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QUALITY CONTROL DOCUMENT BNL/QCD-PFM-111
Issue Date:
DOC TITLE
PROCEDURE FOR FLANGE 18/01/16
MANAGEMENT Page 1 of 13

QUALITY CONTROL DOCUMENT

PROCEDURE FOR FLANGE MANAGEMENT

OF

BRIDGSITE NIGERIA LTD

DOC NO BNL-QCD-PFM-110

18/01/
001 IDC
16
Issued for Internal review T. A. D. H. C. U.

Revision Status Date Revision memo Issued by Checked by Approved by

This document has been generated by an Electronic Document Management System. When printed it is considered as a for information only copy.
The controlled copy is the screen version and it is the holder's responsibility that he/she holds the latest valid version.

CHANGE (S)/AMENDMENT (S)

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The change(s)/amendment(s) noted below have been made and approved by the Managing
Director/CEO for issue.

Change/Amendment No. Date Page Description of Change/

Amendment
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TABLE OF CONTENTS
Content

1.0 Purpose......................................................................................................................................................................4
2.0 Scope.........................................................................................................................................................................4
3.0 References.................................................................................................................................................................4
4.0 Safety Precautions.....................................................................................................................................................4
5.0 Equipment and Man Power.......................................................................................................................................5
5.1 Equipment:............................................................................................................................................................5
5.2 Manpower:...................................................................................................................................................5
6.0 Bolt Tightening.........................................................................................................................................................5
7.0 APPENDIX.............................................................................................................................................................12
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1.0 Purpose
This procedure describes the requirement for bolt tightening for piping system.

2.0 Scope
2.1. The procedure defines the method for bolt tightening using
manual/hand torque wrench, hydraulic torque wrench and hydraulic
stud bolt tensioner.

2.2. Application of bolts tightening tool shall be done as per the following
scope:

Bolt Diameter < 2: General torque wrench (Manual/hand Torque Wrench or

Hydraulic torque wrench if applicable)

3.0 References
ASME B16.5 Pipe, Flange, and Fitting

ASME B16.47 Large Diameter Steel Flange

ASME B31.3 Process Piping

Manufacture Recommended

4.0 Safety Precautions

Special attention is paid and shall be paid to flange management works as it utilizes
high-pressure hydraulic oil. Supervisor must be present at location to supervise the
worker prior to bolt tightening activity. Tools and equipment should be inspected
before use to ensure good working condition. The working area shall be roped of
and warning notices shall be displayed. For high elevation or remote area work,
adequate scafolding shall be erected for safety. Operators shall handle components
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during placing or removing the bolt tightening equipment as per manufacturers
recommendation. Operators shall also be equipped with safety glasses, hard hats,
gloves and safety shoes.

Additional safety equipment shall be worn as advised by the Project HSE

Department.

5.0 Equipment and Man Power

5.1 Equipment:
a. Hi-Force Including Accessories.
b. Manual/Hand Torque Wrench
c. Hand Tools

5.2 Manpower:

a) Mechanical Supervisor
b) Safety man
c) Mechanic/Helper

6.0 Bolt Tightening

6.1 Tightening Preparation
a. Flanged joints shall be properly aligned before torqueing and
maximum allowable translation of flange centerline & faces
should be specified. Maximum allowable run out between
flange faces should also be specified. (To be noted as max
values/tolerances according to the relevant specs). see
Appendix for dimensional tolerance.
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b. Prior to tightening, all equipment shall be checked for any
damage or imperfections. After cleaning, studs should be
lubricated with an approved compound.
c. The operator shall set the correct hydraulic pressure to
achieve the required bolt torque for each stud bolt size
according to appendix 1 (recommended tensioning pressure
table).
d. CLIENT reserves the right to witness the applied pressure for
the torqueing of a joint during reinstatement.

6.2 Recommended Bolt Tightening Procedure

a. Install the gasket on the flange face and bring the
flanges together until contacting the gasket.
b. Install all bolts and studs, making sure they are free
from dirt and grit and that the threads and under nut
faces are well lubricated.
c. Run up nuts finger tight
d. Mark the proper tightening sequence on the studs with
chalk as per diagram on Para 6.3 or as per
recommended by the equipment manufacturer
e. Determine the torque value for the studs or bolt to be
tightened.
1. First tightening stage should be limited to a
maximum of 30% of final torque setting.
2. Second tightening stage should be limited to a
maximum of 60% of final torque setting.
3. Third tightening stage should be carried out at the
100% torque setting.
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Note: 1, 2 & 3 should be tightened using the diagonal bolt sequence shown
in the diagram
f. On the fourth and final tightening sequence change
from diagonal tightening to adjacent bolt-to-bolt
tightening using the 100% torque setting value

6.3 Table for Bolt Tightening

a. For 4 set Bolt Flange

TORQU
BOLT
STAG E REMARK
SEQUENCE
E SETTIN S
TIGHTENING
G

I 30% 1-2-3-4

II 60% 4-3-2-1

III 100% 1-2-3-4

IV 100% 3-4-1-2
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b. For 8 set Bolts Flange

BOLT
TORQUE
STAGE SEQUENCE REMARKS
SETTING
TIGHTENING

I 30% 1-2-3-4;5-6-7-8

II 60% 8-7-6-5;4-3-2-1

III 100% 1-2-3-4;5-6-7-8

IV 100% 2-6;1-5;4-8;3-7

c. For 12 set Bolts flange

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BOLT
TORQUE
STAGE SEQUENCE REMARKS
SETTING
TIGHTENING
1-2-3-4;5-6-7-
I 30%
8;9-10-11-12
12-11-10-9:8-7-
II 60%
6-5-;4-3-2-1
1-2-3-4;5-6-7-
III 100%
8;9-10-11-12
8-5-12;7-6-11;4-
IV 100%
2-10;3-1-9

d. For 16 set Bolt Flange

TORQU
STAG E BOLT SEQUENCE REMARK
E SETTIN TIGHTENING S
G
1-2-3-4;5-6-7-8;9-10-
I 30%
11-12;13-14-15-16

16-15-14-13;12-11-
II 60%
10-9:8-7-6-5-;4-3-2-1

1-2-3-4;5-6-7-8;9-10-
III 100%
11-12;13-14-15-16
1-12-8-13;2-11-7-
IV 100% 14;3-9-5-15;4-10-6-
16
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e. For 20 set Bolt Flange

TORQU
BOLT
STAG E REMARK
SEQUENCE
E SETTIN S
TIGHTENING
G
1-2-3-4;5-6-7-8;9-
10-11-12;13-14-
I 30%
15-16;17-18-19-
20
20-19-18-17;16-
15-14-13;12-11-
II 60%
10-9;8-7-6-5;4-3-
2-1
1-2-3-4;5-6-7-8;9-
10-11-12;13-14-
III 100%
15-16;17-18-19-
20
8-1-20-12;7-2-19-
IV 100% 11;6-4-18-10;5-3-
17-9;16-15-14-13
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f. For 24 set Bolt Flange

BOLT
TORQUE
STAGE SEQUENCE REMARKS
SETTING
TIGHTENING

1-2-3-4;5-6-7-
8;9-10-11-
12;13-14-15-
I 30%
16;17-18-19-
20;21-22-23-
24
24-23-22-
21;20-19-18-
17;16-15-14-
II 60%
13;12-11-10-
9;8-7-6-5;4-3-
2-1
1-2-3-4;5-6-7-
8;9-10-11-
12;13-14-15-
III 100%
16;17-18-19-
20;21-22-23-
24
3-5-21-13;4-
6-22-14;17-
16-1-9;18-15-
IV 100%
2-10;24-12-
20-8;23-11-
19-7
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g. For 28 set Bolt Flange

BOLT
TORQUE
STAGE SEQUENCE REMARKS
SETTING
TIGHTENING

1-2-3-4;5-6-
7-8;9-10-11-
12;13-14-15-
I 30% 16;17-18-19-
20;21-22-23-
24;25-26-27-
28
28-27-26-
25;24-23-22-
21;20-19-18-
II 60% 17;16-15-14-
13;12-11-10-
9;8-7-6-5;4-3-
2-1
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1-2-3-4;5-6-
7-8;9-10-11-
12;13-14-15-
III 100% 16;17-18-19-
20;21-22-23-
24;25-26-27-
28
17-13-3-5-9-
25;18-14-4-6-
10-26;16-20-
IV 100% 8-1-28-11;15-
19-7-2-27-
19;21-22-23-
24

h. For 32 set Bolt Flange

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BOLT
TORQUE
STAGE SEQUENCE REMARKS
SETTING
TIGHTENING

1-2-3-4;5-6-
7-8;9-10-11-
12;13-14-15-
16;17-18-19-
I 30%
20;21-22-23-
24;25-26-27-
28,29-30-31-
32
32-31-30-
29;28-27-26-
25;24-23-22-
21;20-19-18-
II 60%
17;16-15-14-
13;12-11-10-
9;8-7-6-5;4-3-
2-1
1-2-3-4;5-6-
7-8;9-10-11-
12;13-14-15-
16;17-18-19-
III 100%
20;21-22-23-
24;25-26-27-
28,29-30-31-
32
32-6-24-
14;31-5-23-
13;30-7-22-
15;29-8-21-
IV 100% 16;28-4-18-
10;27-3-20-
9;26-1-17-
12;25-2-18-
11
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7.0 APPENDIX
7.1 Recommended flange bolt torque.

Recommended flange bolt torque for ANSI 150 RF

Bolting Torque (Kg.m)
Size Bolt Size Min Torque Max Adopted Step 1 Step 2
Torque Torque
U-1/2 0.16 3.61 2.0 1.0 2.0
U-1/2 0.24 3.61 2.0 1.0 2.0
1 U-1/2 0.33 3.61 2.0 1.0 2.0
1 U-1/2 0.65 3.61 2.0 1.0 2.0
2 U-5/8 0.64 7.2 5.0 1.0 5.0
3 U-5/8 1.10 7.2 5.0 2.0 5.0
4 U-5/8 1.57 7.2 5.0 3.0 5.0
6 U-3/4 2.14 12.84 8.0 3.0 8.0
8 U-3/4 3.09 12.84 8.0 4.0 8.0
10 U-7/8 3.6 20.72 11.0 5.0 11.0
12 U-7/8 4.91 20.72 12.0 6.0 12.0
14 U-1 5.15 31.09 17.0 6.0 17.0
16 U-1 6.5 31.09 18.0 8.0 18.0
18 U-1 1/8 7.63 45.83 26.0 9.0 26.0
20 U-1 1/8 9.11 45.83 27.0 10.0 27.0
24 U-1 1/4 13.84 64.61 39.0 15.0 39.0

7.2 Recommended flange bolt torque for ANSI 300 RF

Bolting Torque (Kg.m)

Size Bolt Size Min Torque Max Adopted Step 1 Step 2
Torque Torque
U-1/2 0.38 3.61 2.0 1.0 2.0
U-1/2 0.70 7.2 4.0 1.0 4.0
1 U-1/2 0.97 7.2 4.0 2.0
1 U-1/2 2.30 12.84 8.0 3.0 8.0
2 U-5/8 1.50 7.2 5.0 3.0 5.0
3 U-5/8 3.08 12.84 8.0 4.0 8.0
4 U-5/8 4.41 12.84 9.0 5.0 9.0
6 U-3/4 5.00 12.84 10.0 6.0 10.0
8 U-3/4 8.48 20.84 15.0 10.0 15.0
10 U-7/8 9.79 31.09 22.0 11.0 22.0
12 U-7/8 14.79 45.83 30.0 16.0 30.0
14 U-1 13.58 45.83 30.0 15.0 30.0
16 U-1 19.04 64.61 32.0 20.0 32.0
18 U-1 1/8 19.85 64.61 32.0 21.0 32.0
20 U-1 1/8 23.72 64.61 33.0 25.0 33.0
24 U-1 1/4 38.86 116.25 76.0 40.0 76.0
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7.3 Recommended Flange bolt torque for ANSI 600 RF

Bolting Torque (Kg.m)

Size Bolt Size Min Torque Max Adopted Step 1 Step 2
Torque Torque
U-1/2 1.26 3.61 3.0 2.0 3.0
U-1/2 2.31 7.2 6.0 3.0 6.0
1 U-1/2 3.17 7.2 6.0 4.0 6.0
1 U-1/2 7.55 12.84 12.0 8.0 12.0
2 U-5/8 4.92 7.2 6.0 6.0 6.0
3 U-5/8 10.12 12.84 12.0 11.0 12.0
4 U-5/8 16.91 20.72 19.0 17.0 19.0
6 U-3/4 21.92 31.09 30.0 23.0 30.0
8 U-3/4 35.63 45.83 44.0 36.0 44.0
10 U-7/8 40.21 64.61 60.0 41.0 60.0
12 U-7/8 53.98 64.61 80.0 55.0 60.0
14 U-1 54.50 87.92 100.0 56.0 80.0
16 U-1 75.04 116.25 120.0 76.0 100.0
18 U-1 1/8 84.76 150.08 120.0 86.0 120.0
20 U-1 1/8 101.28 236.21 200.0 102.0 120.0
24 U-1 1/4 159.55 289.49 250.0 160.0 200.0