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CONTROLLED DOCUMENT

Title: FLANGE BOLTING STANDARD

Controlled Ref No: W1000SM3131997 Revision: 2

Name Date

Prepared by: G Ralls 8/1/09

Approved by: M Hamblin 13/1/09

Custodian: Godfrey Howard 28/1/09

Concurrence (Agreement that must be obtained if an item is prepared external to, but impacts, a department or division. If
concurrence is required, it must be noted within the body of the item).

1.

2.

3.

Woodside Management System Sub-processes MUST obtain concurrence endorsement from BopCom. The date of the BopCom
meeting where endorsement is granted should be indicated below.

BopCom Endorsement Meeting date when endorsement granted:

REVISION HISTORY

Revision Description Date Prepared by Approved by

00 Merged W8000MM001 and L0000AG143374 03/2007 D Gomes M Hackett

01 Clarification of bolting sequence 11/2007 M Davey M Hackett

02 Revised to allow use on external website 01/2009 G Ralls M Hamblin

INFORMATION SECURITY REVIEW STATUS PREPARED


CONFIDENTIALITY CLASSIFICATION (Check one box only) (Check one box only)
(Check one box only)
Unclassified Review on/by By WEL
(Shared without Restrictions) (20/05/2011):
Restricted Review Not Required For WEL
(Freely Shared within Woodside and Under PO/Contract No:
Associated Companies)

Confidential
(Shared With Selected Personnel)

Most Confidential
(Strict Need-to-Know Basis)

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OPERATIONS / PROJECTS USE ONLY

Operating Facility:

Key TAG No’s:

DOCUMENT DISTRIBUTION

Full Name / External Organisation Name (if applicable) Electronic


Copy No. (Show Username (WOPID) to differentiate between persons with identical Hard Copy
Notification
names).

00 WEL Document Control

01 TW Doc Control

02 CAJV Doc Control

03 Gilbert Habets(10063)

04 Peter Nalepa(3019)

05 Mike Hamblin(3227)

06 Pluto Eng Coordinator(2404)

07 Sunrise Eng Manager(7521)

08 Browse Eng Coordinator(4350)

09 LNG Project Development Eng Manager(8927)

10 Clive Saxton(3606)

11 Tony Glesson – TW ENG Manager

12 Iain Denholm – CAJV Eng Manager

This document is protected by copyright. No part of this document may be reproduced, adapted, transmitted, or stored in any form by
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Title: Flange Bolting Standard

PREFACE
Woodside Energy Ltd. (WEL) has developed a suite of Engineering and Technical Standards
and Guidelines. It is intended that these reflect the most suitable engineering practices for
use on all new WEL facilities as well as the modification of existing facilities. The application
of the Standards is mandatory. The applications of Guidelines are to support the
implementation of the Standards, and are considered best practice, but are not mandatory.

The Standards are based on the experience acquired by WEL personnel and contractors
during WEL’s involvement with the design, construction, operation and maintenance of WEL
processing units and facilities. Where appropriate, the Standards are based on or make
reference to national and international standards and codes of practice.

The objective of this publication is to ensure the overall integrity of engineering design and to
achieve maximum technical and economic benefits through the standardisation of
engineering and technical practices.

The use by WEL contractors or manufacturers/suppliers of the Engineering and Technical


Standards contained in this publication does not relieve them of any responsibility
whatsoever for the quality of design, materials and workmanship that they have been
engaged to provide.

Where the standards to be used for a certain application are not provided for in this
publication, WEL expects that the standards that are used will achieve the same level of
integrity as reflected in this publication. If WEL contractors or manufacturers/suppliers have
any doubt as to the relevant standard to use, then they must consult WEL, however they will
remain responsible at all times for the use of the most appropriate standard. Specific
requirements may be added as an addendum to these Standards and Guidelines for various
projects. Project specific requirements must not depart from the requirements of the
Engineering and Technical Standards contained in this publication. Where changes or
additions to these Standards are required, they must be raised as a deviation and presented
to the WEL Technical Authority for consideration.

WEL grants the right to use these Standards and Guidelines to WEL’s consultants,
contractors and suppliers who are contractually authorised to do so and to any tier of
contractor to its consultants, contractors and suppliers who are contractually required to
comply with them.

DISCLAIMER

WEL and its joint venture partners disclaim any liability of whatsoever nature for any damage
(including injury or death) suffered by any company or person whomsoever as a result of or
in connection with the use, application or implementation of any standard, combination of
standards or any part thereof contained in this publication.

This document is protected by copyright. No part of this document may be reproduced, adapted, transmitted, or stored in any form by
any process (electronic or otherwise) without the specific written consent of Woodside. All rights are reserved.
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Title: Flange Bolting Standard

TABLE OF CONTENTS

1 INTRODUCTION ............................................................................................ 6
1.1 Scope ............................................................................................................. 6
1.2 Summary ........................................................................................................ 6
1.3 Aims of this Standard ..................................................................................... 6
2 BOLT STRESS LEVELS FOR ASME FLANGES.......................................... 7
2.1 Criteria for Selection of Bolt Stress for ASME Flanges................................... 7
2.2 Stipulated Bolt Stress Levels for ASME Flanges ............................................ 7
3 INSTRUCTIONS FOR FLANGE & CLAMP MAKE UP.................................. 8
3.1 ASME Flange Assemblies .............................................................................. 8
3.2 Gasket Selection ............................................................................................ 8
3.3 Bolt Tensioning Equipment............................................................................. 8
3.4 Bolt Torquing Equipment ................................................................................ 9
3.5 Sequence of Bolting ....................................................................................... 9
3.6 Making Up Clamp Connectors........................................................................ 9
3.7 The Use of Flange & Clamp Connector Checklists....................................... 10
3.8 Accuracy, Calibration and Care of Equipment .............................................. 10
3.9 Re-use of Stud Bolts and Nuts ..................................................................... 10
3.10 Re-use of Ring Tight Joints (RTJ) ................................................................ 11
3.11 Use of Threaded inserts ............................................................................... 11
3.12 Sight Glass Refurbishment ........................................................................... 11
4 GUIDANCE ON MAKE UP OF SPECIAL FLANGE TYPES........................ 12
4.1 Ameron GRE Flange Assemblies ................................................................. 12
4.2 DIN Flange Assemblies ................................................................................ 12
4.3 Non-steel flanges.......................................................................................... 12
5 PROCEDURE FOR HOT BOLTING ............................................................ 13
5.1 Hot Bolting to Replace Corroded Bolts ......................................................... 13
5.2 Hot Bolting to Replace Non-Corroded Bolts ................................................. 14
6 TIGHTENING OF LEAKING JOINTS UNDER PRESSURE ........................ 15
6.1 Instructions for Tightening Leaking Joints Under Pressure........................... 15
7 INSULATING FLANGES.............................................................................. 16
8 REFERENCES ............................................................................................. 18
APPENDIX A ............................................................................................................ 19
APPENDIX B ............................................................................................................ 20
APPENDIX C ............................................................................................................ 25
APPENDIX D ............................................................................................................ 28

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Title: Flange Bolting Standard

APPENDIX E ........................................................................................................... 30
APPENDIX F............................................................................................................ 33
APPENDIX G ............................................................................................................ 34
APPENDIX H ............................................................................................................ 35
APPENDIX I.............................................................................................................. 36
APPENDIX J............................................................................................................. 37
APPENDIX K ............................................................................................................ 48
APPENDIX L............................................................................................................. 51

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Title: Flange Bolting Standard

1 INTRODUCTION

1.1 Scope
This document covers the philosophy and bolt stress levels for steel flanges and clamp
connectors. Other flange materials are not considered (eg. cast iron, plastic). Refer to
the Mechanical Integrity Custodian for the make up of these flanges.

1.2 Summary
It is important for flanges to be tightened up correctly to minimise problems such as
gasket deformation, leaks and misalignment.

This standard outlines the procedures that shall be used within Woodside to
standardise the method in which flanges and clamp connectors are made up.

1.3 Aims of this Standard


The objectives of this standard are:

• To specify a bolt stress level that can be safely applied to ASME flanges and
Clamp Connectors for each flange and bolt material type.

• To develop a philosophy for the controlled bolt loading of ASME flanges and
Clamp Connectors to include:
- Bolting procedures for different flange installations.
- Procedures on the use of tensioning and torquing equipment.
- Checklists for the correct installation of flanges, connectors and sight-
glasses.
- Calibration requirements for equipment.
- Instructions on the re-use of stud bolts.
- Instructions on the use of threaded inserts.
- Procedures for the refurbishment of sight-glasses.

• To set standards on hot bolting to replace corroded and non-corroded bolts.

• To set standards on tightening of leaking joints under pressure.

• To standards for correct gasket selection.

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Title: Flange Bolting Standard

2 BOLT STRESS LEVELS FOR ASME FLANGES

2.1 Criteria for Selection of Bolt Stress for ASME Flanges


See W8000CM001 for discussion.

2.2 Stipulated Bolt Stress Levels for ASME Flanges


The stipulated bolt stress levels are shown in Table 1.

Minimum Req’d Bolt


Percentage
Bolt Specification Bolt Material Bolt Yield Stress
of Bolt Yield
(MPa) Level
Carbon steels
A193-B7, A320- Duplex Stainless Steels
44% Min
L7 Super Austenitic Stainless 655 290 MPa
Yield
and equivalent Steels
Zeron
A193-B8M Class 50% Min
316 Stainless Steel 345 174 MPa
2 Yield

Table 1: Stipulated Bolt Stress Levels

Note: The minimum yield value for bolts varies with the material grade and the bolt diameter. In
the bolt yield column above, the lowest minimum yield value is shown.

e.g. For B7 bolts of diameter 2 1/2” and less, the minimum yield is 725 MPa.
For B7 bolts of diameter greater than 2 1/2”, the minimum yield is 655 MPa.

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3 INSTRUCTIONS FOR FLANGE & CLAMP MAKE UP


Experience has proven that the likelihood of a leaking joint following maintenance is
significantly reduced if the joint is made up using controlled procedures and techniques.
One of the aims of this document is to eliminate the practice of flogging up flanges in
critical services and as such the following methods shall be used.

3.1 ASME Flange Assemblies

All flanges in critical services such as hydrocarbons, glycol and hot oil or rated 900 lbs
and above non critical services shall have their bolts tightened to the stipulated stress
levels for their piping material class and a Flange Checklist must be used.

a) Whenever physically possible all flanges with bolt diameters 1 3/8” and greater
shall be tensioned using Hydraulic Bolt Tensioning equipment. Refer to Appendix
B for the offshore bolt tensioning procedure.

b) Whenever physically possible all flanges with bolt diameters 1 3/8” and greater
shall be tensioned using Hydraulic Bolt Tensioning equipment.

(Hydraulic Bolt Tensioning equipment produces a more accurate bolt tensile stress in
flange make ups; however it does require additional stud length to facilitate the use of
the specialised equipment, for this reason it may not be practicable to use on all WEL
facilities)

3.2 Gasket Selection


The appropriate gasket is selected by cross-referencing the P&ID line details with the
relevant Piping Material Specification. An example of gasket selection is provided in
Appendix A for training purposes.

3.3 Bolt Tensioning Equipment


Appendix B details the procedure to be used on tensioning equipment. This shall be
used in all cases. Also in Appendix B are two tables of hydraulic pressures to be used
with:

a) Furmanite “Hydratight” bolt tensioning equipment.


b) Hedley Purvis “Hypur-Mate” bolt tensioning equipment.

These tables provide the recommended tool type and its corresponding pressure for
each bolt size 1-3/8” and greater. Care must be taken to use the correct pressure for the
listed equipment and tools as the hydraulic areas on different tools vary. (Note that the
pressures have been calculated to obtain the bolt stress specified in Section 2.2.)

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3.4 Bolt Torquing Equipment

Appendix C details the procedure to be used on torquing equipment. This shall be used
in all cases. Also in Appendix C is a chart detailing recommended bolt torques. This
assumes a friction factor of 0.11 (This friction factor is based on the use of graphite based
anti-seize and is not affected significantly by the respective stud and bolt surface
treatment).

The torque table can also be used to determine the pressures for the “HyTorc”
equipment. Conversion charts are attached to Appendix D and for a bolt torque give a
corresponding hydraulic pressure. It is important, however, that for a particular bolt size
the correct pressure is used with the correct tool. There is potential for over/under
torquing of bolts if pressures and tools are mixed.

3.5 Sequence of Bolting

Tightening sequence for flange make-up

3.6 Making Up Clamp Connectors


Clamp connectors, such as Destec and Grayloc clamps, have not been used extensively
on offshore process piping, and their design is not controlled by a dimensional industry
standard. Subsequently, all clamp connectors shall be assembled according to the
manufacturer’s guidelines and recommended bolt torque values (see Appendices F to H).

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3.7 The Use of Flange & Clamp Connector Checklists


Prior to the make up of any ASME flange or Clamp Connector, it should be inspected to
ensure that the correct parts are being used and that there is no damage to the joint. An
inspection check list (such as those attached in Appendix I) should be filled out for every
joint made up in critical services.

A checklist should be completed for:


a) All flanged joints in hydrocarbon service.
b) All flanged joints in chemical service.
c) All flanged joints in steam service.
d) All flanged joints for class 300 flanges and over.
e) All flanged joints for class 150 flanges, DN100 and above

3.8 Accuracy, Calibration and Care of Equipment


Two benefits of using tensioning equipment on flanges are that surfaces are pulled
together squarely and that the load stress applied to each of the bolts is much more
accurate than other methods. Typically, bolt tensioning is accurate to ± 10% when bolt
length to diameter ratio is greater than 5:1. In comparison, the accuracy of bolt torquing
is in the order of ± 30%.

In order to obtain the best flange joints possible it is important that equipment is
adequately maintained. Hired tensioning equipment should be serviced every 3 months
by the manufacturer’s service representative. The content of this service can be as
recommended by the service representative, however, should involve tool stripping,
cleaning, checking of seals and a visual examination. The equipment should also be
calibrated against a test gauge and a service record maintained.

Similarly, Woodside owned hydraulic torquing equipment should be serviced every 3


months by Woodside personnel. The torquing equipment should be stripped, cleaned
and calibrated to a calibrated test gauge. In addition to this, the torquing equipment
should be lubricated prior to use. Note also that more frequent servicing may be required
if the torquing equipment is being used on a daily basis.

3.9 Re-use of Stud Bolts and Nuts


Stud bolts and nuts (of all materials) can be re-used where necessary, subject to the
following:

a) There is no noticeable degradation.


b) They are free from obvious defects (corrosion, cracks, etc.).
c) There is no sign of yielding (i.e. deformed threads, stud shaft, etc).
d) Nuts must run freely by hand on the bolt.

In addition to the above points, please note the following about the re-use of bolts:

a) 316SS (A4) bolts installed prior to 30/06/2000 are not to be re-used.


b) Carbon Steel bolts of size 5/8” and below are not to be re-used.

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For joint assemblies on the critical path of a maintenance or shutdown program (or
where tight time schedules are to be adhered to), it is recommended that replacement
bolting be made available in case the existing bolting is found to be unfit to return to
service.

3.10 Re-use of Ring Tight Joints (RTJ)


316 SS RTJ rings may be re-used where necessary, subject to close inspection by an
experienced pipe fitter provided there are no signs of damage to the ring such as
corrosion, bruising, flat spots or scoring.

For joint assemblies on the critical path of a maintenance or shutdown program (or
where tight time schedules are to be adhered to), it is recommended that replacement
RTJ rings be made available in case the existing ring is found to be unfit to return to
service.

3.11 Use of Threaded inserts

Threaded inserts can be used provided:


a) A technical deviation is registered.
b) They are only used in steel based materials.
c) They are made only of Inconel X750 material.
d) The thread insert length is at least 1.5 times the bolt/stud diameter.
e) The manufacturer’s installation procedure is followed.
f) All threads are engaged.
g) Drilled and tapped holes with incomplete or damaged threads are not used.
h) The minimum remaining thickness (NOT pressure containing section) after
drilling and tapping a hole is not less than 0.25 times the maximum diameter of
the drilled and tapped hole.

3.12 Sight Glass Refurbishment


Appendix J contains a checklist for sight glass refurbishment.

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4 GUIDANCE ON MAKE UP OF SPECIAL FLANGE TYPES


4.1 Ameron GRE Flange Assemblies
Due to the nature of the fibreglass construction material, all GRE flanged joints should be
assembled according to the manufacturer’s guidelines and recommended bolt torque
values (see Appendix E).

4.2 DIN Flange Assemblies


Guidelines for the make up of DIN flanged joints are currently under review. Should any
assistance be required regarding DIN Flange Assemblies, contact Technical Services and
Integrity Group (Mechanical) – OZE4.

4.3 Non-steel flanges


Only steel flange assemblies are covered by this document. Refer to the mechanical
integrity custodian (OZE4) for make up of other material flanges (eg. cast iron, plastic).

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5 PROCEDURE FOR HOT BOLTING

5.1 Hot Bolting to Replace Corroded Bolts


The practice of replacing corroded bolts one at a time on live systems is widespread in
many industries. The major concern is of a gas leak rather than bolt failure during hot
bolting.

To check the integrity of the flange is not compromised during this operation, the Taylor-
Forge method from ASME was used to generate the calculations in A8000CM001.
Based on these calculations hot bolting shall only be carried out on Class 150 and 300
flanges that have 8 or more securing fasteners. Hot bolting on Class 600 and 900
flanges that have 8 or more studs is also acceptable if the operating pressures are limited
to 8 MPa and 12 MPa respectively, due to inadequate bolting after allowance has been
made for corrosion.

On 4 bolt flanges it is feasible to hot bolt up to Class 900 based on the calculations,
however, the possibility of a leak is quite high due to the large bolt spacing. It is therefore
allowable to hot bolt flanges with 4 securing fasteners only with the installation of two
external clamps. See Appendix K for guidelines on selection and placement. The flange
clamps that are readily available in the market (Lindapter) are only suitable for Class 150
and 300 flanges. These clamps cannot be used on Class 600 or 900 flanges due to
limited space and/or inadequate capacity. Therefore, hot bolting of the flanges with 4
securing fasteners is limited to Class 150 and 300.

Hot bolting is not permitted on Class 1500 and 2500 flanges due to inadequate bolting
strength and the heightened consequences of a leak developing.

A table summarising the hot bolting procedure is given below.

Summary of Hot Bolting Procedure to Replace Corroded Bolts

8 or more securing
Class 4 securing fasteners
fasteners
150 Yes (with clamps installed) Yes
300 Yes (with clamps installed) Yes
600 No Yes (limit pressure to 8 MPa)
Yes (limit pressure to 12
900 No
MPa)
1500 No No
2500 No No

Hot bolting is considered to be a potentially hazardous practice and shall only be


undertaken when all other options have been considered and there remains an
outstanding, fully justified operational advantage.

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In all cases the tightening of joint fasteners shall be done by controlled means. The
‘flogging’ of fasteners is not permitted. The removal or existing studs should be done
without applying excess strain, shocks or heat on the system.

Hot bolting shall be controlled under the Permit to Work system. The possibility of a leak
should always be considered and such scenarios should be fully developed, with
personnel protection and support services available on stand-by. If leaks develop then it
is permissible to ‘nip-up’ these joints whilst the system is pressurised in accordance with
Section 5.0. It is preferred that every attempt be made to depressurise the line prior to
attempting any tightening of leaking joints.

5.2 Hot Bolting to Replace Non-Corroded Bolts


Due to the extra capacity of the bolts when loss of bolt area to corrosion is not allowed
for, hot bolting of non-corroded bolts is allowed on Class 600 and Class 900 flanges with
more than 8 securing fasteners without limiting the pressures. This is the only change to
the above procedure.

A summary of the hot bolting procedure to replace non-corroded bolts is given below.

Summary of Hot Bolting Procedure to Replace Non-Corroded Bolts

8 or more securing
Class 4 securing fasteners
fasteners
150 Yes (with clamps installed) Yes
300 Yes (with clamps installed) Yes
600 No Yes
900 No Yes
5B15
No No
00
2500 No No

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6 TIGHTENING OF LEAKING JOINTS UNDER PRESSURE

6.1 Instructions for Tightening Leaking Joints Under Pressure

Under controlled conditions it is acceptable to tighten a leaking ASME flange or Clamp


Connectors whilst under pressure. Leaking joints are mostly found during post
maintenance commissioning activities such as leak testing using either nitrogen or
hydrocarbons. Experience has proven however, that if the Flanges and Clamps are
tightened under controlled conditions using approved procedures such as that detailed on
the “Check Lists” then the number of leaking joints found will be significantly reduced to
the order of 1% of all joints tested.

The results of trials undertaken by SIPM (see reference 12) support this view and prove
that tightening leaking joints even under full test pressure can reduce down time without
compromising safety.

Procedures for tightening leaking joints will vary from case to case depending on the
operational constraints affecting a particular activity. The following criteria should be used

a) Bolts loads shall only be checked or tightened on a single bolt at a time.

b) Tightening should be attempted with the system pressure at less than 4 MPa.

c) Bolt loads shall only be applied using controlled techniques and equipment such
as torque wrenches, torque guns and hydraulic tensioning gear.

d) The recommended bolt loads detailed in this standard can be exceeded as


follows:

For ASME Flanges


- all sizes 10 %

For Destec Clamps


- up to size G2 20%,
- size G3 to G8 25%,
- size G10 and above 30%

For Grayloc Clamps


- all sizes 50%

For Galperti Clamps


- all sizes 25%

Note: Working outside the above instructions should not be attempted without prior
consultation with the appropriate Technical Authority.

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7 INSULATING FLANGES
The sketch below shows a flange type insulation joint using an insulating gasket
assembly to provide electrical isolation between dissimilar piping materials. Insulating
joints are designed to prevent galvanic corrosion and/or cathodic current cross flow.

Flanges shall be free of pits, gouges, rust, debris, oil and grease. Surface finish shall be
no greater than 250 RMS. Check and remove burrs from bolt holes and flanges.

Ensure bolts and nuts are clean and nuts rotate freely along length of the stud.
Minimise the possibility of steel washer distortion and subsequent damage to insulating
washer. Nuts should be flat faced to maximise contact area with washer and minimise
possibility of deflection. Steel washers should be flat and extra thick for strength.

Open the insulating kit and confirm components are as specified. Check the gasket ID.
It should be no greater than the flange ID. The insulating washers shall have sealed
edges to prevent ingress of moisture.

Insulating gaskets that lack history of successful application shall be tested to the
satisfaction of the Principal; prior to being considered for evaluation along with already
proven gaskets.

Align flanges so they are concentric and parallel and insert gasket carefully. No
lubricant, grease or adhesives shall be used on the gasket or flange faces. Do not
damage sealing element.

Line up bolt holes with non-tapered drift pins using preferably three at 120 degrees
separation (large flanges) but at least two at 180 degrees separation. Insert bolt
sleeves. Do not force! If force is needed recheck / realign flanges.

Apply non-conductive lubricant to threads and the nut face contacting the steel washer.
This will help to reduce galling of the insulating washer on the flange.

WARNING: Do not use nickel based anti-seize. It is electrically conductive and will
provide a path for current leakage across the flange.

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Install studs, steel washers, insulating washers and nuts. Cross-tighten bolts until
flange to gasket contact has been made. Check for a flange segment that may show a
gap or separation between gasket and flanges using a feeler gauge. If a gap exists the
flanges are not parallel and shall be realigned. Misaligned flanges can result in
excessive flange to gasket contact forces when nuts are tightened. The subsequent
gasket damage may destroy electrical insulation properties.

Tighten nuts as per section 3.1 Making Up ASME B16.5 Flanges

WARNING: The non-conductive lubricant will have a different friction factor that
invalidates the torque values listed in section 7.4. Seek engineering advice from the
mechanical integrity custodian to determine appropriate torque values

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Title: Flange Bolting Standard

8 REFERENCES

Item Number Title

1 R.D Tscheuschler, “The Basic Problem with Bolt Connections”


Oil & Gas Aust. November 1985.

2 E.C Rodabaugh, “Background of ANSI B16.5 Pressure


Temperature Ratings” 1972

3 Hydratight - Various Publications

4 Furmanite - Various Publications

5 AS 1210 - 1989, “Unfired Pressure Vessels”

6 AS 2465 - 1981, “Unified Hexagon Bolts, Screws and Nuts”

7 AS 2528 - 1982, “Bolts, Studbolts and Nuts for Flanges and


Other High + Low Temperature Applications”

8 AS 3635 - 1990, “Unified Screw Threads, Associated Gauges,


and Gauging Practices”

9 API 601 - 1988, “Metallic Gaskets for Raised Face Pipe


Flanges and Flanged Connections”

10 Shell DEP 31.38.01.11, “Piping General Requirements”

11 Shell DEP 70.08.10.11, “Equipment and Tools for


Maintenance and Inspection, part 2, Bolt Tensioning”

12 D. Dykes, “Flange Bolt Tensioning - Avoid Rework.” Shell


Production Newsletter, March 1995

13 Shell UK Exploration and Production, “Maintenance and


Inspection Code of Practice, No. 1.003, Bolting for
Containment”, Maintenance and Inspection Management
System, 3804-002.
14 Bickford, J.H, “An Introduction to the Design and Behaviour
of Bolted Joints”, New York.

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APPENDIX A

GASKET SELECTION EXAMPLE

The line class and diameter specified on the P&ID is cross-referenced with the ‘Offshore Piping
Material Specification’ to determine the correct gasket.

E.g. Interpret the P&ID line details as follows:

P – 80 – X – 9A

Service Designation Sequential


Numbering
Line Size Piping Class

The new offshore piping class in the rationalised piping specification is selected using the ‘Cross
Reference for Replaced Offshore Piping Classes’ table in W9000MX001 part 1.

Eg. NRA piping class ‘9A’ is equivalent to piping class 91428 in the rationalised piping
specification from the table:

C.A. Temp.
Class Material Notes GWA NRA
(mm) Range
91428 CS 0°C min 1.5 0 / 250°C 9C1, 9C3 9A

All relevant information pertaining to each piping class is contained within the data sheets.

Eg. For piping class 91428

ITEM DESC DN 15 20 25 40 50 80 100


GASKET

SWCI CLASS 900 10060927 10060928 10060929 10061055 10060931 10060921 1000922

Therefore, for an 80mm Class 9A flange assembly (corresponding to rationalised piping class
91428 in the new piping specification W9000MX001), the correct gasket selection is material no.
10060921.

Note: prior to installation the gasket dimensions should be checked with the manufacturer’s
catalogue to ensure correctness.

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APPENDIX B

ASSEMBLY PROCEDURE FOR THE HYDRAULIC


TENSIONING OF ASME FLANGES.

Additional Precautions When Using Hydraulic Equipment.

1. Ensure that adequate safety gear is being worn and that work permit
requirements are being met.

2. Particularly ensure that glasses and thin gloves that do not restrict hand
movements are worn.

3. Before using the hydraulic equipment check for any defects.


- Particularly check the hydraulic hoses for any cracks or damage.
- Ensure that the hoses have been inspected and tagged within the last 3 months

4. When first applying pressure to the system recheck for any leakage of hydraulic
fluid.

To be followed in conjunction with the “Flange Check List”.

1. Before torquing the bolts, ensure that the threads and the nut/flange contact face are
coated with nickel based anti-seize. Anti-seize should not be applied to the gaskets.
PTFE coated bolts should also be lubricated with anti-seize.

2. Install bolts and hand-tighten. Flanges should be squared and concentric using a
straight edge and verniers. Check for correct positioning of both the bolts and the
gasket.

3. Ensure exposed stud bolt thread above each nut is at least 1.5 bolt diameters. This is
to accommodate the jacking nut of the hydraulic tensioning equipment.

WHEN USING ENOUGH TENSIONERS FOR HALF OF THE BOLTS. (i.e. 50% TENSIONING)

1. Using the tables attached select the hydraulic pressures A & B along with the
appropriate tool type for the bolt size to be tightened.

2. Fit tensioning tools to every other bolt and apply pressure A. Tighten nuts and relax
pressure. (Note that the nuts should be quite firmly tightened by hand using a Tommy
bar. Nuts should be tightened as uniformly as possible.)

3. Reapply pressure A, tighten the nuts and relax the pressure. Repeat this step once
again. I.e. there should be 3 applications of pressure and relaxation before the next
set of nuts is started.

4. Shift the tensioning tools to the other half of the bolts and apply pressure B.
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Tighten nuts and relax pressure.

5. Reapply pressure B, tighten the nuts and relax the pressure. Repeat this step
once again. I.e. there should be 3 applications of pressure and relaxation before
the next set of nuts is started.

6. Shift the tensioning tools back to the first half of the bolts and apply pressure B.
Check the nuts are tight. If any nuts require tightening repeat this step for the
other half of the bolts. Continue this until no nut rotation occurs.

WHEN USING FOUR TENSIONING TOOLS.

1. Using the tables attached select only hydraulic pressure B along with the appropriate
tool type for the bolt size to be tightened.

2. Fit tensioning tools to the first set of bolts as per the diagram attached and apply 40%
of pressure B. Tighten nuts and relax pressure. (Note that the nuts should be quite
firmly tightened by hand using a Tommy bar. Nuts should be tightened as uniformly
as possible.)

3. Following the sequence on the diagram shift the tensioning tools to the next set of
bolts and apply 40% of pressure B. Tighten nuts and relax pressure.

4. Repeat step 6 for the remaining sets of nuts.

5. Repeat steps 5 - 7 for 75% and 105% of pressure B.


(note that 105% allows for initial relaxation of the joint)

6. Finally to ensure even tensioning, repeat steps 5 - 7 at 100% of pressure B until all
nuts are tight.

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BOLT TENSION TABLE for ASME FLANGES


USING “HYDRATIGHT” EQUIPMENT

“HYDRATIGHT” Tool Pressures (in psi)

Carbon Steels, Duplex SS, 316 Stainless Steel material


Super Austenitic SS & B8M Class 2
Zeron
B7, L7 & Equivalent Bolt Stress is 174 MPa
Bolt Stress is 290 MPa (25,000 psi)
(42,000 psi)

Bolt Size Tool Type Pressure A Pressure B Pressure A Pressure B

1 3/8” 1 - Dk Blue 13,500 11,400 8,200 6,900

1 1/2” 2 - Orange 13,500 11,400 8,200 6,900

1 5/8” 3 - Black 11,800 9,800 7,000 5,800

1 3/4” 3 - Black 13,800 11,600 8,300 7,000

1 7/8” 4 - Red 12,100 10,000 7,300 6,000

2” 4 - Red 13,800 11,600 8,300 7,000

2 1/4” 5 - Grey 14,300 11,900 8,600 7,300

2 1/2” 6 - White 13,800 11,600 8,300 7,000

2 3/4” 7 - Brown 13,500 10,400 8,200 6,900

3” 8 - Lt Green 14,100 11,800 8,600 7,200

3 1/4” 8.5 - Lt Blue 14,100 11,800 8,500 7,200

3 1/2” 8.5 - Lt Blue 16,400 13,700 9,900 8,300

Note: These pressures are for “Hydratight” Equipment only. Tools for other equipment can
have different hydraulic areas which require different applied pressures to get the desired
bolt loads.
For more information, contact Mechanical Integrity Custodian - OZE4.

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BOLT TENSION TABLE for ASME FLANGES


USING “HEDLEY PURVIS HYPUR-MATE” EQUIPMENT

“HYPUR-MATE” Tool Pressures (in psi)

Carbon Steels, Duplex 316 Stainless Steel


SS, Super Austenitic Material
SS & Zeron B8M Class 2
B7, L7 & Equivalent
Bolt Stress is 290 MPa Bolt Stress is 174 MPa
(42,000 psi) (25,000 psi)

Bolt Size Tool Type Tool Marking Pressure A Pressure B Pressure A Pressure B

1 3/8”UN8 PS2 HPP-2-Serial No. 16,200 13,000 9,700 7,700

PS3 HPP-3-Serial No. 11,100 8,900 6,600 5,300

1 1/2”UN8 PS3 HPP-3-Serial No. 13,500 10,800 8,100 6,,400

PS43 HPP-4-Serial No. 9,000 7,200 5,300 4,300

1 5/8”UN8 PS3 HPP-3-Serial No. 16,200 12,900 9,600 7,700

PS4 HPP-4-Serial No. 10,700 8,600 6,400 5,100

1 3/4”UN8 PS4 HPP-4-Serial No. 12,600 10,100 7,500 6,000

1 7/8”UN8 PS4 HPP-4-Serial No. 14,700 11,800 8,700 7,000

2”UN8 PS4 HPP-4-Serial No. 16,900 13,500 10,100 8,000

PS5 HPP-5-Serial No. 13,100 10,500 7,800 6,200

2 1/4”UN8 PS5 HPP-5-Serial No. 16,800 13,500 10,000 8,000

PS6 HPP-6-Serial No. 14,400 11,500 8,600 6,900

2 1/2”UN8 PS6 HPP-6-Serial No. 18,000 14,400 10,700 8,600

2 3/4”UN8 PS7 HPP-7-Serial No. 16,100 12,800 9,600 7,600

3”UN8 PS7 HPP-7-Serial No. 19,300 15,400 11,500 9,200

PS8 HPP-8-Serial No. 16,400 13,100 9,700 7,800

3 1/4”UN8 PS8 HPP-8-Serial No. 19,400 15,500 11,500 9,200

3 1/2”UN8 PS8 HPP-8-Serial No. 21,800 17,400 12,900 10,400

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Title: Flange Bolting Standard

Note: 1. These pressures are for “Hedley Purvis Hypur-Mate” Equipment only. Tools for other
equipment can have different hydraulic areas which require different applied pressures to
get the desired bolt loads.
2. If bolt length:diameter ratio varies from approximately 6.5:1 then OZE4 should be
consulted for modified pressures.
3. PS4 head will clash if used on a DN350, class 900 flange which requires a 1 1/2” bolt.
PS3 is acceptable. PS4 is acceptable for a 1 ½” bolt with large flange. PS3 should be
strongly considered.

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APPENDIX C

ASSEMBLY PROCEDURE FOR THE TORQUING OF ASME


FLANGES USING TORQUE WRENCHES, GUNS AND
HYTORC HYDRAULIC EQUIPMENT.

Additional Precautions When Using Hydraulic Equipment.

1. Ensure that adequate safety gear is being worn and that work permit
requirements are being met.

2. Particularly ensure that glasses are being worn and thin gloves, that do not
restrict hand feel or movements are worn.

3. Before using the hydraulic equipment check for any defects.


- Particularly check the hydraulic hoses for any cracks or damage.
- Ensure that the hoses have been inspected and tagged within the last
3mnths.

4. When first applying pressure to the system recheck for any leakage of hydraulic
fluid.

Caution: be careful not to trap fingers between the flange and tool reaction bar.

To be followed in conjunction with the “Flange Check List”.

1. Before torquing the bolts, ensure that the threads and the nut/flange contact face are
coated with nickel based anti-seize. Anti-seize should not be applied to the gaskets.
PTFE coated bolts should also be lubricated with anti-seize.

2. Install bolts and hand-tighten. Flanges should be squared and concentric using a
straight edge and verniers. Check for correct positioning of both the bolts and the
gasket.

3. Obtain the final bolt torque setting from the tables attached.

4. Torque the bolts first to 30% of this setting following a standard star pattern across
the flange. This is VERY IMPORTANT to ensure that the flange remains aligned.

5. Repeat step 5 for 60% and then 100% of the torque setting.

6. Finally, starting at bolt number 1 and proceeding clockwise around the flange, re-
torque each bolt to 100% of the setting. Continue until all bolt torques are even.

7. Ensure the stud protrudes past the nut i.e. at a minimum the thread on the stud is
partially exposed.

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Title: Flange Bolting Standard

BOLT TORQUE TABLE for ASME FLANGES

Bolt Torque Level (all Studs)


Coated with Nickel based Anti-Seize

Carbon Steels, Duplex SS, 316 Stainless Steel


Super Austenitic SS & Zeron B8M Class 2
B7, L7 & Equivalent
Bolt Stress is 290 MPa Bolt Stress is 174 MPa
(42,000 psi) (25,000 psi)

Bolt Size Nm Ft-lb Nm ft-lb

1/2” 50 40 30 25

5/8” 100 75 60 45

3/4” 175 130 105 80

7/8” 280 200 165 130

1” 410 300 250 180

1 1/8” 600 440 360 270

1 1/4” 840 620 500 370

1 3/8” 1,130 830 680 500

1 1/2” 1,480 1,100 890 660

1 5/8” 1,900 1,400 1,150 840

1 3/4” 2,400 1,770 1,450 1,050

1 7/8” 3,000 2,200 1,800 1,350

2” 3,650 2,700 2,200 1,600

2 1/4” 5,200 3,850 3,150 2,300

2 1/2” 7,200 5,300 4,350 3,200

2 3/4” 9,700 7,100 5,800 4,300

3” 12,600 9,300 7,600 5,600

3 1/4” 16,100 11,900 9,700 7,200

3 1/2” 20,200 14,900 12,200 9,000

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Title: Flange Bolting Standard

Notes
1. The above bolt torque values assume a friction factor u = 0.11, and have been rounded for
ease of application. (This friction factor is based on the use of graphite based anti-seize and is
not affected significantly by the respective stud and bolt surface treatment)

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APPENDIX D

“HYTORC” TABLES for HYDRAULIC TORQUING.

HYTORC ULC-SERIES
Pressure / Torque Conversion Chart (- in ft-lb)
Pressure (psi) HY-4ULC HY-7ULC HY-10SL

1000 310 765 1,100

1200 380 920 1,320

1400 440 1,075 1,540

1600 500 1,225 1,765

1800 560 1,380 1,980

2000 620 1,535 2,200

2200 680 1,685 2,425

2400 740 1,840 2,645

2600 810 1,995 2,860

2800 870 2,145 3,080

3000 940 2,300 3,305

3200 1,000 2,450 3,525

3400 1,060 2,605 3,745

3600 1,120 2,760 3,960

3800 1,180 2,910 4,185

4000 1,250 3,065 4,405

4200 1,310 3,220 4,625

4400 1,380 3,370 4,845

4600 1,440 3,525 5,065

4800 1,500 3,680 5,285

5000 1,560 3,830 5,505

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HYTORC ULC-SERIES
Pressure / Torque Conversion Chart (- in ft-lb)
Pressure (psi) HY-4ULC HY-7ULC HY-10SL

5200 1,620 3,985 5,725

5400 1,690 4,140 5,945

5600 1,750 4,290 6,170

5800 1,800 4,445 6,385

6000 1,850 4,595 6,605

6200 1,910 4,750 6,825

6400 1,980 4,905 7,045

6600 2,040 5,060 7,270

6800 2,110 5,210 7,485

7000 2,170 5,365 7,710

7200 2,230 5,515 7,930

7400 2,290 5,670 8,145

7600 2,340 5,825 8,370

7800 2,400 5,975 8,590

8000 2,470 6,130 8,810

8200 2,520 6,285 9,030

8400 2,590 6,435 9,250

8600 2,650 6,590 9,470

8800 2,710 6,745 9,690

9000 2,770 6,895 9,910

9200 2,840 7,050 10,130

9400 2,910 7,205 10,350

9600 2,980 7,355 10,570

9800 3,050 7,510 10,790

10000 3,120 7,665 11,010

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APPENDIX E

ASSEMBLY PROCEDURE FOR THE MAKE-UP OF AMERON GRE


FLANGE ASSEMBLIES.

Additional Precautions

1. Ensure that adequate safety gear is being worn and that work permit
requirements are being met. Particularly ensure that glasses are being worn
and thin gloves, that do not restrict hand feel or movements are worn.

2. When first applying pressure to the system recheck for any leakage.

1. Before torquing the bolts, ensure that the threads are clean and are coated with nickel-
based anti-seize. Lubricated washers should be used under the nuts and bolt heads to
protect flange back-facing. Anti-seize should not be applied to the gaskets. PTFE bolts
should also be lubricated with anti-seize.

2. Install bolts and hand-tighten. Flanges should be squared and concentric using a straight
edge and verniers. Check for correct positioning of both the bolts and the gasket.

3. Obtain the final bolt torque setting from the tables attached.

4. To prevent unnecessary stresses on the fibreglass flanges, tighten the bolts in a


staggered sequence as indicated in the diagram below. It is important that the torque
increments specified in the table overleaf are not exceeded.

Tightening sequence for GRE flange make-up

5. After all nuts have been tightened to the recommended torque value, recheck the torque
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Title: Flange Bolting Standard

on each bolt in the same sequence, since previously tightened bolts may have relaxed.
Caution: Excess torque can prevent sealing and can damage moulded flanges.

BOLT TORQUE TABLE for AMERON GRE FLANGES

Bolt Torque (all Studs)


Coated with Nickel based
Anti-Seize
Carbon Steels, Duplex SS,
Super Austenitic SS & Zeron
materials

Flange Size B7, L7 & Equivalent


PTFE Coated & Uncoated
mm in Nm (ft-lb)

25 – 100 1–4 27 (20)

150 – 300 6 – 12 41 (30)

350 – 400 14 – 16 68 (50)

450 – 500 18 – 20 81 (60)

600 – 900 24 – 36 102 (75)

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ALLOWABLE TORQUE INCREMENTS


FOR AMERON GRE FLANGES

Flange Size Torque Increments


Nm (ft-lb)
mm in

25 – 100 1–4 7 (5)

150 – 300 6 – 12 14 (10)

350 – 400 14 – 16 14 (10)

450 – 500 18 – 20 27 (20)

600 – 900 24 – 36 34 (25)

Note: all Bondstrand flanges listed in the piping specification mate with other Bondstrand flanges
and flat-faced steel flanges using these bolt torque values. Moulded flanges should not be
connected to wafer valves or raised-face steel flanges.

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APPENDIX F

BOLT TORQUE TABLE FOR DESTEC CLAMPS

Bolt Torque (all Studs)


Coated with Nickel based Anti-Seize

Carbon Steels, Duplex SS, 316 Stainless Steel material


Super Austenitic SS & Zeron
materials

Clamp Bolt B7 & B7 & B8M Class 2 B8M Class 2


Size Size Equivalent Equivalent
PTFE Coated PTFE Coated
Nm (ft-lb) Nm (ft-lb) Nm (ft-lb) Nm (ft-lb)

G1 1/2” 16 (12) 11 (8) 16 (12) 11 (8)


G1 1/2 5/8” 31 (23) 22 (16) 31 (23) 22 (16)

G2, G3 3/4” 54 (40) 38 (28) 54 (40) 38 (28)

G4, GC 7/8” 139 (102) 98 (72) 130 (96) 92 (68)

G5 1” 207 (153) 146 (108) 194 (143) 137 (101)

G6 1 1/8” 303 (223) 213 (157) 285 (210) 200 (147)

G8 1 1/4” 530 (391) 371 (274) 399 (294) 279 (206)

GX8 1 3/8” 718 (530) 500 (369) 540 (398) 376 (277)

G10 1 5/8” 1,216 (897) 842 (621) 914 (674) 633 (467)

G12 1 3/4” 1,533 (1,131) 1,059 (781) 1,153 (851) 796 (587)

GZ16, 1 7/8”
1,902 (1,403) 1,310 (967) 1,430 (1,055) 985 (727)
GZ18
GP, 2”
GX12, 2,324 (1,715) 1,599 (1,179) 1,748 (1,289) 1,202 (887)
GZ20

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APPENDIX G

BOLT TORQUE TABLE FOR GRAYLOC CLAMPS

Bolt Torque (all Studs)


Coated with Nickel based Anti-
Seize
Carbon Steels, Duplex SS,
Super Austenitic SS &
Zeron materials

Clamp Size Bolt Bolt Length B7, L7 & Equivalent


Size PTFE Coated & Uncoated
Nm (ft-lb)

1 1/2” 3 1/2” 23 (17)

1 1/2 5/8” 5” 48 (35)

2, 2 1/2 - 3 3/4” 5 1/4”, 6” 75 (55)

4, C, B 7/8” 7”, 6 3/4” 122 (90)

5, D, E 1” 8 1/2” 190 (140)

6, F 1 1/8” 9 3/8” 278 (205)

8 1 1/4” 10 1/2” 393 (290)

XF 1 1/8” 11 3/4” 448 (330)

X8, G 1 3/8” 11” 529 (390)

H, 10H, X14 1 5/8” 14 1/4”, 14 1/8”, 17” 854 (630)

X10H, 12M, X16 1 3/4” 16”, 19 1/2” 1,180 (870)

X18 1 7/8” 21 1/2” 1,586 (1,170)

P, X12M, X20 2” 16 1/2”, 18 1/2”, 24 3/4” 1,762 (1,300)

X24, 30, 3V 2 1/4” 27”, 20 3/4”, 24” 2,535 (1,870)

S, U, 32, 36, 3W, 5P 2 1/2” 22”, 31”, 29 1/2”, 20” 3,485 (2,570)

Y 2 3/4” 28 3/4” 4,745 (3,500)

40 3 1/4” 35 1/2” 9,626 (7,100)

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Controlled Ref No: W1000SM3131997 Revision: 2 DRIMS No: 3131997 Page 34 of 53

Uncontrolled when printed. Refer to electronic version for most up to date information.
Title: Flange Bolting Standard

APPENDIX H

BOLT TORQUE TABLE FOR GALPERTI CLAMPS

Bolt Torque (all Studs)


Coated with Nickel based
Anti-Seize
Carbon Steels, Duplex SS,
Super Austenitic SS & Zeron
materials
Clamp Bolt B7, L7 & Equivalent
Size Size PTFE Coated & Uncoated
Nm (ft-lb)

4 7/8” 187 (138)

6 1 1/8” 374 (276)

8 1 1/4” 499 (368)

10H 1 5/8” 1,158 (854)

12M 1 3/4” 1,367 (1,010)

AP 2” 1,951 (1,439)

16B3V 2 1/4” 4,080 (3,009)

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Controlled Ref No: W1000SM3131997 Revision: 2 DRIMS No: 3131997 Page 35 of 53

Uncontrolled when printed. Refer to electronic version for most up to date information.
Title: Flange Bolting Standard

APPENDIX I

BOLT TORQUE TABLES FOR API FLANGES


Tabulated bolt torque differs to those given in API documentation as a friction coefficient of µ =
0.11 is used here.

Medium - High
Low Pressure Flange
Pressure Flange
(2 ksi, 3 ksi)
(5 ksi, 10 ksi, 20 ksi)
If Bolt Size > 2 1/2" then Bolt
Bolt stress = 290 MPa Stress = 340 MPa otherwise
Bolt Stress = 390 MPa

Bolt Bolt
Nm Nm
size size
1/2" 50 1/2" 70
5/8" 100 5/8" 135
3/4" 180 3/4" 235
7/8" 280 7/8" 370
1" 420 1" 550
1 1/8" 610 1 1/8" 800
1 1/4" 845 1 1/4" 1,110
1 3/8" 1,130 1 3/8" 1,500
1 1/2" 1,480 1 1/2" 1,950
1 5/8" 1,900 1 5/8" 2,500
1 3/4" 2,350 1 3/4" 3,100
1 7/8" 2,950 1 7/8" 3,850
2" 3,600 2" 4,700
2 1/4" 5,150 2 1/4" 6,750
2 1/2" 7,050 2 1/2" 9,300
2 3/4" 11,200
3" 14,600
3 1/4" 18,600
3 1/2" 22,600

Note: Bolt material to be used as specified in API 6A.

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Controlled Ref No: W1000SM3131997 Revision: 2 DRIMS No: 3131997 Page 36 of 53

Uncontrolled when printed. Refer to electronic version for most up to date information.
Title: Flange Bolting Standard

APPENDIX J

JOINT MAKE UP CHECK LISTS


Includes the following:

“FLANGE CHECKLIST”

“DESTEC CLAMP CHECKLIST”


(INCLUDES STAND-OFF TOLERANCES FOR SEAL RINGS)

“GRAYLOCK CONNECTOR CHECKLIST”


(INCLUDES STAND-OFF TOLERANCES FOR SEAL RINGS)

“GALPERTI CONNECTOR CHECKLIST”


(INCLUDES STAND-OFF TOLERANCES FOR SEAL RINGS & NOMINAL
GAP BETWEEN GALPERTI CLAMP HALVES)

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Controlled Ref No: W1000SM3131997 Revision: 2 DRIMS No: 3131997 Page 37 of 53

Uncontrolled when printed. Refer to electronic version for most up to date information.
Title: Flange Bolting Standard

FLANGE CHECKLIST
Flange Details: No.: Flng Size: Rating: Pipe Class:
Bolting Details: Qty: Stud Size: Nut Size: Stud Mat'l:
Line No./Description: Project:
INSPECTION REQUIRED PASS FAIL COMMENTS
(YES) (NO)
FOR THE FLANGES:
1 Is either flange made from a material other than steel? (eg. cast If yes or unsure, refer to mechanical
iron, plastic) integrity custodian (OETM)

2. Check both Flange Faces are Clean, Damage Free and that the
Gramaphone Finish is in Good Condition

3. Ensure that there is no:


- Circumferential Scoring deeper than the Depth of Machining
- Radial Scoring Longer than 1/4 the Raised Face Width
- Localised Defects more than 2mm Deep or Wide

4. Are the Flanges Aligned within Tolerance, see the Chart Below
(Record the Maximum Angular Mis-Alignment in the Comments Column)

5. Are the Flanges parallel within Tolerance, see the Chart Below
(Record the Maximum Parallel Mis-Alignment in the Comments Column)

6. Confirm the Nut Seating Area on the Flanges is Clean, Smooth


and Free of Paint.

FOR THE GASKET AND STUDS:


7. Check the Gasket is the Correct Size and Type for the Pipe Class
and SWGF Gaskets have both an Inner and Outer Ring made of 316SS

8. Is the New Gasket Free of Damage, check for defects in the


Spiral Windings or Scoring of the RTJ Surface

9. Check that the Studs are in Good Condition and are the Correct
Size and Material for the Pipe Class

MAKING UP THE FLANGE:


press. A press. B
10. TENSIONING: PRESSURE SETTING: psi

11. TORQUEING
- Confirm approved Anti-seize has been Applied to the
Studs and the Nut Seating Area.
- Torque Studs at: 30% N.m (for DN > 20" only)
60% N.m
100% N.m
- Confirm all studs 100% tight

##
C Pipe Size: Tolerance:
A+B
"B & C"
Up to 4" 1.0mm
6" to 10" 2.0mm
A
10" to 24" 3.5mm
Angular mis-alignment Parallel mis-alignment #REF!
CHECKED BY NAME SIGNATURE DATE
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FITTER
any process (electronic or otherwise) without the specific written consent of Woodside. All rights are reserved.
Controlled Ref No: W1000SM3131997 Revision: 2 DRIMS No: 3131997 Page 38 of 53
SUPERVISOR
AND OR QC Uncontrolled when printed. Refer to electronic version for most up to date information.
Title: Flange Bolting Standard

DESTEC CONN ECTOR CHECKLIST

D e ste c Hub No.: ___________________ Size : __________ R ating:


_______________
Line N umbe r/D e scription :__________________________________________________

IN SPECTION REQUIRED PASS FAIL COM M EN TS


(Yes) (No)

F OR THE DESTEC HU BS:

1 . Check all Destec hubs and clamps are Clean and


damage free.

2. Check the hub sealing surfaces are in good condition


and that there is no :
- Circumferential Scoring
- Radial Scoring
- Localised Defects

3. Ensure that the Hub to Seal Ring Stand-Off is within


tolerance. Refer to the separate table for tolerance data.

NOTE: Record the Stand-Off in the Comments column.

4. Are the Destec Hubs Parallel and Aligned

NOTE: Any mis-alignment should be reported to your Supervisor.

5. Confirm that the nut seating area on the Destec clamps


is clean, smooth and free of paint.

FOR THE SEAL RING AND G ASKETS :

6. Check the seal ring is the correct size and type for the
pipe class.

7. Is the seal ring free of damage, check for defects in the


sealing surfaces.

8. Apply dry lubricant/anti-scuff to old seal rings if they are


to be reused. (Molykote D321R or equivalent)

9. Check that the studs are in good condition and are the correct
size and material for the pipe class.

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Uncontrolled when printed. Refer to electronic version for most up to date information.
Title: Flange Bolting Standard

IN SPECTION R EQUIR ED PASS FAIL COM M EN TS


(Yes) (N o)

M AK IN G U P THE DESTEC C LAMP :

1 0. C onfirm that nickel based anti-seize has been applied to


the studs and the nut seating area.

1 1. TO RQ UE GUN / W REN C H - Torque Setting :_______


Ensure that all studs are tight.

DESTEC HU B MISALIG N MEN T :

R EPOR T AN Y M ISALIGN M EN T AT "B " TO YOUR SUPER VISOR

N ote : M is -alignme nt M UST be corre cte d PR IOR to fitting of the clamps.

C HEC K ED BY :_______________________________ DATE :____________

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Uncontrolled when printed. Refer to electronic version for most up to date information.
Title: Flange Bolting Standard

STAND-OFF TOLERANCE for DESTEC CLAMP SEAL RINGS

Stand-Off (in) Stand-Off (in)

Seal Ring New Seal Minimum Seal Ring New Seal Minimum
Size Rings for Re-Use Size Rings for Re-Use

7, 8 .016 .006 76 .108 .042

11 .020 .010 87 .123 .060

14 .017 .008 91 .125 .062

16 .018 .009 97 .134 .065

20 .022 .010 106 .139 .072

23 .025 .013 112 .150 .072

25 .027 .014 122 .160 .077

27 .030 .014 130 .168 .080

34 .036 .016 137 .178 .083

40 .039 .020 144 .177 .088

46 .044 .022 154 .188 .094

52 .050 .025 170 .212 .100

54 .053 .026 182 .224 .105

62 .093 .030

66 .087 .043

72 .104 .040

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Controlled Ref No: W1000SM3131997 Revision: 2 DRIMS No: 3131997 Page 41 of 53

Uncontrolled when printed. Refer to electronic version for most up to date information.
Title: Flange Bolting Standard

GRAYLOC CONNECTOR CHECKLIST

Grayloc Hub No.: ___________________ Size: __________ Rating: _______________


Line Number/Description :______________________________________________________

INSPECTION REQUIRED PASS FAIL COMMENTS


(Yes) (No)

FOR THE GRAYLOC HUBS:

1. Check that both Grayloc hubs and clamps are clean and free of damage.

2. Check that the hub sealing surfaces are in good condition and ensure that
there is NO:
- Circumferential scoring deeper than the depth of machining.
- Radial scoring longer than 1/4 the raised face width.
- Localised defect more than 2mm deep or wide.

3. Ensure that a small clearance, or stand-off exists between the ring rib
hub face.
NOTE: If no stand-off is present, use a new seal ring.

4. Are the Grayloc hubs parallel and aligned?


NOTE: Any misalignment should be reported to your Supervisor.
For misaligned systems, it is acceptable to apply an external load to the
mating piping (using jacks, comealongs, etc.) to align the hubs prior to
assembly.

5. Confirm that the nut seating area on the Grayloc clamps is clean, smooth
and free of paint.

FOR THE SEAL RING AND STUDS:

6. Check the seal ring is the correct size and type for the pipe class.
Check and record the material type.

7. Is the seal ring free of damage? Check for defects in the sealing

8. Check that the studs are in good condition and are the correct size and
material for the pipe class.

9. Ensure that stud length is correct and that studs do not bottom out.

10. Check that the nuts run freely for the full length of stud thread.

11. Check that the studs have a sliding fit into the body before torquing.

MAKING UP THE GRAYLOC CLAMP:

12. Install the seal ring in the sealing surface of the hubs.
NOTE: The seal ring should rock slightly (ie. the seal ring rib
to firmly contact the hub face). If it does not rock, use a new seal

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Uncontrolled when printed. Refer to electronic version for most up to date information.
Title: Flange Bolting Standard

INSPECTION REQUIRED PASS FAIL COM M ENTS


(Yes) (No)

13. Install the clamps around the hubs.

NOTE: Apply lubrication to the hub-clamp contract area to reduce


will aid assembly.

14. Confirm that Nickel based anti-seize has been applied to the studs
nut seating area.

NOTE: When applying lubricant, tak e special care to ensure that no solid or
particles are present in the lubricant. Also, tak e care to prevent
damage to the seal ring and the hub sealing surfaces.

15. Insert the stud bolts into the bolt holes of the clamp ears. Install the
ensuring that the spherical surfaces of the nuts and the clamp are in
position for mating.

16. TORQUE GUN/WRENCH - Torque Setting:


(REF: Appendix H)

NOTE: To prevent damage from distortion to the other components of the


the maximum torque applied to the connection should not be more
that given in the Appendix.

17. Tighten the bolting in a criss-cross pattern (ie. bolt #1, #3, #2, #4) to
each half of the clamp at a similar distance apart along each stud.

NOTE: Assembly should include jarring the clamps during the bolting
sound blow to the back of the clamp with a soft hammer (torque, jar,
jar, etc.) until bolt torque does not change after jarring.

1 8. Ensure that the hub faces will sit with the shoulder flush against the
ring rib at full make-up.

G RAYLOC HUB MISALIGNMENT:

NOTE: M isalignment M UST be corrected PRIOR to fitting the clamps.


CHECKED BY: _______________________________ DATE: ____________

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Controlled Ref No: W1000SM3131997 Revision: 2 DRIMS No: 3131997 Page 43 of 53

Uncontrolled when printed. Refer to electronic version for most up to date information.
Title: Flange Bolting Standard

STAND-OFF TOLERANCE for GRAYLOC CLAMP SEAL RINGS


(BOTH NEW RINGS AND RINGS FOR RE-USE)

Stand-off dimensions for both new and re-used seal rings must be within the minimum and
maximum limits provided below:

Stand-Off (in) Stand-Off (in)

Seal Ring Seal Ring


Min. Nom. Max. Size Min. Nom. Max.
Size

4 0.003 0.009 0.019 72 0.035 0.052 0.085

5 0.003 0.009 0.019 76 0.033 0.054 0.091

7 0.005 0.011 0.021 82 0.036 0.058 0.095

11 0.006 0.011 0.021 84 0.038 0.060 0.096

13 0.008 0.013 0.024 87 0.036 0.061 0.102

14 0.008 0.012 0.022 91 0.055 0.080 0.121

16 0.007 0.012 0.021 94 0.040 0.065 0.106

20 0.006 0.011 0.027 97 0.042 0.067 0.108

23 0.008 0.013 0.028 102 0.044 0.069 0.109

25 0.008 0.014 0.031 106 0.068 0.093 0.134

27 0.009 0.015 0.032 112 0.046 0.075 0.119

31 0.008 0.015 0.034 114 0.033 0.058 0.099

34 0.011 0.018 0.036 120 0.050 0.078 0.122

40 0.011 0.019 0.038 122 0.048 0.080 0.128

42 0.021 0.030 0.050 125 0.036 0.064 0.107

46 0.014 0.022 0.040 130 0.051 0.084 0.132

50 0.013 0.023 0.045 134 0.055 0.088 0.135

52 0.014 0.025 0.046 137 0.057 0.089 0.137

56 0.016 0.027 0.049 140 0.053 0.086 0.134

62 0.029 0.047 0.080 144 0.061 0.093 0.141

64 0.044 0.061 0.095 152 0.061 0.097 0.148

67 0.025 0.043 0.076 160 0.097 0.132 0.184

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Controlled Ref No: W1000SM3131997 Revision: 2 DRIMS No: 3131997 Page 44 of 53

Uncontrolled when printed. Refer to electronic version for most up to date information.
Title: Flange Bolting Standard

GALPER TI CON N ECTOR CHECKLIST

G alpe rti Hub N o.: ___________________ Size : _________ R ating: ____________


L ine N umbe r/D e s cription :__________________________________________________

IN SPECTION R EQUIR ED PASS FAIL COM M EN TS


(Yes) (N o)

F OR THE G A LP E RTI HU BS:

1. C heck all Galperti hubs and clamps are clean and


damage free.

2. C heck the hub sealing surfaces are in good condition


and that there is no :
- C ircumferential Scoring
- Radial Scoring
- Localised Defects

3. Ensure that the Hub to Seal Ring Stand-O ff is within


tolerance. Refer to the separate table for tolerance data.
Record the Stand-O ff in the comments column.

4. Are the Galperti Hubs Parallel and Aligned


N OTE: An y mis-a lig n men t sh o u ld b e rep o rted to yo u r S u p erviso r.
Fo r misa lig n ed systems, it is a ccep ta b le to a p p ly a n
extern a l lo a d to th e ma tin g p ip in g ( u sin g ja ck s,
co mea lo n g s, etc.) to a lig n th e h u b s p rio r to a ssemb ly.

5. C onfirm that the nut seating area on the clamps is clean,


smooth and free of paint.

F OR THE SE A L RIN G A N D STU DS :

6. C heck the seal ring is the correct size and type for the
pipe class.

7. Is the seal ring free of damage, check for defects in the


sealing surfaces.

8. Apply dry lubricant/anti-scuff to old seal rings if they are


to be reused. (M olykote D321R or equivalent)

9. C heck that the studs are in good condition and are the
correct size and material for the pipe class.

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Controlled Ref No: W1000SM3131997 Revision: 2 DRIMS No: 3131997 Page 45 of 53

Uncontrolled when printed. Refer to electronic version for most up to date information.
Title: Flange Bolting Standard

IN S PE C T IO N R E Q U IR E D PA S S FA IL CO M M EN TS
(Y e s) (N o )

M A K IN G U P T H E G A L P E RT I C L A M P :

1 0 . C o nfirm tha t nic k e l b a se d a nti- se ize ha s b e e n a p p lie d to


the hub - c la mp c o nta c t a re a .

1 1 . C o nfirm tha t nic k e l b a se d a nti- se ize ha s b e e n a p p lie d to


the stud s a nd the nut se a ting a re a .

1 2 . Insta ll the se a l ring, c la mp a nd stud s.

1 3 . TO R Q U E G U N / W R EN C H - To rq ue S e tting :_ _ _ _ _ _ _
To rq ue stud s in a c riss- c ro ss p a tte rn (ie . stud # 1 , # 3 , # 2 , # 4 ).
K e e p sp a c ing b e tw e e n c la mp ha lve s a p p ro xima te ly e q ua l.
N O T E : A ss e m b l y sh o u l d i n c l u d e ja rr i n g t h e c l a m p s d u ri n g t h e
b o l t i n g p ro c e d u re . A p p l y a so u n d b l o w t o t h e b a c k o f t h e
c l a m p w i t h a s o ft h a m m e r. R e -t i g h t e n st u d s a ft e r ja r ri n g .

1 4 . A fte r a ll stud s a re tighte ne d , e nsure tha t a ga p e xists


b e tw e e n the c la mp ha lve s. R e fe r to the se p a ra te ta b le
fo r no mina l ga p w id th.

G A L P E RT I H U B M IS A L IG N M E N T :

R E PO R T A N Y M IS A L IG N M E N T A T " B " T O YO U R S U PE R V IS O R

N o te : M is -a lig nm e nt M U S T be c o rre c te d PR IO R to fitting o f the c la m ps .

C H EC K ED B Y :_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ D A TE :_ _ _ _ _ _ _ _ _ _ _ _

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Controlled Ref No: W1000SM3131997 Revision: 2 DRIMS No: 3131997 Page 46 of 53

Uncontrolled when printed. Refer to electronic version for most up to date information.
Title: Flange Bolting Standard

STAND-OFF TOLERANCE for GALPERTI CLAMP SEAL RINGS

Stand-Off (mm) Stand-Off (mm)


Seal Ring New Seal Minimum Seal Ring New Seal Minimum
Size Rings for Re-Use Size Rings for Re-Use

34 0.75 0.38 82 1.35 0.68

40 0.80 0.40 94 1.40 0.70

52 0.90 0.45 102 1.70 0.85

62 1.10 0.55 106 1.70 0.85

67 1.10 0.55 120 1.80 0.90

72 1.10 0.55 170 2.50 1.25

NOMINAL GAP BETWEEN GALPERTI CLAMP HALVES for ASSEMBLED CONNECTOR


(Note: Gap will vary with dimensional tolerance limits and seal ring condition)

Clamp Nominal Gap


Bolt Size
Size (mm)
4 7/8” 9.6

6 1 1/8” 15.8

8 1 1/4” 19.4

10H 1 5/8” 19.4

12M 1 3/4” 19.4

AP 2” 25.4

3V 2 1/4” 25.4

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Controlled Ref No: W1000SM3131997 Revision: 2 DRIMS No: 3131997 Page 47 of 53

Uncontrolled when printed. Refer to electronic version for most up to date information.
Title: Flange Bolting Standard

APPENDIX K

SIGHTGLASS REFURBISHMENT CHECK LIST

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Controlled Ref No: W1000SM3131997 Revision: 2 DRIMS No: 3131997 Page 48 of 53

Uncontrolled when printed. Refer to electronic version for most up to date information.
Title: Flange Bolting Standard

SIGHTGLASS REFURBISHM ENT CHECKLIST

TAG Number: ___________________ Size: __________ Rating: _______________


INSPECTION REQUIRED PASS FAIL COM M ENTS
(Yes) (No)
FOR THE COVERS:

1. Check that both cover faces are clean, free of damage and in
good condition

2. Ensure that there is NO:


- Circumferential scoring deeper than the depth of machining
- Radial scoring longer than 1/4 the raised face width
- Localised defect more than 2mm deep or wide

3. Confirm the nut seating area on the cover is clean, smooth and free
of paint

FOR THE SIGHTGLASS:

4. Check that the NEW sightglass are the correct size (34mm) and
type (transparent, clear or reflex)

SAFETY NOTE..... The sightglasses should NOT be re-used, even


when they appear in perfect condition. Replace them with new ones.

USED GLASSES ARE POOR SAFETY RISKS


Chipped or scratched glass should not be used because such
defects become points of high stress concentration. Even though
a used glass may look perfect, it is not reliable as a new one. Best
practice is to always use a new glass.

FOR THE CUSHIONS/GASKETS:

5. Check that the NEW cushion and gasket are the correct size and
type (Klingersil C4430)

6. Ensure that the NEW cushion/gasket free of damage

7. Check that both the cushion and gasket fit snugly in the cover and
chamber recesses so that they can NOT be offset on assembly

FOR THE BOLTS:

8. Check that the bolts are in good condition and the correct material
has been used (Duplex)

9. Ensure that bolt length is correct and that bolts do not bottom out

10. Check that the nuts run freely for the full length of bolt thread

11. Check that the bolts have a sliding fit into the body before torquing

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Controlled Ref No: W1000SM3131997 Revision: 2 DRIMS No: 3131997 Page 49 of 53

Uncontrolled when printed. Refer to electronic version for most up to date information.
Title: Flange Bolting Standard

IN SPECTION R EQUIR ED PASS FAIL COM M EN TS


(Yes) (N o)
SIGHTGLASS PRESSURE TEST and REFURBISHM ENT:

12. Repaint the sightglass gauges according to the Woodside Offshore


P etroleum "P rotective Coatings Specification", W9000SM001

13. Assemble the gauges, confirming that the following items are used:
(a) NEW Duplex bolting
(b) Loctite Nickel Anti-seize lubricant applied to the bolts
(c) NEW transparent sightglass (34mm)
(d) Klingersil C4430 cushions and gaskets

14. Tighten as per the manufacturer's procedure (see Table below)


(a) Finger-tight
(b) 25% torque
(c) 50 % recommended torque
(d) 75 % recommended torque
(e) 100% recommended torque

15. Leave the sightglass for 12 hours to allow the gaskets to settle

16. Recheck the bolt torques

17. Nitrogen pressure test to 1.5 x Design P ressure - hold for 2 hours

18. Recheck bolt torques. If the torque values have fallen, repeat
from step 14

19. Attach a suitable tag to identify the sightglass as "refurbished"

Parts Lis t

Torque Proce dure

CHECKED BY: _______________________________ DATE: ____________

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Controlled Ref No: W1000SM3131997 Revision: 2 DRIMS No: 3131997 Page 50 of 53

Uncontrolled when printed. Refer to electronic version for most up to date information.
Title: Flange Bolting Standard

APPENDIX L

LINDAPTER CLAMP ARRANGEMENT FOR HOT BOLTING

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Uncontrolled when printed. Refer to electronic version for most up to date information.
LINDAPTER FLANGE CLAMP SELECTION AND PLACEMENT

4
3
2
1 1 1

150

2 3
1 1

300

15 20 25 40 50 80
Note: Clamps should be placed so that the clamp bolt is as close as possible to the flange whilst still leaving clearance for the wrench.
Caution: Do not use clamps on tapered flanges.

This document is protected by copyright. No part of this document may be reproduced, adapted, transmitted, or stored in any form by any process (electronic or otherwise) without the specific written
consent of Woodside. All rights are reserved.
Controlled Ref No: W1000SM3131997 Revision: 2 Native file DRIMS No: 3131997 Page 52 of 53
Uncontrolled when printed. Refer to electronic version for most up to date information.
Title: Flange Bolting Standard

LINDAPTER FLANGE CLAMP – F9

Safe Working
Bolt Load* Torque
Dimensions (mm)
Clamp Size Tensile (kN) (Nm)
Number (per single bolt)
Bolt Grade
Z Bolt Grade 4.6 X W V T S
4.6
1 M10 1.96 20 25 19 - 42 13 19 24
2 M12 2.8 39 35 26 - 60 17 24 30
3 M16 5.6 93 43 29 - 69 21 28 35
4 M20 8.4 177 51 32 - 82 25 35 44

* Safety factor of 5

This document is protected by copyright. No part of this document may be reproduced, adapted, transmitted, or stored in any form by
any process (electronic or otherwise) without the specific written consent of Woodside. All rights are reserved.
Controlled Ref No: W1000SM3131997 Revision: 2 DRIMS No: 3131997 Page 53 of 53

Uncontrolled when printed. Refer to electronic version for most up to date information.