JOB SPEC.

BD0425A-57A1
Page: 1 of 22
Rev.: I01
Date: Dec. 11, 2008

BOLT-UP POCEDURE FOR

CRITICAL FLANGES

Hellenic Petroleum S.A.

Thessaloniki Refinery Upgrading Project
Thessaloniki Greece
1-BD-0425A

REVISION INDEX
PAGE

REV

DATE

1
I01
11/12/08
2*
I01
11/12/08
3
I01
11/12/08
4*
I01
11/12/08
5*
I01
11/12/08
6
I01
11/12/08
7
I01
11/12/08
8
I01
11/12/08
9
I01
11/12/08
10
I01
11/12/08
11
I01
11/12/08
12
I01
11/12/08
13
I01
11/12/08
14
I01
11/12/08
15
I01
11/12/08
16
I01
11/12/08
17
I01
11/12/08
18
I01
11/12/08
19
I01
11/12/08
20
I01
11/12/08
21
I01
11/12/08
22*
I01
11/12/08
* Asterisk represents pages revised for this issue.

Initial issue
Entire specification reissued
Revised pages only attached

Please replace revised pages with those now in your possession.

Prepared by: E. De Rogatis

Signature:

Approved by: F. Chisoli

JOB SPEC. BD0425A-57A1

Page: 2 of 22
Rev.: I01
Date: Dec. 11, 2008

BOLT-UP POCEDURE FOR

CRITICAL FLANGES

CONTENTS

PARA.

SUBJECT

I.
II.
III.
IV.

V.
VI.
VII.
VIII.

INTRODUCTION
FACTORS AFFECTING BOLT-UP RELIABILITY
PREPARATION PROCEDURE
BOLT-UP PROCEDURE
A. TORQUE WRENCH METHOD
B. BOLT TENSIONING METHOD
ASSEMBLY PROCEDURE QUALIFICATION
MAXIMUM BOLT STRESS
STAMPING/TAGGING OF FLANGED JOINTS
INFORMATION FOR MATERIAL REQUISITION PREPARATION

FIGURE "1"
FIGURE "2"
FIGURE "3"
FIGURE 4"

ALIGNMENT ALLOWANCES FOR PIPING FLANGES

FLANGE MAKE-UP CHECK-LIST
BOLT ELONGATION RECORD FOR CRITICAL FLANGES
BOLT UP REPORT FOR FLANGED JOINTS

JOB SPEC. BD0425A-57A1

Page: 3 of 22
Rev.: I01
Date: Dec. 11, 2008

BOLT-UP POCEDURE FOR

CRITICAL FLANGES

I.

INTRODUCTION
A.

This Job Specification is applicable for bolt-up of critical flanges of equipment

and piping, as defined at below paragraph I.C, by means of adequate tools
procedure.

B.

The information contained here is aimed to provide a controlled bolt-up

procedure for critical flanges to achieve the plant delivery to the Owner with
leakage free joints at any condition.
This Job Specification does not cover "Post Start-up" operations.

C.

A recommended criteria for selecting critical joints requiring special treatment,

including controlled bolt-up, is as follows:
1.

2.

Equipment
a.

Flanged joints with bolt size 1-" and greater.

b.

Flanged joints with A-193 Grade B7M (when required by

ExxonMobil GP 06-01-01, paragraph 8.1.1.1) and A-320 Grade
L7M bolts, regardless the size.

Piping system
a.

Flanged joints with nominal size 6" NPS and above and rating
900# and above.

b.

Flanged joints with bolt size 1- and greater.

D.

This Job Specification has to be considered a guideline for

Vendors/Contractors rater than a series of mandatory requirements.
Vendors/Contractors shall develop their own bolt-up procedure (to be issued
for FW/HELPE review) based on the indication shown on their document. This
Job Specification does not cover flange joint design that shall be in
accordance with the applicable specifications, ASME code and standards.

E.

As "Vendor" it is intended the equipment (Vessel, exchanger etc.)

manufacturer; as "Contractor" it is intended the organization in field that will
supply the bolt-up services.

F.

Vendor is responsible for correct bolt up procedure of all critical flanges proper
of his supply, whether performed by him in his shop or repeated by other in
field.
Vendor has to perform the bolt-up activity in his shop according to a.m.
procedure, considering that a waive may be asked for critical joints to be
reopened in field (such as Vessel manways).

BOLT-UP POCEDURE FOR

CRITICAL FLANGES

G.

Contractor is responsible for correct bolt up procedure of all critical piping

joints.
He shall perform the bolt-up activity of:
-

II.

Piping joint as per his own procedure

Equipment joint as per Vendor procedure (see F above)

H.

In particular, Vendor/Contractor shall define in his procedure the maximum

bolt stress to be reached without damaging the gasket flange assembly,
recognizing that the values given in TABLE 2 and para VI are indicative and
referred to piping standardized flanges only. Appropriate calculation shall be
submitted for FW/HELPE review in order to demonstrate the suitability of the
gasket flanged assembly for the selected maximum bolt stress.

I.

Vendor/Contractor shall provide a Final Bolt up Report for any flanged joint
using the form given in FIGURE N 4 of this Job Spe cification.

FACTORS AFFECTING BOLT-UP RELIABILITY

A.

III.

JOB SPEC. BD0425A-57A1

Page: 4 of 22
Rev.: I01
Date: Dec. 11, 2008

The major factors for successfully making up a bolted joint and eliminating
leakage are:
1.

proper selection and design of the component, i.e. flanges, gaskets

and bolts;

2.

proper preparation, inspection and installation;

3.

correct bolt-up procedure.

PREPARATION PROCEDURE
A.

Prior to gasket insertion

1.

Clean gasket seating facing using wire brush (use stainless steel
bristles on alloy components).

2.

Check conditions of flange faces for scratches, dirt, scale, remnant

gasket and protrusions. Flange faces with coarse tool marks or
scratches that form leakage paths should be refaced.

3.

Check that flange facing, gasket material, dimensions and type of

bolting are in accordance with the general specifications.

BOLT-UP POCEDURE FOR

CRITICAL FLANGES

4.

5.

JOB SPEC. BD0425A-57A1

Page: 5 of 22
Rev.: I01
Date: Dec. 11, 2008

All gaskets should be replaced with new ones whenever an opened

joint is to be closed again. This recommendation is mandatory for soft
material gaskets and metalloplastic gasket (such as spirally wound or
double jacketed gaskets).
Visually examine gaskets prior to installation to assure they are free
from defects. All damaged gaskets (including loose spiral windings)
should be rejected.

6.

Use straight steel rule edge to check facing flatness. Flange shall have
bearing surfaces for bolting that are parallel to the flange face within 1
(one) degree. Wrapped or badly corroded flanges should be
replaced/repaired.

7.

Flanges at rest should be parallel. Alignment should be achieved by

cutting and re-welding the pipe where possible. When trueing flanges,
make sure that there are no residual stresses in the joint, particularly in
machinery piping. Guidelines of alignment allowance are given in
FIGURE N 1 of this Job Specification for pipe flan ges and 0,8 mm
maximum out of parallel tolerance for exchanger girth flanges. Final
alignment shall be filed and recorded for future reference using the
form given in FIGURE N 2 of this Job Specification . The use of flame
for the alignment of flanges is not permitted.

NOTE: Alignment can be checked using a straight steel rule.

B.

8.

Studs and nuts shall be cleaned using wire brush to remove any dirt
on the threads. Visually examine studs and nuts after cleaning to
ensure free from burrs. Nuts should turn freely on the studs for a
distance equal to their in-service make-up. Lubricate the threads and
nuts to flange contact surfaces with one of the anti-seeze products
indicated in TABLE 1 of this Job Specification; lubrication aids in
achieving required bolt tension uniformly for the flange.

9.

Align flange faces exactly, leaving just sufficient gap to insert the
gasket. Once flanges have been aligned up, visually examine them to
assure that an acceptable fit has been obtained. Use flange spreader
instead of wedges for wedging.

10.

Prior to inserting slip-blind, it should be checked for protrusion or burrs

at blind expecially at edges.

Gaskets and bolts insertion

1.

Visually examine gaskets, prior to installation, to assure they are free

from defects. Do not use sealing compound, grease or other paste or
adhesive on gasket or flange faces. Holding gasket in place may

BOLT-UP POCEDURE FOR

CRITICAL FLANGES

JOB SPEC. BD0425A-57A1

Page: 6 of 22
Rev.: I01
Date: Dec. 11, 2008

present a problem, but use of greases, pastes or other substances to

stick them in place should be avoided.
If absolutely necessary to use something to hold gasket in place, the
thin adhesive tapes such as surgical tapes or relatively stiff glazing
type putty may be used in place along the outside edges of gasket.
Tape/putty need to be located with care to avoid infringing on the
flange face/gasket seating surfaces.
2.

Visually examine the flange alignment to ensure that an acceptable fit

has been obtained. Studs inserted through the bolt holes of the flanges
should guarantee the sustained alignment of the flanges without
blocking insertion of the gasket.

3.

Insert the gasket between the flanges carefully to assure proper

placement. Make certain that gasket is properly true in joint.

4.

Insert all remaining studs and nuts on hand-thight. Do not pull up

studs in a manner that reaches uneven compression of the gasket.

5.

Ensure all bolts are installed with at least two threads protrusion
through the nuts at both sides. Where bolt tensioner is to be used,
protrusion shall be at least one bolt diameter on one of two sides.

NOTE: Vendor/Contractor shall carefully complete the table given in FIGURE

2 of this Job Specification (Flange make-up check list).

JOB SPEC. BD0425A-57A1

Page: 7 of 22
Rev.: I01
Date: Dec. 11, 2008

BOLT-UP POCEDURE FOR

CRITICAL FLANGES

ANTI-SEEZE - PRODUCTS
NAME

COMPOSITION

TEMPERATURE

MANUFACTURER

KEY

Graphite and Oil Paste

Maximum
343 C (650 F)

W.K.M.
P.O. box 2117 - Houston,
TX 77001

FEL PRO
C - 100

Molybdenum Disulfide

Maximum
400 C (750 F)

FEL PRO INC.

P.O. box 7450 - North
McCormick Boulevard
Skokie, IL 60076

MOLYLUBE
ANTI
SEEZE

Molybdenum Disulfide

Maximum
400 C (750 F)

BEL-RAY CO. INC.

P.O. box 526 - Farmingdale,
NJ 07727

FEL PRO
C5 - A

Colloidal Copper

Maximum
540 C (1000 F)

FEL PRO INC.

P.O. box 7450 - North
McCormick Boulevard
Skokie, IL 60076

(1)

JET-LUBE

Colloidal Copper

Maximum
540 C (1000 F)

JET-LUBE
P.O. box 212558,4849
Homestead Road - Houston,
TX 77026

(2)

NEVER
SEEZE
NICKEL
SPECIAL

Colloidal Nickel

All Temperatures

NEVER SEEZE CORP.

P.O. box 2910 - South
18th Avenue - Broadview,
IL 60153

(3)

SILVER
GOOP

Colloidal Silver

All Temperatures

CRAWFORD FITTING CO.

P.O. box 29500 - Solon Road
Solon, OH 44139

(3)

THREAD
EZE

Aluminium Powder
Talk and Oil

Maximum
1200 C (2200 F)

CHEMSEARCH SINGAPORE
P.O. box 1544 - Parkway
Builders' Centre, 02
Singapore

(1)
(2)
(3)

NOTES:
Not suitable for use on austenitic stainless steel materials.
Suitable for use on stainless steel materials.
Suitable for use on austenitic stainless steel materials.

TABLE 1

NOTES

BOLT-UP POCEDURE FOR

CRITICAL FLANGES

IV.

JOB SPEC. BD0425A-57A1

Page: 8 of 22
Rev.: I01
Date: Dec. 11, 2008

BOLT-UP PROCEDURE
A.

TORQUE WRENCH METHOD

This method shall be applied to piping flanges of case 2.a of the paragraph I.C
of this Job Specification (i.e. only for piping system when the flanged joints
have nominal size equal to or greater than 6 inches NPS and rating equal to
or greater than 900# but with bolts having a size less than 1 inch).
Hydraulic, pneumatic or beam type torque wrenches are commonly used in
bolt tightening. The hydraulic wrenches are normally preferred. Calibrated
torque wrenches have been used successfully for flange bolt-up. However,
their successful use in achieving a target bolt stress live depends on
qualification of the flange make-up operations and consistency in applying the
procedure developed. This involves consistency in:
1.

Determining by test the torque values necessary to achieve the

desired bolt stress.

2.

Ensure that the load bearing surfaces are in good conditions; check
the thread flanks, bearing surfaces of bolt head, nuts and the flange
surface.

3.

Clean and lubricate threads, nuts and/or bolt head bearing surfaces.
For thread lubricants and anti-seeze compound see TABLE 1 of this
Job Specification.

4.

Always run the nuts down by hand; if they don't run by hand, there is a
probably defect in the thread.

5.

"Hand" tighten bolts with a short wrench using the "CRISS-CROSS"

pattern shown in SKETCH 1. Do not tighten the bolts using impact
force.

6.

All torque wrenches shall be of adequate capacity and recently

calibrated. The system shall be tested on the "MOCK-UP" rings to
familiarize operators with its use and also to calibrate the equipment
before use. Certification of torque wrenches calibration shall be
available

7.

In the event that set-up or seizure of the nut being torqued is

encountered, back the nut off until seizure is eliminated and torque
again. Apply lubricant if necessary and replace the nut and/or bolt if
seizure occurs.

8.

Hold torque wrenches perpendicular to the axis of the bolt while torque
is being applied. If hydraulic torque wrench is used, ensure that the

JOB SPEC. BD0425A-57A1

Page: 9 of 22
Rev.: I01
Date: Dec. 11, 2008

BOLT-UP POCEDURE FOR

CRITICAL FLANGES

torque wrench reacts against a rigid support which is oriented parallel

to the axis of the bolts.
9.

The check of effective final bolt stress shall be performed as described

at paragraph VI.B of this Job Specification, therefore the two ends of
each bolt shall be machined smooth finish, perpendicular to the bolt
axis to allow the use of ultrasonic devices for bolt measurement.

10.

Bolts tighten by a Torque Wrench Method shall be submitted to a

qualification procedure as indicated in paragraph V of this Job
Specification.

TORQUING SEQUENCE
a.

Torque bolts and nuts in a "CRISS-CROSS" pattern as shown in SKETCH 1

using a minimum of four torquing passes and the maximum bolt stress as
defined at prevoius para I.H. Effective flanges bolting final torque value shall
be based on the calculated maximum bolt stress (the values indicated in the
TABLE 2 are for reference only)
PASS 1

Bring all nuts up snug-tight with a short wrench.

PASS 2

Torque to a maximum of 40% of the final torque value in

accordance with the sequence of SKETCH 1. Check the flange
is bearing uniformly on the gasket.

PASS 3

Torque to a maximum of 70% of the final torque value.

PASS 4

Torque to the final torque value.

b.

After the four basic torque passes are completed, repeat torquing the nuts at
least once using the final torque in a "CRISS-CROSS" manner until no
further rotation of the nut is observed.

c.

Continue torquing with the final torque in a clockwise or anti-clockwise

manner to ensure no further rotation.

d.

All torque readings and sequences of tightening shall be filed and recorded
for future reference using the form given in FIGURE N 2.

NOTE: Consideration should also be given to using "BOLT ELONGATION"

technique to confirm proper and uniform preload achieved on selected
critical flanges, i.e. Powerformer Effluent Exchangers girth flanges and pipe
flanges say exceeding 10" diameter and 900F in add ition to qualification of
equipment/operators as covered later.

JOB SPEC. BD0425A-57A1

Page: 10 of 22
Rev.: I01
Date: Dec. 11, 2008

BOLT-UP POCEDURE FOR

CRITICAL FLANGES

TYPICAL "CRISS-CROSS" BOLT TIGHTENING SEQUENCE

SKETCH 1

JOB SPEC. BD0425A-57A1

Page: 11 of 22
Rev.: I01
Date: Dec. 11, 2008

BOLT-UP POCEDURE FOR

CRITICAL FLANGES

FLANGE BOLTING TORQUE TO DEVELOP 345 N/mm2 BOLT STRESS

NOMINAL BOLT
DIAMETER (in.)

INITIAL
( N.m )

INTERMEDIATE
( N.m )

FINAL
( N.m )

MAXIMUM
( N.m )

1/2

27

40

55

70

5/8

40

80

110

135

3/4

95

135

200

240

7/8

135

230

340

410

200

340

470

570

1-1/8

270

470

680

810

1-1/4

340

680

950

1220

1-3/8

540

950

1350

1620

1-1/2

675

1080

1755

2095

1-5/8

1080

1890

2835

3375

1-3/4

1220

2295

3510

4185

1-7/8

1350

2970

4455

5335

1350

3375

5400

6480

NOTES :
1)

The shaded zone is indicated for reference only.

2)

Maximum torque shall only be used if leakage is still occurred after tightening to
the final torque.

3)

All bolts are assumed to be well lubricated. The figures in this table are intended
as a guide. Many unknown including the amount and type of lubrication will
affect the torque to obtain 345 N/mm2 bolt stress. The only reliable way to
determine bolt stress is to measure bolt elongation. If elongation measurement
indicate that higher or lower torque loads are necessary to achieve 345 N/mm2,
then the table shall be revised accordingly.

4)

This table is developed for ASTM A-193 Gr. B7 bolt material and for Raised
Face flange; in case of different material and/or facing refer to the maximum bolt
stress listed in TABLE 3 and decrease the bolt torques proportionally.
TABLE 2

BOLT-UP POCEDURE FOR

CRITICAL FLANGES

B.

JOB SPEC. BD0425A-57A1

Page: 12 of 22
Rev.: I01
Date: Dec. 11, 2008

BOLT TENSIONING METHOD

The use of a bolt tensioner is foreseen for cases 1.a, 1.b and 2.b of the
paragraph I.C (i.e. equipment and piping system flanged joints having bolts
with size equal or greater than 1 inch or equipments having bolts made of
A-193 Grade B7M / A-320 Grade L7M). This device saves labor and will
facilitate attaining very even bolt loading. The tensioning of bolts should be
performed by speciality company (Furmanite, UVIT or equivalent) using
proprietary equipment (bridges, pullers, hydraulic pumps, connection pipes,
manometers, etc.). Is important to notice that the herebelow procedure is a
recommended guideline and not mandatory; Vendor/Contractor has to submit
a proper bolt-up procedure for FW/HELPE review.
Ideally all bolts should be tensioned in one operation to ensure even loading
on the bolts and gaskets. It may not be practical to tension all bolts in one
operation, but at least 50% of the bolts equally spaced should be tightened in
one operation to ensure an acceptable degree of uniformity in loading. Bolt
tensioning should not be carried out for equipments that are in service under
pressure.
The following procedure is recommended (using an example of 20" - 900#
flange bolt-up) and 50% of the bolts will be tightened at the same time.
1.

Group the 20 bolts into two groups (10 A's and 10 B's) as shown in
SKETCH 2 and then mark them accordingly on the flange.

2.

Mount the 10 hydraulic pullers on the first 10 bolts say A's group of
bolts.

3.

Apply equivalent hydraulic pressure by operating the hydraulic pump

to give a bolt load equal to 100% of the maximum bolt stress (see
paragraph 1.H and paragraph VI).

4.

Check the hydraulic system if there is any pressure problem.

5.

Verify that the specified hydraulic pressure is applied to the tensioner

before running the nut down on each stud.

6.

Shift the pullers to the next group (group B) and repeat the steps 3 to
5, but applying a bolt load equal to 125% of the maximum bolt stress.

JOB SPEC. BD0425A-57A1

Page: 13 of 22
Rev.: I01
Date: Dec. 11, 2008

BOLT-UP POCEDURE FOR

CRITICAL FLANGES

BOLT PARTITION FOR BOLT TENSIONING METHOD

SKETCH 2

BOLT-UP POCEDURE FOR

CRITICAL FLANGES

JOB SPEC. BD0425A-57A1

Page: 14 of 22
Rev.: I01
Date: Dec. 11, 2008

7.

Repeat steps 2 to 6 by increasing the hydraulic pressure to 125% of

maximum hydraulic pressure, on the bolts of group "A".

8.

Repeat the steps 2 to 5 on the bolts of group "B" to check the hydraulic
pressure is 125% of the maximum required to obtain the required bolt
stress.

9.

The hydraulic operating pressure varies according to the type and size
of tools used. Reference shall be made to the equipment's
manufacturers specification.

10.

The specialized technician selected to perform the controlled bolt

tensioning of critical flanges shall develop in the preliminary operation
a diagram correlating the required pressure to be reached in the
hydraulic circuit connected to the tensioners and the required stress in
each bolt.

11.

The two ends of each bolt shall be machined smooth finish,

perpendicular to the bolt axis to allow the use of ultrasonic devices
(such as the BOLT SCOPE SMS produced by Pilgrim Moomside Ltd.
or equivalent) for bolt elongation measurement (in order to perform the
check of the effective final bolt stress as described at paragraph VI.B).
In addition a bolt extra length shall be provided to permit the use of bolt
tensioners (refer to paragraph III.B.5).

12.

Bolts 11/2 inch and larger and bolts made of A-193 Grade B7M / A-320
Grade L7M shall be fitted with hardened washers conforming to ASTM
F 436 under each nut. Washers fabricated from AISI 4140 material are
acceptable. Surface finish shall be 125 microinch (3.2 micrometers) Ra
or smoother on both sides.

13.

The specialized technician selected to perform the bolt tensioning shall

fill the form given in FIGURE N 3 stating the proc edures adopted
during the operations and the parameters adopted (pressure in the
hydraulic circuit, temperature of flanged joints, etc). The form shows
also the original length of bolts (unstressed conditions) and the final
length of bolts (stressed conditions).

14.

The protruding end of the tensioned stud bolts for equipment and for
piping flanges having diameter greater than 1 inches shall be
protected against impact by means of aluminium protectors for nut and
thread, type HTNTPCM by Hydratight Boltech or equivalent.

JOB SPEC. BD0425A-57A1

Page: 15 of 22
Rev.: I01
Date: Dec. 11, 2008

BOLT-UP POCEDURE FOR

CRITICAL FLANGES

V.

ASSEMBLY PROCEDURE QUALIFICATION

Each size of bolts for flange of case 2.a of paragraph I.C of this Job Specification (i.e.
only for piping system when the flanged jonts have a nominal size equal or greater
than 6 inches NPS and a rating equal or greater than 900# but with bolts having a
size less than 1 inch and therefore tighten with a Torque Wrench Method) shall be
submitted to a qualification procedure.
The qualification shall be carried out on mock-up flange and elongation of each bolt
shall be measured to ensure uniform bolt tension. For the finished joint, bolt
elongation should correspond to maximum bolt stress value tertermined as per para
I.H. 10%.
A.

B.

MOCK-UP QUALIFICATION PROCEDURE

1.

Prepare the stud bolt end to improve the accuracy of the stretch
measurement. The elongation measurement will be on the order of
tenths of millimeters.

2.

Measure and record (using the form of the FIGURE 3 of this Job
Specification) the initial length of bolts. Each reading should not differ
by more than 2%.

3.

Tight the bolts using the method described in paragraph IV.A of this
Job Specification. Read the final length of bolts and calculate the
elongation (at least 2 or 3 reading in order to determine the average
value; each single reading should not differ by more than 2% from the
average).

4.

Record the desired elongation and also the recommended tool setting
(torque value).

5.

The crew is considered "qualified" after having make-up two sets of

flanges bolted-up with the maximum bolt stress 10% (refer to
paragraph V.B of this Job Specification).

CORRELATION BETWEEN ELONGATION AND STRESS

1.

A suitable device for measuring bolt elongation is the use of an

ultrasonic probe.

2.

The formula derived from the basic stress-strain relationship is:

Stress
Strain = E, Modulus of Elasticity

JOB SPEC. BD0425A-57A1

Page: 16 of 22
Rev.: I01
Date: Dec. 11, 2008

BOLT-UP POCEDURE FOR

CRITICAL FLANGES

Elongation B - A Stress
Strain = Bolt Lenght = L = E
Elongation =

Stress
E xL

where L is the effective bolt length measured from center of nuts.

Stress
NOTE: for A-193 Grade B7 bolts: E = 0,001672.

VI.

MAXIMUM BOLT STRESS

A.

Correspondences
Vendor/Contractor shall define in his procedure the maximum bolt stress to be
reached without damaging the gasket flange assembly.
TABLE 2 of this Job Specification gives an example of torque values for
Torque Wrench Method (for reference only) based on the bolt stress of A-193
Grade B7 or A-320 Grade L7 for standard flanges.
TABLE 3 indicates the maximum bolt stress values recommended for some of
the flanges present in a refinery.
It is important to notice that there are some flanges where lower bolt stress
values are appropriate depending on the flange rating, and/or type bolting and
gaskets.
In case of the Ring Joint Flanges, lower maximum bolt stress values are
recommended for the higher flange ratings to avoid excessive bolt loads
which can lead to undesiderable deformations to ring gasket and flange
groove seating surfaces. Unlike raised face flanges, there is a little difference
in gasket seating area with ring joint flanges as flange ratings increase so
bolting loads are more concentrated in narrow zones of the ring groove. The
remaining situations are all governed by the material strength of the specific
bolt indicated (See also the previous point I.H.)

B.

Check of final bolt stress in Production

The check of final bolt stress shall be performed for all critical flanges. The
verification shall be based on the measurement of the bolt elongation
described at the previous para V.B.
The check will be spot, 10% of flanged joint (for piping) and at least 4 bolts of
every joint for equipment tightened by each crew, and it shall be performed as
follows:

JOB SPEC. BD0425A-57A1

Page: 17 of 22
Rev.: I01
Date: Dec. 11, 2008

BOLT-UP POCEDURE FOR

CRITICAL FLANGES

1.

measure with ultrasonic device (such as the BOLT SCOPE SMS

produced by Pilgrim Moomside Ltd. or equivalent) the bolt elongation
of four bolts diametrically opposite;

2.

check the correspondence of the specified bolt stress in the range of

10% of the bolt elongation measured;

3.

if the above correspondence will not be met in one bolt, then all the
bolting of the joint will be checked and, in case of no compliance, retensioned;

4.

in case of no compliance of all 4 bolts for more than two joints in the
same sampling, all the flanged joint tensioned by the crew who
performed the bolt-up during that working day, will be completely
checked.
MAXIMUM BOLT STRESS

FLANGES TYPE/RATING
Ring Joint Flanges
ANSI CLASS 900
Ring Joint Flanges
ANSI CLASS 1500
Ring Joint Flanges
ANSI CLASS 2500
RAISED FACE
RAISED FACE
RAISED FACE

BOLT MATERIAL
A-193 Grade B7
A-193 Grade B16
A-193 Grade B7
A-193 Grade B16
A-193 Grade B7
A-193 Grade B16
A-193 Grade B8M
A-193 Grade B8
(Strain Hardened)
A-193 Grade B7
A-320 Grade L7

MAX. BOLT STRESS (N/mm2)

275
205
205
170
275
345

TABLE 3

VII.

STAMPING/TAGGING OF FLANGED JOINTS

Each bolted joint shall be identified with a tag or stamp with the initials of lead man of
crew that performed the bolt-up.

VIII.

INFORMATION FOR MATERIAL REQUISITION PREPARATION

The following information shall be included in a Material Requisition covering the
specialist bolting Contractor/Vendor supply.

JOB SPEC. BD0425A-57A1

Page: 18 of 22
Rev.: I01
Date: Dec. 11, 2008

BOLT-UP POCEDURE FOR

CRITICAL FLANGES

A.

INFORMATION
REQUIRED
BY
A
SPECIALIST
CONTRACTOR/VENDOR (BEFORE BEGINNING)

BOLTING

The following information will be available to the Contractor based on

equipment drawings, Vendors procedures, piping sketches etc.
1.
Number of flanged joints;

B.

2.

Size and rating of flanges;

3.

Number of bolt, size and material.

Recommended bolt load

INFORMATION TO BE PROVIDED BY A SPECIALIST

CONTRACTOR/VENDOR (BEFORE WORK BEGINNING)
Before work
information:

C.

beginning,

Contractor/Vendor

will

submit

the

BOLTING

following

1.

Bolt-up procedure based on the recommendations of the present Job

Specification.

2.

Type of tools (tensioners) and accessories with number of hydraulic

heads and number of crews foreseen.

3.

Maximum pressure at which the tensioners are capable to operate.

4.

Maximum bolt extension needed beyond nut to accept puller bar.

5.

Hydraulic pump and accessories needed.

DOCUMENTATION TO BE PROVIDED BY A SPECIALIST BOLTING

CONTRACTOR/VENDOR (AFTER WORK COMPLETION)
After completion of the work, the following documentation shall be provided:
1.

Final bolt-up procedure.

2.

Flange make-up check list (FIGURE 2 of this Job Specification).

3.

Bolt elongation record (FIGURE 3 of this Job Specification).

4.

Flange alignment sheet.

JOB SPEC. BD0425A-57A1

Page: 19 of 22
Rev.: I01
Date: Dec. 11, 2008

BOLT-UP POCEDURE FOR

CRITICAL FLANGES

FIGURE N 1

A = 1 mm MAXIMUM OUT OF PARALLEL ALIGNMENT OF FLANGES MEASURED

ACROSS ANY DIAMETER
B = 3 mm MAXIMUM TRANSLATION OF BRANCHES OR CONNECTIONS

ALIGNMENT RAISED FACE ALLOWANCES FOR PIPING FLANGES

JOB SPEC. BD0425A-57A1

Page: 20 of 22
Rev.: I01
Date: Dec. 11, 2008

BOLT-UP POCEDURE FOR

CRITICAL FLANGES

FIGURE N 2

LOCATION

OF

FLANGES

Reference No. As Per Attached Drawing

Is Raised Face In Good Condition ?
Is Gasket Surface Clean ?

BOLTING

GASKET

Is Flange Alignement Within Tolerable Limits ?

Is The Gasket New ?
Type Of Gasket Used
Size & Rating Of Gasket
At Least 2 Threads protrusions
Are Threads Lubricated ?
Size Of Bolts Used
Type Of Material
Bolts Tightened In Correct Sequence ?
Is Controlled Torque Tightening Required ?
Initial Torque Value
Intermediate Torque Value
Final Torque Value

REMARKS

NOTES:

Contractor

: _______________________ Name of Technician : ________________________

Supervisor

: _______________________

Signature

: ________________________

FLANGE MAKE-UP CHECK LIST

Date : ___________

JOB SPEC. BD0425A-57A1

Page: 21 of 22
Rev.: I01
Date: Dec. 11, 2008

BOLT-UP POCEDURE FOR

CRITICAL FLANGES

FIGURE N 3

Flange Description/Location
Bolt Size

: ____________________________
L = Nut Face Distance Plus 1 Nut Height

: ____________________________

Hydraulic Pressure

: ____________________________

Temperature of Flanged Joint

Maximum Bolt Stress

: ____________________________

A or B

: ____________________________

125 % of Maximum Bolt Stress : ____________________________

BOLT N.

EFFECTIVE

ORIGINAL

FINAL

BOLT LENGTH

BOLT LENGTH

BOLT LENGTH

ELONGATION

BOLT ELONGATION

CALCULATED

(L)

(A)

(B)

(B)-(A)

( 0,001672 x L ) [1]

REMARKS

NOTES:
[1] The elongation coefficient mentioned is based on ASTM A-193 Grade B7 material; in case of different material or facing of flange, the
coefficient shall be revised accordingly.

Contractor

Supervisor

: _______________________

: _______________________

Name of Technician : ________________________

Signature

: ________________________

BOLT ELONGATION RECORD

FOR CRITICAL FLANGES

Date : _____________

JOB SPEC. BD0425A-57A1

Page: 22 of 22
Rev.: I01
Date: Dec. 11, 2008

BOLT-UP POCEDURE FOR

CRITICAL FLANGES

FIGURE N 4

BOLT UP REPORT FOR FLANGED JOINTS