware of the importance of the following issues when werking with bolted joints. While same areas, such as health and safety, are ‘outside the scope of ASME PCC-1, for completeness in describing a typical training course, thay Aave been, Included for purposes of awareness only. Asa minimum, the following topics shall be addressed: (2) General Health and Sojety Precautions. Discuss common health issues and safety precautions per the re- quitements of applicable government health and safety: regulatory bodies and plant-specific regulations. Ensure awareness iu areas such as hazardous chemi cals/gases, personal protective equipment (PPE), hazard communication, procedures for opening process: aquipment or piping, kearing protection, confined ‘space entiy, scaffold safety, personal fal prazaction, stair ways and laddars, rigging, respiratory protection, asbestos considerations, walking and working surfaces, and job safety analysis, including (1) common procedures for work permits and ensuring system isolation (2) finger pinch pointe with assembly and alignment equipment @ ry from tightening tole 23 (4) werking around heavy equipment (eranes and bundle putters) (5) awareness of asbestos gaskets and fiber insula- tion or refractory dust (8) Generat Personal foinr Assembly Equiprient Require- (1) PPE — use of appropriate PPE is required at al times (2) flashlight, for checking gasker allzament/condi- tion in joint (3) tape measure, for checking component dimen- sions (4) wire brush (matorial specific; eg, stainless steel for stainless flanges and bolts} (3) cleaner (material and process-medium compa- Able) and light dusting of gasket adhesive for vertical flanges; see pare. 6c), (6) basic joint alignment equipment (pry-bar, drift ing. 28 Appendix E) (7) site or corporate guidelines () Principles of Bott Elongation, Bolt Load, ahd Gasket Seress (1) relationship berween bolrstress and boleelongs- tion {see para. 10.2) 2) relationship between belt stress and gasket stress during assembly and operation (pressure and temperature effects) (3) influence of bolt length on bolt lead lors due to ‘Sasket creep relaxation and surface embedment loss (4) relationship between applied torque and achieved bolt stresa/load (5) bolting terminology, inctuding common terms found in the field and their relationship to each other fea. kips, psig, pst. tb ft-lb, Nem, ket, tpl) (@) Fanctianatty of Gasket and Sea! (1) purpose of a gasket (2) effect of gasket stress on leak rate (3) effect of bolt load loss (creep/relaxation and ‘operating conditions) on joint leakage and overall joint reliabitiry (2) Gasket Types and Their Limitations (1) summary of common gasket cypes and materials (2) sensitivity of diferent gasket types to-assembly procedures (3) maximum allowaiile gasket stress (4) minimum required gasket stress (5) awareness ofthe need for chemical compatibility (6) awareness of temperature limits (B Bote Types and Their Limitations (i) brief decail of commen bolting specifications, including yield strength (2) nut=bolt combinations, nut strength versus bole strength (3) generic material temperatare limits (4) materials for stress-corrosion-cracking environ- ments ‘beeraed Lug A. Cardenas. Singh aae ense on Copy neluorng and sharing praiaForm A-1__ Example Reference Sheet ASME PCC-1 Appendix A Qualification: Confirmation of Work-Site Experience Please type or print legibly and return to the applicant. INSTRUCTIONS APPLICANT: Cormplate tems 1 ai 2, then farward thes farm to the individual serving as your wotk-experience reference. Allwork experience references must have worked with you atleast during the time pesiod being validated, REFERENCE: The following individual ic applying to receive qualification a=: 9 Golting Speciaet per the qualifications ant requirements outlined in Appendin A of ASME PCE-7. Your name has tcen given ase reference ta verify the requited Minimum Wark Site Expecienee. The ASME PCC 1 Appendix A Qualifying Organization is charged with the responsibility of usltying only thaze indisduale who have demanstrated a proficiency inthe wezembly, operation, and quality assurance of bold jones. Your assictance in helping mate that determination is appreciated. Applicant ntormation 1. Applicants name: os ee pee Fist) (dale) ast (Ste th 2, Mailing address: ‘Street acess) (State iGounary) Reerenes Information 8. Raterence’s names i Fret ‘tice ast iSt arti) 4. Maiting address: ‘ureet address cay ise) \Gountryh (Pons cade) 5. Work phon Home phone: mai 6. Ara yous (select one) — Senior Botting Assombler? To. 71 Yes 1 Yeo stata experionce Ousted Senior Setting Specialist? (I No [] Yes 1 yes: Qualifying Organization and nursbce Expiration date: _— Ousted Senior Boting Specialist ssructor? “I no C] Yes 1 ye8, Gusting Organization and number Expiration date 4 Leersed to Luig A Candenas Sale wer leensecr Copying set, and sharing pohForm A-1 (Back) 7. Wot i your busines reltionship to the applicant? 8, Hew many years have you known the applicant? 9. Keeping in mind the intent to-ensure that applicants for Botting Specaliet qualiication havo broad, prior ww rksia ‘experienc in boited joint essembiy that meets the iment of ASME PCC-1 Appendix A, nara, A:2.2 {8} Do you confirm nat the applteant has worked in the fota-with the assembly af bolted joints for ipiogsn check one _at leat 6 manthe fulltime wih frequent joint assembly on city ba Ne D ves ‘a Jenst 1 year with infrequent jeint assembly, with intense periods sceurting at eset 1 week permanth snd at least a total of one thie ofthe time worked in that year? Ne Eves atleast 2 years with mutiie, sporadic periods of joint assembly? Ne Dv {t) Inyour estimation, hax the applicant's boted jcint szeambly work experiance been sufficiently brosd for himvhar {0 develop a wide renge of sills and knowledge nazessary o form the foundation fr further training end wtimate ‘quallcation 26 a Cualied Boiting Specsalit? ON Dive 10, Do you recommend the applicant for quaificetion 63 @ Qualified Botting Specialist? [] No C1 Yes 17, Signature of reersace 25 Leersed to Luig A Candenas Sale wer leensecr Copying set, and sharing poh(5) corrsion resistance (6) coatings for assembly and disassombly @) ldtentification of Correct joint Components (4) bolt and nur identification marks (2) installation of bolts and studs such that marked ‘ends are all on samne side of jolnt, with mut identification ‘marks facing out, to facilitate inspection (3) Mange identication marks (3) gasket identification marks and spiral-wound ‘gasket color codes and types (3) use of piping-arrangement drawing er system diagram to sdentify and verity correct materials far gasket and fasteners (h) Manual Torque joint Tightening (1) working parts of a torque wrench (2) setting required torque values on commen types of wrenches (3) bolting procedures (number of crass-pattern passes) requlved to achieve desired bolt torque (see section 9) (a) accuracy of belt torque tightening versus that of ‘manual tightening, (5) variables affecting toque () The Importance of Using the Specified Lubricone (see section 7) (1) purpose of lubricant (2) effect of type of lubricant (3) where to use lubricant (under not and on bolt threads) (9) limitations of lubricants, including oxygen teni- ton, exidation, temperature, shel! life, catalyst peisoning, ‘and stress corrosion cracking (compatibitity with process uid and materiale of construction} (5) amount of lubricant to be usd (6) contamination of lubricants during assembly (7) Interpreting the label and MSDS information G Techniques ised for Loa Control [2) techniques used for load contral by torque measurement (2) techniques used for load contrel by hydraulte tension (3) techniques used far load control by Length ar strain measurement (see paras, 10,1 and 10.2 and Figures 1 and 2) (4) accuracy of each method and relationship to service or folnt criticality (see Table 2) (4) Calibration and Maintenance of Bolt-Tightening Equipment (1) requirements for maintenance of common field equipment (2) inspection of common field equipment (espo- lally torque wrenches) (3) familiarization with methods for calibrating ‘common field equipment (4) importance and frequency of calibration ) Anepection and Reporting Defects or Faults 26 (41) flange-face gasketcontactsurfaceinspestion (see section $ and Appendix D) (2) acceptable levets of surface imperfections corre- sponding to different gasket types (3) bolt inspection (thread form. corrosion. and free- running not for triggering replacement, see section # and Appendix N (4) inspection of flange and nut cantact surfaces (for azalliag, paint, or corrosion, see section 4) (5) joint gap measurement (see section 11) (4) joint tolerances and alignment (see Appendix E) (7) joint-tightnass leak check (see section 12) mu) Procedure for Preparing a joint for Clesure Pa (2) methods for holding gasket in place (including the detrimental effects of excessive adhesive and use ‘of nonapproved methods such as heavy grease or tape, se2 section 6) (2) system cleanliness requirements {h) Gasket Hondiing, Preparation, and Instllotion (1) tse ofa single, now (not used or damaged) gasket for final installation (see section 6) (2) final inspection of gasket seal surfece and gasket (dimensions, type, and damage} (3) ensuringgasket can be inserted intojointwithout damage (4) ensuring gstketiscorrecty located (use offlange bolts or light dusting of approved adhesive sprays) (0) Sources of Information on joint Assembly (1) ASME Pot-L (2) corporate and site standards ahd specifications for gaskets and piping (3) corporate and site standards for joint assembly (4) corporate and site standards and specifications for bolt loads and assembly techniques (P) Safe Joint Disassenibiy ane Assernbiy (2) ensuring pressure isolation, valve-tagging systems, and safe work practices {ge# section 15) (2) verification of pressure isolation, gas detection, and safe entry into systom (2) temporary support and/or rigging considera- tions for joint components (4) working on Internal foines and high-level or bbelow-grade joints (scaffold and confined-space entry) (@) Joint Assembly Procedures (1) identification ofcorrect assembiy target boltlaad (2) reason tor needing yatvern passes in procedure (2) reason for needing multiple passes in procedure (see Appendix |) (A) measurement of jaint gapsdturing assembly (see para. 11.1) (5) hydraulic or pneumatic testing of joint after assembly (see section 13) (8) measurement of joint gaps after assembly (sce para. 1.1) ‘beeraed Lug A. Cardenas. Singh aae ense on Copy neluorng and sharing praia