WORK PLAN 1

EVALUATION AND PLANNING WORSHEET FOR BOLTED FLANGE/JOINT ASSEMBLY

Before beginning work on any bolted flange or joint it is important to review the following factors:
PURPOSE OF THE JOINT/FLANGE
What is the purpose of this flange/joint? (Example: Coupling in shaft between turbine and generator; maintains connection
and alignment at high rpms./ or Valve in steam crossover pipe, etc.)
______________________________________________________________________________________
PURPOSE OF THE CURRENT WORK
What work will I be performing? (Example: Remove and replace leaking gasket. / Disassemble to allow maintenance on
turbine / etc) ____________________________________________________________
______________________________________________________________________________________
SAFETY:
What special safety precautions apply to this job?______________________________________________
______________________________________________________________________________________
What special equipment should be at hand? (gloves, glasses, face shields, breathing apparatus, ventilation fans, spill
absorbent, fire extinguishers, insulation, lighting, ladders/scaffolding, other)
______________________________________________________________________________________
Have I assembled all required safety equipment? __________ Do I have a copy of appropriate work permit/welding permit/
confined space permit, etc.? _________ (Attach copy of required permit)
In case of emergency who should be contacted? __________________ Contact number ______________
How can I verify if the flange/joint is out of service? ___________________________________________
Is there any remaining pressure, spring tension, electrical voltage, or other stored energy? ______________
Have I locked out any electrical or valve actuators? ____________________location of lock____________
Assembly/Disassembly limitations: How much time do I have to complete work? ___________ How many people will
assist? __________ List space or clearance issues?______________________________
______________________________________________________________________________________
Is corrosion a problem? _________ How will it be addressed? ___________________________________
S- (SIZE)
What is the nominal size of this flange/joint? (diameter, thickness, pipe schedule, etc. _________________
What are the critical dimensions I must observe/achieve/maintain? (gap, linearity, load, stretch, etc.)
______________________________________________________________________________________
Who is responsible for inspection? ________________________________ When? __________________
T (TEMPERATURE)
What is operating temperature? max____ min____ avg.____ cyclic? ______ cycle period? _______
Does the machinery have to cool before work starts? _____ What is a safe temperature? ______________
A- (ATTRIBUTES)
What are the specifications of this flange/joint?
Raised face ______ flat face______ lap joint _____ other ______
Do I need/have drawings or specifications? _________
What fasteners are used? Number ______ Diameter _______ Grade/Class _______ Thread pitch ______
Target load or torque _______ Lubricant ________ New or used? _______ Condition ________
Bolting Pattern: number of tools_______ number of passes _______ percent of target/pass ____________ (Sketch bolting
pattern and progressive steps on reverse of this page. See examples below.)
M- (MEDIA)
What material or media, if any, will be contained by this joint/flange? (Example: Steam, Nitric Acid, Hydrogen, vacuum,
etc.) _____________________________________ Hazardous? ___________ Are all safety procedures listed and followed?
______ (Attach copy of MSDS sheet for hazardous materials.) ____
Have all hazardous materials been flushed or neutralized? __________
P- (PRESSURE)
What is the operating pressure? Max____ min_____ avg._____ cyclic? _____ cycle period? ________
Has all pressure been released? _________

WORK PLAN 1

ASSEMBLY
INSPECTION AND PREPARATION
__ Examine and clean/dress all working surfaces:
__ Check joint faces for damage, nicks, scratches, cracks, warping, etc.
__ Check bolt/nut threads, washer faces for rust, corrosion, burrs, uniformity, etc.
Problems found ________________________________________________________
__ Select and procure all necessary tools and parts
__ studs/bolts
__ nuts
__ washers
__ gasket
__ lubricant
__ wrenches
__ sockets
__ markers
__ backup tools __ micrometer
__ other ______________________________________________________________
__ Verify bolt and nut specifications (size, grade, threads, new/used, (replace all or none) etc.)
__ Align mating surfaces
__ Install proper gasket if required (OD, ID, thickness, material, concentric, handling, adhesives(?))
__ Lubricate working surfaces (friction, corrosion, avoid galling)
Appropriate lubricant (temp., chemicals, etc.), threads, nut/washer faces
__ Install bolts and snug hand tight
__ Align studs for length
__ Check nut engagement
__ Number bolts for assembly sequence depending on number of wrenches
__ Select desired torque/load and set hydraulic system
__ Tighten nuts in sequence
1.
Install
2.
20-30%
check alignment
3.
50-70%
check alignment
4.
100%
5.
Tighten in rotation at 100% until no movement
6.
Re-check critical applications or soft gasket flanges after time
__ Pressurize and check for leaks
__ For critical flanges Record (date, assembler, procedure, problems,
recommendations, etc.)
DIS-ASSEMBLY
__ Ensure flange is out of service and free of hazards
__ Check records for any concerns
__ Examine for corrosion or damage
__ Apply solvent or lubricant as appropriate
__ Choose tools with sufficient capacity (break-out torque is more than assembly torque)
__ Set hydraulic pressure to maximum
__ Determine loosening sequence
(critical flanges may require load control during dis-assembly
remove in reverse of assembly sequence two flats at a time until unloaded then remove)
__ Safety considerations (sockets, pinch points, reaction, etc.)
__ Judicious use of heat and shock
__ Remove bolts, nuts, washers and gaskets
__ Inspect and prepare for re-assembly

WORK PLAN 1

Here is an example of a flange. This one has twenty bolts. Depending on the number of torquing tools to be employed
simultaneously, mark out the bolting pattern. If four tools are to be employed then place a 1 on the studs at 12:00, 3:00, 6:00
and 9:00 positions. Place a 2 on the set of bolts splitting the angle and continue to split the angles until you have marked all
of the studs with ascending numbers until you reach 5 which is 1/4th of the total studs (20/4wrenches).
I you were employing two tools opposite one another you would start by marking a 1 on the studs at 12:00 and 6:00, then a 2
on the studs at 3:00 and 9:00 and continue to split the angles in half, increasing the numbers up to 10 which is of the total
number of studs (20/two wrenches).
With each successive pass of the tools, each time you come back to the beginning point, you will increase your pressure on
the pump resulting in a higher torque applied to the studs. Depending on the critical nature of the flange you may be required
to make two or three passes. Note: when you are using 4 wrenches simultaneously it is almost never necessary to make more
than two passes on the flange because of the inherent parallel closure you achieve with 4 tools.
No matter how many wrenches you are using, after you have completed your final pass, you must then rotate bolt by bolt
clockwise or counterclockwise form that point, at the same final pressure on the pump until you get no movement on any
bolt, to ensure that you have evened out the load on all bolts.

Using this pattern as

an example, make a
sketch of your flange
and bolting pattern
below

WORK PLAN 1

3-2-4 method for numbering bolts for tightening sequence from ASME PCC-1 standard for bolting

WORK PLAN 1

48 bolt tightening sequence showing groupings. If the number of bolts in the flange is large ( say 36 or more) it may be
adviseable to tighten the bolts in groups. This accomplishes two positive things: 1) it reduces the number of times you have
to move the wrenches across the flange and 2) it avoids putting undue stress on one bolt at a time. Once again, depending on
the number of wrenches you are using simultaneously, adjust the numbers accordingly to maintain even cross-loading of the
flange.

WORK PLAN 1

PICTURES ILLUSTRATING BOLTING OF A FLANGE USING HYDRAULIC TOOLS

VIEW

OF

FLANGE AND SURROUNDING CONDITIONS

FLANGE OPEN, READY FOR INSPECTION

FLANGE MARKINGS

INSERTING GASKET IN FLANGE (NOTE BOLTS

IN PLACE TO ALIGN AND SUPPORT GASKET

GASKET MARKINGS

LUBRICATING ONE END OF STUD

WORK PLAN 1

LUBRICATING BEARING FACE OF NUT

ALIGNING THE FLANGE

MARKING BOLT SEQUENCE PATTERN

ADJUSTING STUD PROTRUSION

SETTING PUMP PRESSURE FOR DESIRED TORQUE

CONTINUING BOLTING SEQUENCE

WORK PLAN 1

AVANTI SET UP TO TIGHTEN

(WHEN PISTON ADVANCES DRIVE WILL MOVE CLOCKWISE)

TIGHENING WITH TWO AVANTI TOOLS SIMULTANEOUSLY

REACTION ARM SWIVELS RELATIVE TO TOOL

FOR EASY PLACEMENT

AVANTI TOOL SET UP TO LOOSEN (WHEN PISTON

ADVANCES, DRIVE WILL MOVE COUNTERCLOCKWISE

HYTORC LOAD DISC INSTALLED UNDER NUT

AVANTI WITH DISC SOCKET TIGHTENING NUT

NO REACTION ARM OR BACKUP WRENCH NEEDED

WORK PLAN 1

HYTORC CLAMP NUT INSTALLED ON STUD

AVANTI TIGHTENING CLAMP NUT WITHOUT

REACTION ARM OR BACKUP WRENCH NEEDED

SPIRAL WOUND GASKET SHOWING CRUSH AFTER

REMOVAL

DETAIL OF GASKET CRUSHING