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CONTROLLED BOLTING
DIALOG
DPS/OPT/PRO/07/2010
Revision : 0
Date
: 26/07/10
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: 1 OF 18
WORK INSTRUCTION
0
REV.
26/07/10
FAUZI
DATE
PREPARED BY
WAN
AHMID
REVIEW BY
APPROVED BY
DESCRIPTIONS
DIALOG
WORK INSTRUCTION
CONTROLLED BOLTING
DPS/OPT/PRO/07/2010
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Date
: 26/07/10
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TABLE OF CONTENTS
SECTION
DESCRIPTION
PAGE
1.0
INTRODUCTION
2.0
3.0
PRIORITY
4.0
METHODOLOGY
4.1
WORK FLOW
4.2
TAGGING SYSTEM
4.3
JOINT BREAKING
5.0
GENERAL PROCEDURE
6.0
ATTACHMENTS
ATTACHMENT
DESCRIPTION
II
III
IV
VI
VII
VII
IX
DIALOG
1.
WORK INSTRUCTION
CONTROLLED BOLTING
DPS/OPT/PRO/07/2010
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INTRODUCTION
DIALOG has recognized the importance of leak proof bolted joints, at
the time of startup. To ensure the integrity of the bolted joints, a
dedicated Joint Integrity Team(JIT) comprising of trained personnel
within DIALOG group is to ensure this instruction is done properly.
For high-pressure oil and gas piping systems, the relatively large high
tensile fasteners would require specialized tools for bolting up the
flanges.
The conventional method of using sledgehammers and striking
wrenches is time consuming, strenuous and very dangerous practice.
Proper construction practice now calls for proper tensioning or torquing
with air-hydraulic or electric/hydraulic torque wrenches/or tensioners, in
general application on standard length bolts, air driven or electric
driven hydraulic torque wrenches.
The purpose of this instruction is to provide guidelines to ensure all bolted
joints are leak proof and fit for purpose through
Correct method Correct
material Traceability of
joint makers
Acceptable joint mating surfaces
Proper joint alignment
Appropriate new gaskets
Proper documentation
2.
DIALOG
WORK INSTRUCTION
CONTROLLED BOLTING
DPS/OPT/PRO/07/2010
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All other bolting for low and high temperature application shall be
tightened as appropriate for the application and in conformance with
the applicable ASTM Standards.
3.
PRIORITY
The Joint Integrity Team (JIT) shall assign inspection priorities to the
following joints:
Battery Isolation limits
Isolation joints with intervening slip blinds
4.
1)
2)
3)
Manhole:
Mechanical damage may occur when the manhole is
opened. JIT shall inspect the mating surface of manhole cover and
flange prior to fit up record any damage.
4)
METHODOLOGY
4.1
Work Flow
Flow diagram is attached to illustrate the function of the JIT
(attachment II)
4.2
Tagging System
Three (3) different colours of tags (attachment III) shall be used to
control and indicate the status of any disturbed joints. All tags, after
servicing their respective purpose, shall be returned to the JIT for
record compilation of completion.
DIALOG
WORK INSTRUCTION
CONTROLLED BOLTING
DPS/OPT/PRO/07/2010
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Date
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(No damage)
This tag shall be attached to any disturbed joint that is found in good
condition at
Initial inspection after the joint is parted and
The joint is found satisfactory
The Green Tag will be withdrawn by JIT supervisor when the joint has
been hand tightened and set up for tightening.
4.2.2 Red Tag
(Repair required)
This tag shall be attached to indicate the joint has been tightened and
accepted by the JIT supervisor.
The yellow tag shall not be removed until:
The equipment or system has been pressure tested and
accepted and
The equipment or system has been handed over to Operations.
The JIT supervisor will remove the yellow tag
4.2.4 Documentation of Tags.
All joint integrity tags shall be returned to Joint Integrity Team Leader
for record and compilation.
DIALOG
4.3
WORK INSTRUCTION
CONTROLLED BOLTING
DPS/OPT/PRO/07/2010
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DIALOG
WORK INSTRUCTION
CONTROLLED BOLTING
DPS/OPT/PRO/07/2010
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Hydraulic tensioned studs and nuts. Not less than two (2) full
nuts length prior to tensioning. The stationary nut shall
protrude not less than one full thread.
4.3.6 Joint lubricant
Joint lubricant shall be clients approved.
Bolts that are torque shall be lubricated.
Bolts that are tensioned should not be lubricated.
Do not apply lubricant to the bolt face of the nut that remains
stationary.
Do not apply lubricant to the joint face.
Lubricant shall be applied in a thin layer and spread evenly.
Excessive lubricant shall be avoided.
4.3.7 Used gaskets
Used gasket shall be identified and where possible, shall be removed
from the vicinity of the joint.
4.3.8 Replacement of gaskets.
The specification of replacement gaskets shall be verified. Damaged
gaskets shall be returned to Material Controller.
4.3.9 Align Mating surfaces.
Mating surfaces shall be aligned axially and rotationally without
excessive force. Inability to mate the flanges shall be reported to
clients representative.
4.3.10 Installation of gasket
Gasket shall be installed centrally/concentric with the bolt circle. The
inner disk of the gasket shall not protrude into the bore of the flange.
4.3.11 Tightening sequence
Cross pattern tightening sequence shall be adopted to ensure even
tightening and drawing in of the flange. Bolts shall be numbered from
top to dead center and progress in the clockwise direction. Labeling
of bolts on the flange is recommended when the number of bolts
exceeds eight (8). Tightening sequence shall comply to table I or
otherwise approved.
DIALOG
4.
WORK INSTRUCTION
CONTROLLED BOLTING
DPS/OPT/PRO/07/2010
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GENERAL PROCEDURE
This is general tightening procedure for the tightening of standard
pressure containing flanged joints fitted with standard gaskets.
1. Number each bolt consecutively, 1, 2, 3 etc (refer to attachment VI).
2. Using torque wrenches, square up the flanged joint.
3. Workings in a diametrical sequence (tightening opposite bolt - table
I) apply approximately 25% of the torque value specified in the
torque data.
4. Using the same noted tightening sequence, apply approximately
50% of the torque value specified in the torque data.
5. Using the same noted tightening sequence, apply the full torque
value specified in the torque data.
6. Working in the clockwise (or anti-clockwise) direction, make a final
pass around the flange, tightening each bolt to the full torque value
specified in the torque data.
7. Using a hammer ring each nut to ensure that each bolt has been
correctly loaded and that no slack bolts remain.
6.
REPORT/COMPLETION OF WORK
Upon completion of work, adequate signed documentation shall be
supplied to the client, for QA/QC purpose.
DIALOG
WORK INSTRUCTION
CONTROLLED BOLTING
DPS/OPT/PRO/07/2010
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ATTACHMENT I
PROJECT MANAGER
PROJECT ENGINEER
QC INSP.
SUPERVISOR
DIALOG
DPS/OPT/PRO/07/2010
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WORK INSTRUCTION
CONTROLLED BOLTING
ATTACHMENT II
JOINT INTEGRITY FLOW DIAGRAM
PREPARE CONTROL
SHEET
COMPLETE TAG
AND DATA
SHEETS
JOINT
MAKING
TEAM
JIT COORDINATOR
CONTRACTOR BREAKS
JOINTS
(JOINT BREAKING)
NO
INSPECTION OF JOINT
FACES
OK
REPAIR REQUEST
RED TAG
TEAM LEADER
INSPECTION = OK
GREEN TAG
TEAM LEADER
FINAL INSPECTION
YELLOW TAG
TEAM LEADER
FILE
DOCUMENTATION
QC
DIALOG
WORK INSTRUCTION
CONTROLLED BOLTING
DPS/OPT/PRO/07/2010
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ATTACHMENT III
GREEN
Equipt No:
Line No:
Flange No:
RED
Equipt No:
Line No:
Flange No:
Date Insp:
Date Insp:
Inspector
Inspector
120 mm
REPAIR REQUIRED
Type of repair
Serial No :01234
60 mm
DIALOG
WORK INSTRUCTION
CONTROLLED BOLTING
DPS/OPT/PRO/07/2010
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YELLOW
Equipt No:
Line No:
Flange No:
Flange tightened
by supvr:
120 mm
Final Inspection By
Date:
Serial No :01234
60 mm
DIALOG
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WORK INSTRUCTION
CONTROLLED BOLTING
ATTACHMENT IV
CRITICAL JOINT CHECKLIST
DESCRIPTION
LOCATION
PLANT:
JOINT NO:
UNIT NO:
A. JOINT BREAKING
CONDITION
B. JOINT MAKING
NO
CONDITION
YES
REMARKS
25%
YES
REMARKS
NO
Size:
50%
100%
CHECK PASS
TORQUE VALUE
JOINT MADE BY
(CONTRACTOR SUPV):
NAME:
SIGNATURE:
DATE
CHECKED BY (QC ):
FINAL INSPECTION
NAME:
SIGNATURE:
DATE:
DIALOG
WORK INSTRUCTION
CONTROLLED BOLTING
DPS/OPT/PRO/07/2010
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ATTACHMENT V
Description of repair
Repaired by (supv)
Inspected by (QC)
Approved by (Client)
Signature
Name
Date
DIALOG
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WORK INSTRUCTION
CONTROLLED BOLTING
ATTACHMENT VI
1
16
15
14
13
12
11
7
8
10
9
EXAMPLE:
NO: OF BOLTS: 16 BOLTS
SEQUENCE: 1-9-5-13, 3-11-7-15, 2-10-6-14, 4-12-8-16
DIALOG
WORK INSTRUCTION
CONTROLLED BOLTING
DPS/OPT/PRO/07/2010
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ATTACHMENT VII
TABLE OF CROSS PATTERN TIGHTENING SEQUENCE
NO OF
BOLTS
SEQUENCE
32 BOLTS OR LESS, TIGHTEN BOLT INDIVIDUALLY (NOT IN GROUPS)
4
8
12
16
20
24
28
32
1-3-2-4
1-5-3-7, 2-6-4-8
1-7-4-10, 2-8-5-11, 3-9-6-12
1-9-5-13, 3-11-7-15, 2-10-6-14, 4-12-8-16
1-11-6-16, 3-13-8-18, 5-15-10-20, 2-12-7-17, 4-14-9-19
1-13-7-19, 4-16-10-22, 2-14-8-20, 5-17-11-23, 3-15-9-21, 6-18-12-24
1-15-8-22, 4-18-11-25, 6-20-13-27, 2-16-9-23, 5-19-12-26, 7-21-14-28,
3-17-10-24
1-17-9-25, 5-21-13-29, 3-19-11-27, 7-23-15-31, 2-18-10-26, 6-22-14-30, 4-20-12-28,
8-24-16-32
36 BOLTS: TIGHTEN IN GROUPS OF 3
36
40
44
48
52
56
60
64
1-2-3-4, 33-34-35-36, 17-18-19-20, 49-50-51-52, 9-10-11-12, 41-42-43-44, 25-26-2728, 57-58-59-60, 5-6-7-8, 37-38-39-40, 21-22-23-24, 53-54-55-56, 13-14-15-16, 4546-47-48, 29-30-31-32, 61-62-63-64
68
1-2-3-4, 37-38-39-40, 21-22-23-24, 53-54-55-56, 9-10-11-12, 45-46-47-48, 29-30-3132, 61-62-63-64, 17-18-19-20, 57-58-59-60, 33-34-35-36, 5-6-7-8, 41-42-43-44, 1314-15-16, 49-50-51-52, 25-26-27-28, 65-66-67-68
DIALOG
WORK INSTRUCTION
CONTROLLED BOLTING
DPS/OPT/PRO/07/2010
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ATTACHMENT VIII
PROPOSED TORQUE VALUE FOR MANUAL TORQUING
NO.
SIZE (INCH)
RATING (LBS)
1
2
3
4
5
6
7
8
9
10
11
12
1
1 1/2
2
2 1/2
3
4
6
8
10
12
16
20
150
150
150
150
150
150
150
150
150
150
150
150
4 * 1/2"
4 * 1/2"
4 * 5/8"
4 * 5/8"
4 * 5/8"
8 * 5/8"
8 * 3/4"
8 * 3/4"
12 * 7/8"
12 * 7/8"
16 * 1"
20 * 1 1/8"
35
40
65
65
65
78
122
122
205
205
317
467
13
14
15
16
17
18
29
20
21
22
23
1
1 1/2
2
3
4
6
8
10
12
16
24
300
300
300
300
300
300
300
300
300
300
300
4 * 5/8"
4 * 3/4"
8 * 5/8"
8 * 3/4"
8 * 3/4"
12 * 3/4"
12 * 7/8"
16 * 1"
16 * 1 1/8"
20 * 1 1/4"
24 * 1 1/2
69
121
69
122
122
137
205
318
467
656
1175
24
25
26
27
28
29
30
31
32
1
2
3
4
6
8
10
14
16
600
600
600
600
600
600
600
600
600
4 * 5/8"
8 * 5/8"
8 * 3/4"
8 * 7/8"
12 * 1"
12 * 1 1/8"
16 * 1 1/4"
20 * 1 3/8"
20 * 1 1/2"
69
78
122
205
318
467
656
890
1175
33
34
36
39
3
4
14
16
900
900
900
900
8 * 7/8"
8 * 1 1/8"
20 * 1 1/2"
20 * 1 5/8"
243
467
1175
1514
DIALOG
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WORK INSTRUCTION
CONTROLLED BOLTING
ATTACHMENT IX
SAMPLE OF TORQUE CALCULATION
FLANGE SIZE :
Grip length G
Flange to Flange
Bolt Diameter D
Metric equivalent
8"
RATING :
59.5 mm
0.75 in.
2.34 in.
Grade
Spiral wound SS
Tension to
60 % of yield strength
Yield strength of bolt
Fy=
720 Mpa
Bolt Tensile Stress
Area
Bolt stress
Torque =
SA193-B16
20
UN8
Gasket type
150 lb
105 kpsi
200 mm2
=
=
200 X
86 kN
0.31 in2
720
X
0.6
19,396 lbs
Therefore
Torque (ft.lbs)=
122.063 ftlbs
.