Reliance Industries Ltd.

Hazira Maintenance Manual

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2.322 PROCEDURE FOR FLANGE JOINT TORQUE TIGHTENING INTRODUCTION This procedure explains general guidelines about torque tightening the mating flange bolts with gaskets to achieve leak proof joints. This is applicable to piping & equipment flanges of petrochemical plant. This procedure is not applicable for flange joints, where the tightening requirement is specifically spelt by the OEMs. This procedure is applicable to the metallic flanges only. POTENTIAL ENVIRONMENTAL ISSUES As defined by respective Plants POTENTIAL SAFETY/OCUPATIONAL HEALTH ISSUES Proper PPEs to be used wherever required in plant areas as defined by the plant. Permit instructions to be strictly followed to avoid personnel injury. Risk Assessment, as defined by the plant and mentioned in permit to work shall be strictly followed. PROCEDURE 1. 2. 3. 4. Ensure the cleanliness of threads of nuts & bolts- The nut should be driven freely with hand. The nuts & bolts with damaged/corroded threads should be discarded. Ensure the required length of bolts. B8M bolts & nuts should not be used above 455 degC. For high temperature service, i.e. up to 704 degC, ASTM A453 Gr. 660 fasteners should be used. (Any specific application, guidance of C&I deptt. may be obtained) Do not apply grease. Apply Molycote 1000 or specified lubricant depending upon the service conditions. Ensure the cleanliness of the gasket face. Make the rubbing surface of nut & flange absolutey free of dust, burrs, etc. Ensure proper gasket material & dimension. (Asbestos & Asbestos filler gaskets not to be used). Ensure the parallelity & required gap of the mating flanges. Ensure that the bolts are extended sufficiently & equally from the nut at both the ends. (Max. 2-3 Threads out side nut) Install all the bolts & drive nut with hands (Or spanners in case of bigger bolts).

5. 6. 7. 8. 9. 10.

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Reliance Industries Ltd. 11.

Hazira Maintenance Manual

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Start tightening using torque-wrenches (Manual/Pneumatic/Hydraulic/Electric) with proper torque setting. Torque values to be selected from Annexure I & II as per lubricants used. It is to be ensured that the proper sequence of tightening is followed. Torque tightening to be done in 3 steps of 1/3 torque, 2/3 torque & full torque. (The torque wrenches used shall be calibrated as per the calibration procedure & frequency). Inspect the joint for any deformation of gasket, flanges or fasteners after the tightening is completed. Hot-bolting not required for properly torque tightened flange joints. Note All the safety precautions mentioned by the Torque Tightening Gadgets to be followed. Risk Assesment to be carried out & followed as per job & site requirement. RESPONSIBILITY Responsibility for ensuring torque tightening as per the procedure & torque values lies with mechanical supervisor responsible for the job. Responsibility for calibration of torque wrencehes is with CES-Workshop.

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13. 14.

Reason for Revision: 00 First IMS Issue. By : A K Pandey

Approved by : P K Jain

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Reliance Industries Ltd.

Hazira Maintenance Manual ANNEXURE I

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Good For: Mating flange fasteners torque tightening. BOLT / TORQUE TABLE Ft.Lb SAE 1, SAE 2 30000 ASTM A 193 B-7 (See Note Below) 7/8" 1" ASTM 354 B8 60000PSI 7/8" 1" 1-1/4" 1-3/8" 1-1/2" 1-1/4" 1-5/8" 1-3/8" 1-3/8" 1-1/2" 1-3/4" 1-7/8" 1-5/8" 2" 1-3/4" 2-1/4" 2-1/2" 2-3/4" 2-1/4" 3" 2-1/2" 3-1/4" 3-1/2" 3-3/4" 4" 2-1/2" 2-3/4" 2-3/4" 3" 3" 3-1/4" 4-1/4" 3-1/4" 2-1/4" 1-7/8" 2" 1-3/4" 1-7/8" 2" 1-5/8" 1-1/8" 1-1/4" 1-1/8"

300 425 500 600 700 800 900 1000 1250 1350 1500 1600 1800 2000 2200 2600 3000 3700 4000 4400 5100 6000 7000 8000 9000 10000 11500 13000 14500 15500 16500 19500

1" 1-1/8"

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Reliance Industries Ltd.

Hazira Maintenance Manual ASTM A 193 B-7 (See Note Below) 3-1/2"

Page No. 4 of 5 ASTM 354 B8 60000PSI

Ft.Lb 20500 21500 24500 25500 29500 30500 35000 37000 41000 44000 47500 52000 61000 715000

SAE 1/ SAE 2 30000 PSI 4-1/2"

3-1/2" 4-3/4" 5" 3-3/4" 4-1/4" 4" 4-1/2" 4-3/4" 4-1/4" 5" 4-1/2" 4-3/4" 5"

3-3/4" 4"

The desirable load on B-7 Bolts is 55000 psi thro' 2-1/2" Bolt Diameter. The desirable load on B-7 Bolts is 50000 psi thro' 4" Bolt Diameter. The desirable load on B-7 Bolts is 40000 psi thro' Above 4" Bolt Dia. Above data is based on bolts lubricated according to the manufacturer spec. Due to variation in friction, it is recommend in extreme cases to check with bolt manufaturer , as this represents a guideline only.

Section No. : 2.322

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Reliance Industries Ltd.

Hazira Maintenance Manual ANNEXURE- II

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Good For: Mating flange fasteners torque tightening. Values Ft.Lb Annex ure -II SAE Grade SAE Grade SAE Grade 3, SAE Grade 6, SAE Grade SAE 0-1-2 , 8, Coarse 100,000psi 5, 120,000psi 133,000psi 7, 133,000psi 74000psi 150,000psi Thread/Inc Medium Medium Medium Medium Low Carbon Medium h Carbon Steel. Carbon Heat Carbon Carbon Steel Carbon (B-16) T Steel Heat Temp Alloy Steel Alloy Steel Steel 20 6 9 10 12.5 13 14 18 12 17 19 24 25 29 16 20 30 33 43 44 47 14 32 47 54 69 71 78 13 47 69 78 106 110 119 12 69 103 114 150 154 169 11 96 145 154 209 215 230 10 155 234 257 350 360 380 9 206 372 382 550 570 600 8 310 551 587 825 840 700 7 480 872 794 1304 1325 1430 7 375 1211 1105 1815 1825 1975 6 900 1624 1500 2434 2500 2650 6 1100 1943 1775 2913 3000 3200 5.5 1470 2660 2425 3985 4000 4400 5 1900 3463 3150 5189 5300 5650 5 2360 4695 4200 6980 7000 7600 4.5 2750 5427 4550 7491 7500 8200

Bolt Size Inch

1/4" 5/16" 3/8" 7/16" 1/2" 9/16" 5/8" 3/4" 7/8" 1" 1-1/8" 1-1/4" 1-3/8" 1-1/2" 1-5/8" 1-3/4" 1-7/8" 2"

Section No. : 2.322

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Date : 15.02.2005