SAFETY POLICY & PROCEDURES MANUAL Flange Torquing

SF4066 APPROVED BY: R. Keen

th
DATE: March 31 , 2015 REVISION NUMBER 00

Flange Torquing
A CONTROL PROCEDURE

1. PURPOSE & SCOPE

The purpose of these procedures is to protect employees and property from harm due to the improper or
careless use of Manual, Hydraulic, and Pneumatic Torquing Devices. It is your responsibility to make sure
the tool is safe and that you can use it safely before working with it.

2. RESPONSIBILITY
The Division Managers are responsible for safe implementation of this policy.

It is the responsibility of Danos employees to inspect all tools prior to use in order to ensure the safety of
personnel.

3. EXTERNAL REFERENCES
29 CFR 1910.244
29 CFR 1926.302

4. TRAINING GUIDELINES
4.1.1. All employees who engage in any torquing activities must be properly trained and deemed qualified
as defined by Danos and customer requirements.

5. GENERAL GUIDELINES
The following guidelines present the minimum precautionary measures to be followed when using any
torquing device.

5.1 General Torquing Safety

5.1.1 A properly filled JSEA form must be generated before the start-up of any torquing activity.
5.1.2 Select the appropriate type and sized torquing device for the job.
5.1.3 Always wear safety glasses, durable high impact gloves, steel-toed boots and any other
required PPE when engaging in torquing activity.
5.1.4 Inspect tools prior to their use, and continually observe their condition during use. Remove
from service any defective tools or equipment.
5.1.5 Ensure torquing equipment is properly calibrated before using. Refer to manufacturer’s
guidelines for calibration procedures.
5.1.6 Torquing devices should always be held firmly and be kept under control by the user.
5.1.7 Visually Inspect all bolts, nuts, and studs for damaged or corroded threads. Discard or
remove from service any component that is visually or physically defective.
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This document is maintained on electronic media. The current revision of this document is located on the Danos
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SAFETY POLICY & PROCEDURES MANUAL Flange Torquing

SF4066 APPROVED BY: R. Keen

th
DATE: March 31 , 2015 REVISION NUMBER 00

5.1.8 Ensure all burrs and debris is removed from threads.

5.1.9 Do not use instruments or tools that could produce a spark in flammable atmospheres.
Always comply with your work location’s hot-work policy if using tools or equipment that is
not intrinsically safe.
5.1.10 Before tensioning, inspect flanges to ensure they are the correct mating flanges, are free
from damage, and both faces are cleaned and free of debris.
5.1.11 Verify that the correct gasket size has been selected and is free from defects or damage.
5.1.12 Ensure the flange is properly mounted and gasket is centered before torquing.
5.1.1 Never position yourself in line with a bolt being torqued.
5.1.13 Only use an approved lubricant as defined by the customer’s specifications.
5.1.14 Know the proper torque for bolts and nuts to avoid over-torquing them. Lubricating the nuts
and bolts increases the torque amount.
5.1.15 Stop tightening at the required torque setting. Do not under torque or over torque.
5.1.16 After torquing, ensure the correct length of stud is protruding from the bolt’s nut.

5.2 Manual Applications

5.1.2 Ensure the torque wrench is in the correct mode for tightening and loosening.
5.2.1 Keep torque wrenches free from oil or dirt to prevent the tool from becoming slippery or
unmanageable.
5.1.3 Always ensure the correct size torque wrench has been selected for the application and is
properly calibrated to meet the manufacturer’s recommended setting.
5.1.4 Ensure the torque wrench is in the correct mode for tightening and loosening.
5.1.5 Do not modify any equipment. Extensions (cheaters) shall not be used on a torque wrench. If
you need more torque, use a larger wrench.
5.1.6 Ensure proper body positioning and hand placement before pulling on the wrench to
prevent strained muscles.
5.1.7 When using a torque wrench, always pull the wrench when applying force. Never push the
wrench away from yourself.
5.1.8 Never strike a torque wrench with a hammer unless the wrench was designed for striking.
5.1.9 Never use a torque wrench to loosen fasteners.

5.2 Hydraulic and Pneumatic Applications

5.2.1 Do not exceed the equipment’s stated maximum working pressure.
5.2.2 When using hydraulic or pneumatic systems, inspect hoses to ensure they are in good
working condition.
5.2.3 Ensure that the power console is full of hydraulic oil and if an air power console is being
used, that the air lubricator has sufficient oil in it.
5.2.4 Make sure that all air and hydraulic couplings are clean and free from dirt.
5.2.5 Check that the correct size impact socket has been selected and that it has a retaining ring
and pin.
5.2.6 Check that the square drive is in the correct position for tightening operations.
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This document is maintained on electronic media. The current revision of this document is located on the Danos
network. It is the responsibility of the user to verify that this copy is of the latest revision.
SAFETY POLICY & PROCEDURES MANUAL Flange Torquing

SF4066 APPROVED BY: R. Keen

th
DATE: March 31 , 2015 REVISION NUMBER 00

5.2.7 Always position the reaction arm for the best and safest angle, then engage the retaining
device.
5.2.8 With the tool removed from the flange and safely positioned on the ground, connect the
hydraulic hoses to the tool and power console ensuring that all locking collars and
thumbscrews are fully tightened.
5.2.9 All air hose connections shall have whip checks and pins to prevent hoses becoming
disconnected.
5.2.10 Connect the pump to an air supply of the correct pressure, and then switch on the air supply
to check for system leaks.
5.2.11 Pinch Points are present around reaction areas and in tight spaces. Hands and fingers must
be kept clear from pinch points at all times
5.2.12 Always ensure proper communication between personnel is used before energizing the
power console, and all hands and body parts are clear of pinch points.
5.2.13 Improper reaction set up and/or incorrect socket size can cause a concentration of stress
than can make the tool, socket, or nut vulnerable to fracture. Always verify that you are
using the correct size tools and settings.
5.2.14 On air driven pumps, ensure the reservoir unit is filled with hydraulic oil and the correct air
pressure has been applied.

6.1 TORQUING SEQUENCE

6.1.1 4 - Bolt Flange Tightening Sequence
6.1.1.1 Sequential Order: 1-2, 3-4
6.1.1.2 Rotation Order: 1, 3, 2, 4

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This document is maintained on electronic media. The current revision of this document is located on the Danos
network. It is the responsibility of the user to verify that this copy is of the latest revision.
SAFETY POLICY & PROCEDURES MANUAL Flange Torquing

SF4066 APPROVED BY: R. Keen

th
DATE: March 31 , 2015 REVISION NUMBER 00

6.1.2 8 - Bolt Flange Tightening Sequence

6.1.2.1 Sequential Order: 1-2, 3-4, 5-6, 7-8
6.1.2.2 Rotation Order: 1, 5, 3, 7, 2, 6, 4, 8

6.1.3 12 - Bolt Flange Tightening Sequence

6.1.3.1 Sequential Order: 1-2, 3-4, 5-6, 7-8, 9-10, 11-12
6.1.3.2 Rotation Order: 1, 5, 9, 3, 7, 11, 2, 6, 10, 4, 8, 12

Printed on 4/1/2015 Management System Document Page 4 of 6

This document is maintained on electronic media. The current revision of this document is located on the Danos
network. It is the responsibility of the user to verify that this copy is of the latest revision.
SAFETY POLICY & PROCEDURES MANUAL Flange Torquing

SF4066 APPROVED BY: R. Keen

th
DATE: March 31 , 2015 REVISION NUMBER 00

6.1.4 16 - Bolt Tightening Sequence

6.1.4.1 Sequential Order: 1-2, 3-4, 5-6, 7-8, 9-10, 11-12, 13-14, 15-16
6.1.4.2 Rotation Order: 1, 9, 5, 13, 3, 11, 7, 15, 2, 10, 6, 14, 4, 12, 8, 16

6.1.5 20 - Bolt Tightening Sequence

6.1.5.1 Sequential Order: 1-2, 3-4, 5-6, 7-8, 9-10, 11-12, 13-14, 15-16, 17-18, 19-20
6.1.5.2 Rotation Order: 1, 9, 5, 13, 3, 11, 7, 15, 2, 10, 6, 14, 4, 12, 8, 16

Printed on 4/1/2015 Management System Document Page 5 of 6

This document is maintained on electronic media. The current revision of this document is located on the Danos
network. It is the responsibility of the user to verify that this copy is of the latest revision.
SAFETY POLICY & PROCEDURES MANUAL Flange Torquing

SF4066 APPROVED BY: R. Keen

th
DATE: March 31 , 2015 REVISION NUMBER 00

6.1.6 24 - Bolt Tightening Sequence

6.1.6.1 Sequential Order: 1-2, 3-4, 5-6, 7-8, 9-10, 11-12, 13-14, 15-16, 17-18, 19-20, 21-22, 23-24
6.1.6.2 Rotation Order: 1, 9, 17, 5, 13, 21, 3, 11, 19, 7, 15, 23, 2, 10, 18, 6, 14, 22, 20, 8, 16, 24

6. QUALITY RECORDS
All training records associated with this policy shall be maintained for a minimum of three years.

Revision History:

Revision Date Description of changes Requested By

00 3/31/2015 Initial draft Tyler Dupre

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This document is maintained on electronic media. The current revision of this document is located on the Danos
network. It is the responsibility of the user to verify that this copy is of the latest revision.