Jeres-L-351 Bolted Flange Joints Assembly

SAUDI ARAMCO TOTAL REFINING & PETROCHEMICAL COMPANY
Issuer: PMT
May 2012
Rev: 1B
Bolted Flange Joints Assembly JERES-L-351
JERES-L-351
Bolted Flange Joints Assembly
This procedure defines minimum mandatory requirements to assemble bolted flanged joints
in pressure containing piping systems defined in JERES-L-100 as well as process equipment.
This document is the property of SATORP and shall not be reproduced in any form. Copies provided by SATORP shall only be
disclosed or provided to third parties insofar as relevant for the operations of SATORP and the information provided in this
document shall be used for no other purpose than these operations.
The content of this document will be regularly updated by SATORP and the validated version will be published on its intranet
site. Consequently, the validity of hard copies of this document must be verified prior to its use against the version on the
SATORP intranet site. Only soft copies on the SATORP intranet site dedicated to SATORP QMS are considered controlled
documents.
Page 1 of 17
Issuer: PMT
May 2012
Rev: 1B
Name and Signature

Rev Date Description Prepared by Approved by Authorized by
N. Mosson, STC D. Grunemwald

1B 19-May-2012 Issued for Release 5A. F. Lacanlale
F. Silva, Eng. Mgr. Project Director
New Template & Brief

N. Mosson, STC D. Grunemwald
1A 09-May-2012 Scope added on the cover F. Lacanlale
F. Silva, Eng. Mgr. Project Director
page.
Updating Issued for bid
package Rev. 0 to N. Mosson, STC D. Grunemwald
1 15-May-2008 J. Somoza
incorporate technical F. Silva, Eng. Mgr. Project Director
comments.
documents.
Page 2 of 17
Issuer: PMT
May 2012
Rev: 1B
Revision Tracking
Revision Revision Date Scope of Revision
1B 19 May 2012 Issued for Release 5A.
1A 09-May-2012 New Template & Brief Scope added on the cover page.
1 15 May 2008 Updating Issued for bid package Rev. 0 to incorporate technical comments.
0 29 April 2008 Issued for bid package.
02 31 March 2008 Issued for bid package only for review.
01 06 April 2007 First official JERES-L-351 is issued.
First draft issued is based on Saudi Aramco SAEP-351 “Bolted Flange

00 27 February 2007 Joints Assembly” issue date 7 November, 2006. Document was modified to
incorporate amendments and modifications.
documents.
Page 3 of 17
Issuer: PMT
May 2012
Rev: 1B
Table of Contents
Section Contents Page
1 Scope 5
2 Conflicts, Deviations and Clarifications 5
3 References 5
4 Definitions 6
5 Responsibilities 6
6 Pre-Assembly Inspection 7
7 Torquing 7
8 Torquing Tools 8
9 Stud Bolt Tightening Procedure 8
Stud Bolt Additional Tightening Procedure where Leaks

10 9
Occur during Pressure Testing
11 Additional Requirements for PIKOTEK Gaskets 10
Appendixes
A Table -1: Friction Factors for Different Lubricants 12
B Table -2: Torque Value for Low–Alloy Steel Bolting 13

Table -3: Torque Value for Isolating Gaskets (PIKOTEK) on
C ASME B 16.5 and ASME B 16.47 Series A & B Class 150 14
Through Class 2500 Flanges
D Figure JERES- 1 Stud Bolt Tightening Sequence 15
E Figure JERES- 2 Stud Bolt Numbering 16

Table -4: Cross Pattern Tightening Sequence (36 to 68 Bolts)
F 17
per (ASME PCC-1)
documents.
Page 4 of 17
Issuer: PMT
May 2012
Rev: 1B
1 Scope
1.1 This procedure defines minimum mandatory requirements to assemble bolted
flanged joints in pressure containing piping systems defined in JERES-L-100 as
well as process equipment.
1.2 This installation procedure is applicable for both new and existing facilities.
2 Conflicts, Deviations and Clarifications

2.1 Any conflicts between this standard and other applicable Company Engineering
Standards (JERES), Material Specifications (JERMS), Standard Drawings
(JERSD), Engineering Procedures (JEREP), Company Forms or Industry
standards, specifications, Codes and forms shall be brought to the attention of
Company Representative by the Contractor for resolution.
Until the resolution is officially made by the Company Representative, the most
stringent requirement shall govern.
2.2 Where a licensor specification is more stringent than those of this standard, the
Licensor’s specific requirement shall apply.
2.3 Where applicable Codes or Standards are not called by this standard or its
requirements are not clear, it shall be brought to attention of Company
Representative by Contractor for resolution.
2.4 Direct all requests for deviations or clarifications in writing to the Company or its
Representative who shall follow internal Company procedure and provide final
resolution.
3 References
The selection of material and equipment, and the design, construction,
maintenance, and repair of equipment and facilities covered by this standard shall
comply with the latest edition of the references listed below as of the CUT-OFF
DATE as specified in the Contract unless otherwise noted.
3.1 Company References
Company Engineering Standards
JERES-L-100 Applicable Codes and Standards for Pressure Piping
Systems
JERES-L-109 Selection of Pipe Flanges, Stud Bolts and Gaskets
3.2 Industry Codes and Standards
American Petroleum Institute
documents.
Page 5 of 17
Issuer: PMT
May 2012
Rev: 1B
API BULL 5A2 Bulletin on Thread Compounds for Casing, Tubing, and Line
Pipe
American Society of Mechanical Engineers
ASME B16.5 Pipe Flanges and Flanged Fittings NPS ½ through NPS 24
ASME B16.47 Large Diameter Steel Flanges NPS 26 through NPS 60
ASME B31.3 Process Piping
ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons
and Other Liquids
ASME B31.8 Gas Transmission and Distribution Piping Systems
ASME PCC-1 Guidelines for Pressure Boundary Bolted Flange Joint
Assembly
4 Definitions
4.1 Definitions presented in this Standard and other SATORP documents have
precedence over other definitions. Conflicts between various definitions shall be
brought to the attention of Company Representative by the Contractor for
resolution.
Company: SATORP (formerly Jubail Export Refinery - JER)
Company Representative: A designated person from the Company or an
assigned third party representative.
Company Inspector: A designated person or an agency responsible for
conducting inspection activities on behalf of the Company.
4.2 List of Definitions
Purposely left blank.
5 Responsibilities
5.1 For new capital program projects the following shall apply:
5.1.1 The Contractor is responsible for ensuring that this procedure is followed.
5.1.2 The contractor personnel executing the flange assembly shall adhere to flange
assembly procedure. They shall have proper training and skills to conduct the job.
5.2 For existing facilities the following shall apply:
5.2.1 It is the responsibility of Company Representative to ensure that this procedure is
adhered to during the maintenance activities within the facilities under his
jurisdiction.
documents.
Page 6 of 17
Issuer: PMT
May 2012
Rev: 1B
5.2.2 The maintenance personnel executing the flange assembly activities must be aware
of this procedure and ASME PCC-1 Guideline and have the proper training to
conduct the work.
6 Pre-Assembly Inspection
6.1 The gasket shall be verified for correct type, rating, dimension and compatibility
with the flange facing. Also, it shall be free from any damage particularly in the
seating element. Ensure that spiral wound gaskets are stored flat especially for
large sizes, 24 inches and larger.
6.2 Bolts, nuts and washers shall be visually checked for proper size, grade, dimension
and for any physical damage to shanks or threads which would affect the bolt
assembly or performance. Also, check the suitability of the stud bolts and nuts
material for the service temperature and the compatibility with the flange material.
6.3 The flange facing, particularly the seating area, shall be visually examined for
cleanliness and ensure that no damage, such as scratches exist.
For ring joint type flanges, the ring and the ring groove shall be free of damage and
dirt.
6.4 Proper lubricant for bolts and nuts shall be used. Lubricant for bolts and nuts shall
be Jet-Lube SS-30 or other acceptable lubricants listed in Table-1 of the Appendix.
6.5 Tightening tools shall be checked for adequacy, performance and calibration, if
required.
6.6 Lubricant shall not be used in the gasket and the gasket seating area.
6.7 Flange shielding shall be available for installation / reinstallation when required.
Commentary Note:
Flange shielding is normally used for personnel protection against possible liquid splash
or high temperature during operation.
7 Torquing
7.1 Torque values vary according to flange rating, bolt size, type of gasket, and friction
factor of the thread lubricant.
7.2 The torque values are specified in Table -2 and Table -3.
7.3 Table -02 applies to all gaskets listed in JERES-L-109, except for insulating
gaskets.
7.4 Table -03 applies to isolating gaskets (e.g., PIKOTEK), based on a friction factor
of 0.16.
documents.
Page 7 of 17
Issuer: PMT
May 2012
Rev: 1B
8 Torquing Tools
8.1 Selection of the proper tool depends on the stud bolt size, physical location of the
flanged joint, and criticality of the flange. Identifying the proper tools shall be
reviewed by the Company Representative and agreed on.
Commentary Note:
There exist various tools which will achieve the proper torque.
8.2 There are various types of tools available to achieve the proper torque value. The
manufacturer's instructions shall be followed for the operation, limitation and
maintenance of all torque wrenches used to perform flange bolts tightening.
8.3 Torque wrench calibration shall be performed in accordance with manufacturer's
recommendations.
9 Stud Bolt Tightening Procedure
Step 1 Align flanges and gasket. Forced tightening is not allowed to
overcome non acceptable alignment tolerances. Clamp securely in
place.
Step 2 Apply lubricants to stud threads over length and nut engagement and to
face of nut which contacts flange. Ensure that the nuts run freely down
the thread of the studs.
Step 3 Install all studs and nuts hand tight, ensure that studs pass freely
through the flange holes. Position the nut on one end of the stud such
that only the crown of the stud projects beyond the face of the nut. The
excess stud length should project beyond the nut on the other side.
Commentary Note:
By doing this, the nut that is installed nearly flush with the end of the stud can be easily
removed since the threads are not coated, and normally have not been subjected to
corrosion. The side of the stud with the flush nut should be chosen by taking into
consideration factors such as whether one side has better access for maintenance
personnel and/or tightening tools, e.g., torque wrench or impact wrench, etc.
Step 4 Number each stud according to its position in the flange as shown on
Figure 1: Stud Bolt Tightening Sequence.
Step 5 For insulting gaskets like PIKOTEK, enough gap (½" of gap is
recommended) should be available between flange faces to avoid any
damage to seals during inserting the gaskets. If due to any reasons,
seals are damaged, change the seal before installing PIKOTEK.
documents.
Page 8 of 17
Issuer: PMT
May 2012
Rev: 1B
Step 6 Mating flange faces and the gaskets should be dry and free from
grease, oil or water.
Step 7 Comply with the Following Stud Bolt Tightening Sequence:
− For 4 to 32 bolts use Figure -1 for bolts numbering and
− For 36 to 68 bolts see Figure-2 for bolts numbering and Table-4
for the tightening sequence.
− In all cases, the appropriate tool should be used such as an air
impact wrench or equivalent.
Step 8 Tightening Level Progression:
Tighten the stud bolts in stages to obtain the final required torque from
the appropriate torque Table- 2. The first stage should not be more
than 30% of the final torque.
Apply the torque evenly to each stud following the stud bolt tightening
sequence.
The final torque shall be within ±5% of the required torque value.
In all cases, the appropriate tool should be used such as an air impact
wrench or equivalent
The final torque must be within ±5% of the required values per Section
7 above.
Step 9 For joints containing RTJ or Spiral Wound Gaskets, repeat step 7.
10 Stud Bolt Additional Tightening Procedure where Leaks Occur
during Pressure Testing
Step 1 Depressurize the piping system and re-torque stud bolts to maximum
torque value shown on Table- 1 or Table-2 as appropriate.
Step 2 If leak does not stop after re-torquing has been performed, disassemble
the flange joint and inspect as follows:
a) Inspect stud bolts and nuts for defects or damage to threads or
improper cleaning of threads.
b) Inspect flange faces for damage, misalignment.
c) Inspect gasket for damage or defects.
Step 3 After all defective and damaged items have been repaired or replaced,
reassemble the flange joint using a new gasket and tighten the bolts
using the appropriate sequence and maximum torque values.
documents.
Page 9 of 17
Issuer: PMT
May 2012
Rev: 1B
11 Additional Requirements for PIKOTEK Gaskets
Step 1 The insulation kit found in the PIKOTEK package should check -out to
the specifications as listed on the package label.
Step 2 Inspect all flange surfaces and ensure that large pits or defects will not
cause leakage when the system is pressurized. Wipe sealing surfaces
clean prior to installing the gasket.
Step 3 Align the flanges so that the bolt holes line up. Improper alignment
could cause damage to the sleeve during installation by pinching the
thread form through the plastic sleeve. When proper alignment has
been achieved install all of the sleeves onto all of the bolt holes. All
sleeves should slide easily into both mating flanges.
Step 4 Install one nut onto one end of each stud.. Be sure to lubricate the
threads and nut surfaces with a suitable compound. From the opposite
end of the stud nut assembly, install one steel washer and one plastic
washer (in that order). Make sure all steel washers are butted against
the nuts. DO NOT BUTT PLASTIC WASHER AGAINST NUTS.
Remove the sleeves from the flange and slide them over the stud.
Step 5 Insert the stud, nut, steel washer and plastic washer assembly into the
bolt holes around the lower half of the bolt pattern and install a plastic
washer, steel washer and nut on the exposed end of the stud. Do not
thread up studs to the point where the gasket cannot be installed. Be
sure to leave enough space between the flanges to install the gasket
Lubricate the appropriate surfaces before final make-up.
Step 6 Insert the gasket between the flanges and allow the gasket to rest on
the sleeve and stud assemblies. Check the condition of the o-
ring/Teflon seals making sure they are secure in each one’s respective
groove. Install the remaining stud, nut, plastic washer and steel washer
assemblies into the upper half of the bolt circle pattern.
Step 7 If a device was used to spread the flanges then remove it at this time.
Thread all nuts onto all the remaining studs and in doing so bring the
flanges into contact with the gasket. If misalignment exists between the
flanges and gasket, tighten the nuts in such a way as to minimize
pinching or point loading of the flange against the gasket
Step 8 Make sure that a sufficient number of threads are within the nut of
each stud prior to torque-up. Torque the assembly to one-half of the
documents.
Page 10 of 17
Issuer: PMT
May 2012
Rev: 1B
torque limit specified on the torque chart. Do this using an approved

flange bolt tightening sequence pattern. Repeat the sequence this time
torquing to the maximum torque limit as specified.
Step 9 Test for shorts across the flange and then pressure test assembly. For
safety reasons it is best to initiate the test pressures much lower than
those normally encountered by the system. Work the pressure up to
acceptable limits by stepping pressure 10% per pressure increments.
documents.
Page 11 of 17
Issuer: PMT
May 2012
Rev: 1B
Appendix A
Table-1 – Friction Factors for Different Lubricants
Torque
Lubricants Friction Factors Correction Factor
Moly Graphite .06 0.67
Tool Joint Compound .08 0.8
Graphite and Oil
(used as the base line for torque .10 1.0
values in Table-2)
Aerocote #4 .11 1.1
KOPR-KOTE .11 1.1
EL-PRO C5A .11 1.1
FEL-PRO C100 .11 1.1
FEL-PRO C102
(commonly called Anti-Seize) .11 1.1
Jet Lube SS-30 .12 1.2

API BULL 5A2
Thread Compound .125 1.3
Light Machine Oil as shipped .15 1.5

Dry Bolts .2 2
documents.
Page 12 of 17
Issuer: PMT
May 2012
Rev: 1B
Appendix B
Table-2 – Torque Values for Low-Alloy Steel Bolting
Stud Bolt Torque
Size Ft-Lb
inch Noncoated Bolts Coated Bolts
1/2 60 45
5/8 120 90
3/4 210 160
7/8 350 250
1 500 400
1-1/8 750 550
1-1/4 1050 800
1-3/8 1400 1050
1-1/2 1800 1400
1-5/8 2350 1800
1-3/4 2950 2300
1-7/8 3650 2800
2 4500 3400
2-1/4 6500 4900
2-1/2 9000 6800
2-3/4 12000 9100
3 15700 11900
3-1/4 20100 15300
3-1/2 25300 19100
3-3/4 31200 23600
4 38000 28800
Notes:
1) Torque values are based on 50,000 psi prestress on stud bolts and Friction Factor of 0.16 for noncoated
surfaces and 0.12 for new coated surfaces. A combination of various elements such as the conditions
of the threads, the condition of the flange to the nut bearing surface and the type of lubricant used,
makes up the friction factor which can vary from .04 to .20 or as much as 500%.
2) Torque values for stainless steel or other alloy stud bolts can be obtained by multiplying the ratio of the
specified minimum yield strength (SMYS) of stainless steel stud bolts to A193 B7 stud bolts, to the
torque values in the Table-2. The SMYS values for all bolting materials are listed in ASME B31.3
code (Note: SMYS depends on grade, class and size).
documents.
Page 13 of 17
Issuer: PMT
May 2012
Rev: 1B
Appendix C
Table-3 – Torque Values for Isolating Gaskets (PIKOTEK)
on ASME B16.5 and ASME B16.47 Series A & B,
Class 150 Through Class 2500 Flanges
Stud Bolt Size Torque Value
inch Ft-Lb
1/2 30
9/16 45
5/8 60
3/4 100
7/8 160
1 245
1-1/8 355
1-1/4 500
1-3/8 680
1-1/2 800
1-5/8 1100
1-3/4 1500
1-7/8 2000
2 2200
2-1/4 3180
2-1/2 4400
2-3/4 5920
3 7720
3-1/4 8400
3-1/2 9000
3-3/4 9600
4 10000
Note: Torque values based on 30,000 psi tension load and 0.16 Friction Factor from
API BULL 5A2 thread compound. See Table-2 Note (1) for other factors.
Commentary Notes:
a) For ASME Class 900 through Class 2500, API-6B and API-6BX Class 2000 through
Class 15000, and RTJ Flanges, the maximum compressive stresses induced during
installation should not exceed 25,000 psi. Design to 12,500 psi when possible.
b) Calculations for compressive stresses applied during torque-up procedures must
account for ring joint grooves, gasket seal grooves, raised face diameters, and
gasket inside diameter. (See PIKOTEK Gasket User's manual).
c) Bolt tensioning equipment such as HYDRATIGHT may be used for class 900 and
above resulting in a minimum residual bolt stress of 30000 psi and a maximum of
50,000 psi. Refer to PIKOTEK Gasket User's manual for specific bolting
instructions.
documents.
Page 14 of 17
Issuer: PMT
May 2012
Rev: 1B
Appendix D -Figure -1 – Stud Bolt Tightening Sequence (4 to 32 Bolts)
documents.
Page 15 of 17
Issuer: PMT
May 2012
Rev: 1B
Appendix E
Figure -2 – Stud Bolt Numbering (36 to 68 Bolts)
1
2
3
9
14 10
13 11
12
documents.
Page 16 of 17
Issuer: PMT
May 2012
Rev: 1B
Appendix F
Table-4 – Cross-Pattern Tightening Sequence
(36 to 68 Bolts) per (ASME PCC-1)
No. of
Sequence
bolts
36 1-2-3 → 19-20-21 → 10-11-12 → 28-29-30 → 4-5-6 → 22-23-24 → 13-14-15 ↵
31-32-33 → 7-8-9 → 25-26-27 → 16-17-18 → 34-35-36
40 1-2-3-4 → 21-22-23-24 → 13-14-15-16 → 33-34-35-36 → 5-6-7-8 → 25-26-27-28 ↵

17-18-19-20 → 37-38-39-40 → 9-10-11-12 → 29-30-31-32
44 1-2-3-4 → 25-26-27-28 → 13-14-15-16 → 37-38-39-40 → 5-6-7-8 → 29-30-31-32 ↵

17-18-19-20 → 41-42-43-44 → 9-10-11-12 → 33-34-35-36 → 21-22-23-24
48 1-2-3-4 → 25-26-27-28 → 13-14-15-16 → 37-38-39-40 → 5-6-7-8 → 29-30-31-32 ↵

17-18-19-20 → 41-42-43-44 → 9-10-11-12 → 33-34-35-36 → 21-22-23-24 → 45-46-47-48
52 1-2-3-4 → 29-30-31-32 → 13-14-15-16 → 41-42-43-44 → 5-6-7-8 → 33-34-35-36 ↵

17-18-19-20 → 45-46-47-48 → 21-22-23-24 → 49-50-51-52 → 25-26-27-29 ↵
9-10-11-12 → 37-38-39-40
56 1-2-3-4 → 29-30-31-32 → 13-14-15-16 → 41-42-43-44 → 21-22-23-24 → 49-50-51-52 ↵

9-10-11-12 → 37-38-39-40 → 25-26-27-28 → 53-54-55-56 → 17-18-19-20 ↵
45-46-47-48 → 5-6-7-8 → 33-34-35-36
60 1-2-3-4 → 29-30-31-32 → 45-46-47-48 → 13-14-15-16 → 5-6-7-8 → 37-38-39-40 ↵

21-22-23-24 → 53-54-55-56 → 9-10-11-12 → 33-34-35-36 → 49-50-51-52 ↵
17-18-19-20 → 41-42-43-44 → 57-58-59-60 → 25-26-27-28
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 ↵

25-26-27-28 → 57-58-59-60 → 5-6-7-8 → 37-38-39-40 → 21-22-23-24 ↵
53-54-55-56 → 13-14-15-16 → 45-50-51-52 → 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 → 45-46-47-49 ↵

29-30-31-32 → 61-62-63-64 → 17-18-19-20 → 57-58-59-60 → 33-34-35-36 → 5-6-7-8 ↵
41-42-43-44 → 13-14-15-16 → 49-50-51-52 → 25-26-27-28 → 65-66-67-68
documents.
Page 17 of 17

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SAUDI ARAMCO TOTAL REFINING & PETROCHEMICAL COMPANY

Name and Signature

N. Mosson, STC D. Grunemwald

New Template & Brief

Revision Revision Date Scope of Revision

1B 19 May 2012 Issued for Release 5A.

0 29 April 2008 Issued for bid package.

02 31 March 2008 Issued for bid package only for review.

01 06 April 2007 First official JERES-L-351 is issued.

First draft issued is based on Saudi Aramco SAEP-351 “Bolted Flange

Section Contents Page

2 Conflicts, Deviations and Clarifications 5

9 Stud Bolt Tightening Procedure 8

Stud Bolt Additional Tightening Procedure where Leaks

A Table -1: Friction Factors for Different Lubricants 12

B Table -2: Torque Value for Low–Alloy Steel Bolting 13

E Figure JERES- 2 Stud Bolt Numbering 16

2 Conflicts, Deviations and Clarifications

11 Additional Requirements for PIKOTEK Gaskets

torque limit specified on the torque chart. Do this using an approved

Jet Lube SS-30 .12 1.2

Light Machine Oil as shipped .15 1.5

Appendix D -Figure -1 – Stud Bolt Tightening Sequence (4 to 32 Bolts)

40 1-2-3-4 → 21-22-23-24 → 13-14-15-16 → 33-34-35-36 → 5-6-7-8 → 25-26-27-28 ↵

44 1-2-3-4 → 25-26-27-28 → 13-14-15-16 → 37-38-39-40 → 5-6-7-8 → 29-30-31-32 ↵

48 1-2-3-4 → 25-26-27-28 → 13-14-15-16 → 37-38-39-40 → 5-6-7-8 → 29-30-31-32 ↵

52 1-2-3-4 → 29-30-31-32 → 13-14-15-16 → 41-42-43-44 → 5-6-7-8 → 33-34-35-36 ↵

56 1-2-3-4 → 29-30-31-32 → 13-14-15-16 → 41-42-43-44 → 21-22-23-24 → 49-50-51-52 ↵

60 1-2-3-4 → 29-30-31-32 → 45-46-47-48 → 13-14-15-16 → 5-6-7-8 → 37-38-39-40 ↵

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 ↵

68 1-2-3-4 → 37-38-39-40 → 21-22-23-24 → 53-54-55-56 → 9-10-11-12 → 45-46-47-49 ↵

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