WORK INSTRUCTION

CONTROLLED BOLTING

DIALOG

DPS/OPT/PRO/07/2010
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OPTIMAL MINOR PROJECT

WORK INSTRUCTION

0
REV.

26/07/10

FAUZI

DATE

PREPARED BY

WAN
AHMID
REVIEW BY

APPROVED BY

DESCRIPTIONS

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DIALOG

WORK INSTRUCTION
CONTROLLED BOLTING

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TABLE OF CONTENTS
SECTION

DESCRIPTION

PAGE

1.0

INTRODUCTION

2.0

BOLT TENSIONING SPECIFICATIONS

3.0

PRIORITY

4.0

METHODOLOGY

4.1

WORK FLOW

4.2

TAGGING SYSTEM

4.3

JOINT BREAKING

5.0

GENERAL PROCEDURE

6.0

REPORT / COMPLETION OF WORK

ATTACHMENTS
ATTACHMENT

DESCRIPTION

JOINT INTEGRITY TEAM (JIT) ORGANIZATION CHART

II

JOINT INTEGRITY FLOW DIAGRAM

III

JOINT INTEGRITY TAG

IV

CRITICAL JOINT CHECKLIST

FLANGE REPAIR RECORD

VI

CROSS PATTERN TIGHTENING SEQUENCE

VII

TABLE OF CROSS PATTERN TIGHTENING SEQUENCE

VII

PROPOSED TORQUE VALUE FOR MANUAL TORQUING

IX

SAMPLE OF TORQUE CALCULATION

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1.

WORK INSTRUCTION
CONTROLLED BOLTING

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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.

BOLT TENSIONING SPECIFICATIONS

All bolts up to 1-1/8 diameter shall be tightened (tensioned) using
manual type torque wrenches with a positive (click) type indication
when the selected torque value is reached.
All bolts 1-1/4 diameter and larger shall be tightened using hydraulic
tensioning equipment (torque wrenches or bolt tensioners).
ASTM A193 B7 stud-bolt for low and medium temperature applications
shall be tightened to 50% of minimum yield strength of the bolt
material.
ASTM A193 B16 stud-bolt for high temperature applications shall be
tightened to 35% of min. yield of the bolt material.

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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)

Priority shall be assigned to isolation joints to ensure positive

intervention devices (slip blinds etc.) are in position at the earliest
opportunity practicable to provide a leak proof joint

2)

Slip blinds may be inserted between isolation joint with

damaged mating faces, to provide a leak proof joint for
execution of the Turnaround, and the following shall be carried
out:
Flange repair record prepared
Repairs carried out at earliest opportunity and
Other processes in this instruction carried out accordingly.

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)

Attachment Flange of Valves:

JIT shall inspect the attachment of
flanges of valves removed for service or overhaul.

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.

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4.2.1 Green Tag

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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 any disturbed joint that requires

subsequent rework or repair.
Flange repair report shall be prepared for all repairs
The JIT supervisor shall replace this tag upon successful repair and
acceptance with green tag.
4.2.3 Yellow Tag

(Tightened and accepted)

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.

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4.3

WORK INSTRUCTION
CONTROLLED BOLTING

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Joint Breaking (Parting)

4.3.1 Joint identification.
JIT shall confirm all joint identification prior to breaking the joint
Joints shall be identified according to the assigned identification in the
Equipment Isolation Sheet (EIS). The assigned identification shall
include the Equipment Tag No. suffixed by numeral identification.
4.3.2 Joint contact surface inspection.
Wherever accessible, upon breaking (parting) a joint, the contact or
mating faces shall be inspected for damages.
Conditions that are detrimental to the potential joint tightness and
subsequent repair shall be recorded. Critical joint checklist
(Attachment IV)
Detrimental mating face damage include: Indications running radially across the facing
Scratches, nicks, gouges and burrs
Gross misalignment
4.3.3 Reinstatement of joint contact surfaces.
Detrimental joint contact faces shall be reinstated in-situ or off plot.
The repair joint shall be protected from subsequent damage.
4.3.4 Studs, nuts and washers.
Studs, nuts and washer shall be in good condition.
Studs and nuts shall be examined for rust, corrosion and other
damages. Washer shall be examined for burrs, cupped and other
distortion. Questionable items shall be replaced.
Rust shall be removed from the studs and nuts. Approved lubricant,
where permitted, shall be applied to that portion of the stud and nut
for tightening. A smooth turning fit shall be provided along the length
of the stud.
4.3.5 Minimum length of bolts
Bolts shall have the following minimum length,
Manual torque studs and bolts. Not less than one (1) full
thread protruding from the ends of the nuts.

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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.

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4.

WORK INSTRUCTION
CONTROLLED BOLTING

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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.

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ATTACHMENT I

JOINT INTEGRITY TEAM ORGANIZATION CHART

PROJECT MANAGER

PROJECT ENGINEER

QC INSP.

SUPERVISOR

Joint Making Team

4 Fitters
2 Helper

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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

JOINT MAKING AND

TIGHTENED
TEAM LEADER

FINAL INSPECTION
YELLOW TAG
TEAM LEADER

COMPLETE JOINT DATA

CONTROL SHEET
SUPV

FILE
DOCUMENTATION

QC

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ATTACHMENT III

JOINT INTEGRITY TAG

GREEN

Equipt No:
Line No:
Flange No:

RED

Equipt No:
Line No:
Flange No:
Date Insp:

Date Insp:
Inspector

Inspector

Joint in good condition

and can be reassembled
Serial No :01234

120 mm

REPAIR REQUIRED

Type of repair

Serial No :01234

60 mm

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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

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WORK INSTRUCTION
CONTROLLED BOLTING

ATTACHMENT IV
CRITICAL JOINT CHECKLIST
DESCRIPTION

LOCATION

EQPT/PIPING TAG NO:

PLANT:

JOINT NO:

UNIT NO:

A. JOINT BREAKING

CONDITION

JOINT FACE & FLANGES

1. Condition of joint face & flanges inspected
2. Sealing surface condition inspected
3. Any miss alignment sign from the existing
line

B. JOINT MAKING

NO

CONDITION

JOINT FACE & FLANGES

1. Condition of joint face & flanges inspected
2. Flanges aligned / parallel
3. Sealing surface condition inspected
GASKET
Type ( grafoil, spiral wound-sw, etc ) :
Rating:
BOLTS & NUT
1. Clean / or new (if necessary)
2. Anti-sieze / lubricated (threads / nuts)
3. Bolt length
4. Tightened in diagonal sequence
5. Torque W rench / HBT
TORQUE APPLIED (N-m)

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:

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ATTACHMENT V

FLANGE REPAIR RECORD

Record No
Flange Tag No.
Plant:

Equipment Tag No.

Unit No.

Repair Equipment Details

Manufacturer
Model
Serial No.
Others
Repair
Flange Identification No.
(Mfg)
Reported Defect

Description of repair

Contact face rifling

(lines/mm)
Contact face profile
Remaining raise face height
(mm)

Repaired by (supv)

Inspected by (QC)

Approved by (Client)

Signature
Name
Date

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WORK INSTRUCTION
CONTROLLED BOLTING

ATTACHMENT VI

CROSS PATTERN TIGHTENING SEQUENCE

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

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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

1-2-13, 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 BOLTS OR MORE: TIGHTEN IN GROUPS OF 4

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, 25-26-27-28, 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, 5758-59-60, 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, 25-26-2728, 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

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ATTACHMENT VIII
PROPOSED TORQUE VALUE FOR MANUAL TORQUING
NO.

SIZE (INCH)

RATING (LBS)

NO.OF BOLT AND SIZE

(INCH)

TORQUE VALUE (FT.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

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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

threads per inch. (TPI)

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

(K)*BOLT DIAMETER *YIELD *PERCENTAGE OF YIELD X A

12
where K= 0.1 Friction factor, well greased with copper nickle antiseize lubricant.

Therefore
Torque (ft.lbs)=
122.063 ftlbs
.

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