Eng Ets 617

Stanlow Engineering Procedures Document No.
ENG-ETS-617
Title :
Bolt Tightening & Joint Making Page 1 of 21 Rev. F
BOLT TIGHTENING & JOINT MAKING
REV DESCRIPTION DATE AUTHORISER SIGN
F See Revision Log Feb 21 Russell Sparks
Next Review date: Feb 2025
Name Title
Authoriser Russell Sparks Mechanical & Reliability Manager
Technical Approver Dave Waugh Mechanical Refinery Engineer
Custodian Dave Waugh Mechanical Refinery Engineer
Controller Alan Sweenie Quality Management Focal Point
DISTRIBUTION: Held as an electronic document as part of the Engineering Quality System and is uncontrolled once printed,
please check the database for latest revision before use.
Stanlow Engineering Procedures Document No. ENG-ETS-617
Title :
Date Rev Document Revision Log

Jan 1999 O First Issue
Jul 2002 O/1 Custodianship transferred to Dean McDermott, OME/80/06
Significant re-write, acknowledging changes to standards, new work instructions and
Jan 2006 1
tooling. (G.Beevers)
Nov 2006 1/1 Error corrected in Appendix A (G.Beevers)
Renamed from ‘Bolt Tightening – Application Methods’ to reflect joint making
May 2009 A
content. Doc reviewed & front page reformatted and Document Revision Log added.
Added to Para 5.1: “Gaskets shall be considered as single use items and shall not be
Oct 2010 A/1
re-used”
Metric bolt torque table added. Torque tables amended to reflect reduction in
Belzona 8211 anti-seize coefficient of friction. Requirement for manual Torqueing in
July 2011 A/2
critical applications removed for ½” bolts due to working range of most torque
wrenches (low torque value below minimum wrench setting) – Appx A.
Torque tables amended to reflect practical issues with Belzona 8211 antiseize 0.09
Mar 2013 A/3
coefficient of friction. Cast iron reference added
Equipment notes amended, Anti-seize application for tensioned bolts. Approved
Jun 2014 A/4
Nickeleez and Easyrun guidance added.
Jun 2015 B Issued onto new format
Section 5 updated to recognise that in some circumstances MRG gaskets may be
Jul 2016 C
refaced and reused, and new paragraph covering bolt/nut engagement added.
Jul 2016 D Appendix C drawing added
Clarifications and Appendix D added - Torque tables for “Nickeleez” high temperature
Dec 2017 D/1
bolt lubricant.
Aug 2018 D/2 Reference Standard DEP 31.38.01.31-Gen added to list (Section 4)
Jun 2019 E Addition of Section 5.5 QA requirements for heat exchangers
Significant changes to simplify the document and align with existing industry best
Feb 2021 F
practice documents. Authorities & format updated
Title :
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Title :
CONTENTS
1.0 INTRODUCTION ................................................................................................................... 5
2.0 SCOPE ................................................................................................................................. 5
3.0 COMPETENCE ...................................................................................................................... 5
4.0 BOLT TIGHTENING ............................................................................................................... 5
4.1 Flange Assembly ...................................................................................................................... 5
4.2 Tightening Patterns.................................................................................................................. 8
4.2.1 Tightening Pattern for Circular Flanges .................................................................................... 8
4.2.2 Torqueing Method for Rectangular Flanges ............................................................................. 9
4.3 Quality Assurance (QA) of Bolted Joints .................................................................................... 9
4.3.1 Turnarounds.............................................................................................................................. 9
4.3.2 Maintenance ............................................................................................................................. 9
5.0 APPENDIX .......................................................................................................................... 10
Appendix A : Selection of Most Appropriate Bolt Tightening Method ............................................. 10
Appendix B : Values of Bolt Stress and Torque to be Applied .......................................................... 11
B1. Standard Flanges.....................................................................................................................11
Table 1 : Imperial Torque Values using Belzona 8211 Anti-Seize.....................................................12
Table 2 : Metric Torque Values using Belzona 8211 Anti-Seize .......................................................13
B2. Non Standard Flanges .............................................................................................................14
B3. Cast Iron Flanges .....................................................................................................................14
Appendix C : Flange Bolting Diagram ............................................................................................. 16
Appendix D : Nickeleez Torques Values.......................................................................................... 17
Table 3 : Imperial Torque Values for Nickeleez ................................................................................17
Table 4 : Metric Torque Values for Nickeleez ..................................................................................18
Appendix E: Joint Assembly Record QA Sheet ................................................................................ 19
Appendix F: Additional Requirements............................................................................................ 20
Appendix G : Gr660 Stamping ........................................................................................................ 21
Title :
1.0 INTRODUCTION
The purpose of this Engineering Technical Specification is to define the procedure which
shall be followed when tightening flange bolting during maintenance activities on Essar Oil
(UK) Ltd owned assets on Stanlow and Tranmere sites. The specification will detail the
method of flange tightening and the engineering requirements to be followed while
assembling the joint.
The requirements of this document have been compiled after review of industry guidance,
best practise and company learnings from incidents; the aim is to ensure efficient assembly
of lasting leak-free joints.
2.0 SCOPE
This ETS is for the application of bolt tightening methods on flanged connections.
It gives specific instructions on how to bolt tighten on piping flanges conforming to Stanlow
Piping Classes that include all metallic and semi-metallic gaskets, (including Spiral Wound
(SPW), Tanged Graphite (PSM), Maxiprofile™/Kammprofile™), Flexicarb, PTFE reinforced
gaskets, and klingersil™ C4430
This ETS also applies to all non-standard flanges, equipment flanges and standard flanges.
Appendix F lists specific assets where the standard requirements in this document must be
supplemented as detailed in the table provided.
3.0 COMPETENCE
Persons assembling flange joints must be competent to do so. ENG-ETS-620 defines the
competency requirements of personnel making a joint on Essar Oil (UK) Ltd owned assets
on Stanlow and Tranmere sites. ENG-ETS-700 defines the trade standards for personnel
making a joint.
4.0 BOLT TIGHTENING

4.1 Flange Assembly
Whether a flange assembly leaks or not is dependent on a variety of factors. The
following shall always be checked on flange assembly :
Gasket Contact Surface : Ensure the surfaces are free from contaminants and examine
surfaces for damage such as scratches, nicks, gouges, corrosion and burrs. Any defect
to the gasket contact surface, which exceeds one quarter of the width radially across
the face or 0.75mm in depth should be reviewed by the PU Assurance Engineer against
ASME PCC-1 and a concession raised if the flange is out of compliance with this
standard.
The flange faces shall be flat, if the joint assembler is in doubt the flange should be
clocked and should be within 0.15mm in the radial and circumferential direction.
HFA : In HFA service, the flange face must be carefully cleaned free of fluoride scale.
The fluoride scale must be cleaned immediately on breaking the flange, as the scale
hardens when left making it more difficult to remove. When cleaning the scale,
extreme care must be taken to ensure that the flange face area is not scratched /
damaged whilst also ensuring the residual scale does not cause a leak path when the
Title :
flange is re-jointed. The flange shall then be inspected for damage or corrosion. The
condition of the HF acid detection paint on the flange must be examined and if
damaged or unpainted, it must be repainted.
Gaskets : Reconditioning of MRG Type 108 gaskets is permitted when ENG-MNT-016 is
followed; otherwise, gaskets must be new.
Bolt and Nut quality : New bolts and nut should be used according to the piping class
or JIS. They should be examined for any visual damage or imperfection. If necessary,
nut and bolt condition can be tested; they should be able to turn freely by hand past
where they will come to rest after tightening. If bolts are to be re-used, a concession
should be raised by the mechanical engineer and the nuts and bolts shall be
thoroughly cleaned (wire bushed) before doing so.
The back of the flange at the nut seating area should be smooth finished.
When a new Gr 660 bolt is fitted & bolt tensioned for the first time both ends shall be
die stamped with the month of initial tensioning, e.g. 7th April 94 would be 4/94. At
each subsequent tensioning of the Gr660 bolt, the month of the tensioning shall also
be stamped on each end of the bolt. The remaining bolt life shall be calculated as
shown in the full procedure, detailed in Appendix G and if the remaining bolt life does
not meet the next planned maintenance on that joint.
Bolt Lubrication : The standard approved lubricant for use at Stanlow Manufacturing
Complex is Belzona 8211 High Temperature Anti-Seize Grease. Other lubricants may
be used with approval from the PU Assurance Engineer. On Site there is experience of
using SwanTek Nickeleez (μ= 0.12). For nickel based products such as Nickeleez™, the
correct precautions defined in MSDS for handling nickel should be adopted. The
approved lubricant should then be liberally applied to the following :
i) The bolt threads
ii) The spot face and threads of the nut to be tightened.
iii) The spot face of the flange where the nut to be tightened will sit.
If washers are fitted, only lubricate the nut bearing surface of the washer. DO NOT
LUBRICATE THE UNDERSIDE OF THE WASHER OR THE FLANGE.
Bolt / Nut engagement : Bolt thread protrusion shall be a minimum of 1 complete
thread at each nut. Where over length studs are present it is acceptable to have the
excess thread protruding on the side of the joint that will allow stud removal. The
other side shall remain a minimum of 1 thread and a maximum of 2, (flush or recessed
studs are not permitted on Stanlow Site, see Appendix C).
HFA : Pass the bolt through the flange holes BEFORE applying the lubricant. Ensure the
lubricant is applied onto the flange spot face, the threads of the nut and the part of the
bolt thread which will mate with the nut.
Selecting the Correct Bolt Tightening Method : See Appendix A for representation of
the tightening method selection process.
Bolting up sequence : Bolts shall be tightened in four stages, the first to 30% of
load/torque following the diametrical ‘star’ sequence, the second to 60% in the
diametrical ’star’ sequence, the third to 100% in the diametrical ’star’ sequence and
Title :
the fourth in a circular pattern around the whole flange and to continue until no
further nut rotation occurs. This sequence method is further outlined in Section 5.4
Flange Alignment : The flange should sit naturally in position so that it does not cause
any undue stresses to the seal assembly. If the load to align the joint is greater than
20% of the total target assembly bolt load, consult an engineer.
Note : More stringent alignment tolerances are normally required for connections to
machinery, if specific guidance has not been provided then consult to the PU
Assurance Engineer who will refer to API Recommended practise 686.
Note : For normally hot lines that require a cold pull, or any pipe-work that is in
tension, bolt Torquing and tension values are invalid, as the bolt stresses will be
subject to the load induced by the opposing forces of the pipe-work, reducing
the compressive load on the gasket.
Bolt Load : Subject to exceptions in Appendix F or exceptions listed on the JIS: when
using Belzona 8211 lubricant, Appendix B should be used to establish the target bolt
load. Appendix D should be used to establish the target bolt load when using
Nickeleez™ lubricant.
Hot Bolting : Flanges which require hot bolting shall be listed in Appendix F and the
requirement shall be shown on the JIS. Hot bolting is performed when the
temperature of the flange of bolts is between 150 and 230⁰C or within 24 hours if the
joint temperature remains below 150⁰C. Start-up re-torque should be performed in a
circular pattern and continued until the nuts no longer turn at the applicable torque
value.
Cast Iron Flanges : (see Section B3).
Title :
4.2 Tightening Patterns

4.2.1 Tightening Pattern for Circular Flanges
To achieve uniform joint load/stress distribution the bolts shall be tightened in
four stages. The first to 30% of load/torque following the diametrical ‘star’
sequence in the diagram below, the second to 60% in the diametrical ’star’
sequence, the third to 100% in the diametrical ’star’ sequence and the fourth in a
circular pattern around the whole flange and to continue until no further nut
rotation occurs when applying 100% load/torque.
(bolts numbered clockwise around the flange)
4 bolt flange 1, 3, 2, 4
8 bolt flange 1, 5, 3, 7, 2, 6, 4, 8
12 bolt flange 1, 7, 4, 10, 2, 8, 5, 11, 3, 9, 6, 12
16 bolt flange 1, 9, 5, 13, 3, 11, 7, 15, 2, 10, 6, 14, 4, 12, 8, 16
20 bolt flange 1, 11, 6, 16, 3, 13, 8, 18, 5, 15, 10, 20, 2, 12, 7, 17, 4, 14, 9, 19
24 bolt flange 1, 13, 7, 19, 4, 16, 10, 22, 2, 14, 8, 20, 5, 17, 11, 23, 6, 18, 12,
24, 3, 15, 9, 21
28 bolt flange 1, 15, 8, 22, 4, 18, 11, 25, 6, 20, 13, 27, 2, 16, 9, 23, 5, 19, 12,
26, 3, 17, 10, 24, 7, 21, 14, 14, 28
32 bolt flange 1, 17, 9, 25, 5, 21, 13, 29, 3, 19, 11, 27, 7, 23, 15, 31, 2, 18, 10,
26, 6, 22, 14, 30, 8, 24, 16, 32, 4, 20, 12, 28
Title :
4.2.2 Torqueing Method for Rectangular Flanges

To achieve uniform joint load/stress distribution the bolts shall be tightened in
four stages. At each stage of tightening, bolts shall be tightened in a controlled
sequence as shown below. The first stage to 30% of load/torque, the second to
60%, the third to 100% and the fourth follows the same pattern until no further
nut rotation occurs when applying 100% load/torque.
4.3 Quality Assurance (QA) of Bolted Joints

4.3.1 Turnarounds
QA of bolted joints during turnarounds will be carried out according to the
Turnaround Quality Manual for that event. It is standard practice for all bolting
less than 1” to be manually torqued by designated competent persons and
subject to 100% quality checks.
4.3.2 Maintenance
QA is a mandatory requirement for all heat exchanger flanges. A Joint Assembly
Record Sheet shall be used for each exchanger including all bolted joints. The
Joint Assembly Record Sheet can be found in Appendix E.
For piping (including standard piping flanges on equipment), the contractor shall
use the QA system as defined in ENG-ETS-620. The QA checks shall be
completed prior to the signing of the PRS for handback to Operations.
Essar Technicians signing the PRS are confirming that joints have been made to
the requirements of this document.
Title :
5.0 APPENDIX
Appendix A : Selection of Most Appropriate Bolt Tightening Method
Bolt Size ½ 1 1 1 1 1 1 2 2
5/ 1/ ¼ 3/ ½ 5/ 7/ 2 ½
8 8 8 8 8
↔ “ “ ¾“ 7/ “ 1” “ “ “ “ “ “ ” ¼“ “ +
8
Hand Default Tool

Spanner 
Manual
Improved Accuracy
Torque
Wrench
During TA’s
Controlled Default Tool

Power

Torquing
All Services: Default Tool

ASME Class 1500
Controlled and above 
Bolt Hydrogen
Tensioning Service: ASME
Class 600 and
above
The hierarchy per bolt size is: BLUE (if Applicable) then RED 
Note 1 : For a given bolt size, alternative tightening methods can be used, subject to
approval by a maintenance concession.
Note 2 : Appendix F lists those applications that have been deemed necessary to use a
more accurate tightening technique than the default tool. See section 5 for more
details.
Note 3 : Flogging spanners shall only be used when other means of tightening have been
deemed impractical, and their use is strictly controlled see ENG-ETS 700.
Title :
Appendix B : Values of Bolt Stress and Torque to be Applied

B1. Standard Flanges
FLANGE MATERIALS : ASTM A105
ASTM A350 grades LF2 and LF3
ASTM A182 grades,F11,F22,F5,F9,F304,F316 and F321/347
BOLTING MATERIALS
Ferritic Steels : ASTM A193 B7, B16, B7M
ASTM A320 L7, L7M, L43
Austenitic Steels: ASTM A193 B8 cl 2
ASTM A453 660A, 660B and 660C (see OMC/WI/CCU5)
GASKETS : Klinger : Maxiflex™(SPW) All windings and fillers.

Klinger : Maxiprofile (type 109)™
Klinger Type 108™ (MRG-Metal Reinforced Graphite,
Flexitallic : Kammprofile™
Klinger : PSM-AS™ (Tanged insert))
Klinger : Klingersil C4430™
Metal ring joint
Required Residual Bolt Stress (pre-load)

The target bolt stress for all ASME B16.5 Flanged joints with gaskets as listed above is
45000 PSI, with the exception of :
 Class 150 flanges with 5/8” Bolts and all Class 2500 flanges where the target stress is
50000 PSI.
 Cast Iron flat face flanges class 125/250, where the target stress is 30000 PSI
 Where bolt stresses other than those given above are used, this should be recorded
on the job information sheets (JIS’s).
Title :
TORQUE VALUES
Table 1 : Imperial Torque Values using Belzona 8211 Anti-Seize
(coefficient of friction = 0.09)
Required residual bolt stress

Imperial
30 000 psi 35 000 psi 45 000 psi 50 000 psi
Bolt Dia
Torque (ft. Lbs) Torque (ft. lbs) Torque (ft. Lbs) Torque (ft. lbs)
(Inch)
1
/2 28 33 43 47
5
/8 56 65 83 93
3
/4 97 113 146 162
7
/8 156 181 233 259
1 233 272 350 388
1
1 /8 337 394 506 562
1 1/4 470 548 704 783
3
1 /8 631 737 947 1052
1 1/2 827 965 1241 1379
5
1 /8 1129 1318 1694 1882
1 3/4 1330 1552 1994 2217
7
1 /8 1644 1917 2465 2739
2 2007 2341 3010 3344
2 1/2 - - - -
3 - - - -
Table 1 figures derived from the following data source and calculation :
 “Tips on Torque” by F.J. Allen Jr in 1972. – using bolt data from the machinery
handbook.
 “An introduction to the design and behaviour of bolted joints” by John. H. Bickford
this references the same long equation. Endorsed by N. Motosh 1976.
 ASME PCC-1 Guidelines for pressure boundary bolted flange joint assembly
All data has been modified in response to Stanlow experimental data used to determine
the effectiveness of the calculated torque values to achieve the designated residual bolt
stress.
Title :
Table 2 : Metric Torque Values using Belzona 8211 Anti-Seize


Metric
207MPa 241MPa 310MPa 345MPa
Bolt Dia
Torque (Nm) Torque (Nm) Torque (Nm) Torque (Nm)
(Inch)
1
/2 38 45 58 64
5
/8 75 88 113 126
3
/4 132 154 198 220
7
/8 211 246 316 352
1 316 369 474 527
1 1/8 457 534 686 762
1
1 /4 637 743 955 1061
1 3/8 856 999 1284 1427
1
1 /2 1122 1309 1683 1869
1 5/8 1531 1787 2297 2552
1 3/4 1803 2104 2705 3005
7
1 /8 2228 2600 3343 3714
2 2720 3174 4081 4535
1
2 /2 - - - -
3 - - - -
Table 2 figures derived from the following data source and calculation :
handbook.
 “An introduction to the design and behaviour of bolted joints” by John. H. Bickford
this references the same long equation. Endorsed by N. Motosh 1976.
All data has been modified in response to Stanlow experimental data (see document
00846694S000P00000) used to determine the effectiveness of the calculated torque values
to achieve the designated residual bolt stress.
Title :
B2. Non Standard Flanges

 Bolting (using materials specified in the standard) for girth flanges, floating
heads, and fin fan covers must be tightened to achieve a residual bolt stress
of 45000psi (310MPa) unless:
 The JIS (Job information sheet) will indicate another value if required.
 In the event that there is no guidance on the JIS, then the residual bolt
stress, as indicated above should be applied
 For equipment flanges, the values of residual bolt stress should reflect the
values indicated in this ETS (unless specified otherwise) are to be used. If
only torque values are supplied, these must be checked by the assurance
engineer or the Stanlow Design office.
 Where no values are supplied or the gasket and equipment manufacturers
are different, the gasket manufacturer should be consulted, and their
recommendations compared against the resultant flange stresses.
 For bolt and flange materials other than those quoted above, the Design
Office should check ASME VIII bolt and flange allowable stresses.
 For gasket materials other than those quoted above, the gasket
manufacturer should be consulted. For PTFE based soft cut sheet materials,
a residual bolt stress of 35000psi or 240MPa will generally be applicable.
B3. Cast Iron Flanges
Cast Iron Flange Ratings
The two most common ratings for Cast Iron flanges are Class 125 and Class 250.
Other flange ratings are available but are not as common.
Cast Iron flanges are ◊Flat Face and are generally associated with low pressure
cast iron valves and nozzles on cast iron equipment such as some pumps,
ejectors and turbines. Mating forged steel flanges to cast iron flange can pose a
potential to crack the "weaker" cast iron. The main point to remember now is
that a Class 125 Cast Iron flange will mate to a Class 150 forged steel flange, and
a Class 250 Cast Iron flange will mate to a Class 300 forged steel flange. The
Steel B16.5 flanges normally have a raised face and in this case bolting up the
flanges should take place with great care and only with the approval of the Plant
Engineer. Strong preference is to design-out the mis-match if possible (see
below). The solution is to ensure that the mating flange is modified to a flat face
configuration, (a new flange must be obtained and the raised face removed
because the original flange specification, for the rating, included the raised face).
◊ Flat Face (FF) - The contact face of the flange is machined flat.
Alignment :
 Alignment of flange faces is essential, along with control of assembly bolt
torque, so as not to overstress the cast iron flanges.
 Care must also be exercised to ensure that piping loads transmitted to cast
iron flanges are controlled, taking into account its lack of ductility.
Title :
 Flange face separation shall be within the gasket spacing ±1.5 mm (1/16 in.).
Only one gasket per flanged connection shall be used.
 Connecting to any cast iron flange. The flange face alignment check shall be
performed with bolting (inserted easily by hand) loose, the acceptance
criteria shall be as given below.
Flange diameter Maximum misalignment at OD of flange

< DN 300 (NPS 12) 0.2 mm
DN 300 to DN 600 0.3 mm
≥ DN 600 (NPS 24) 0.5 mm
Gaskets
Gaskets for FF flanges (ASME B16.5)
For all Class 125 and 250 FF flanged connections, soft cut gaskets must be used
these include Gortex GR™, rubber, Klinger grades PSM and C4430.
IBC (Inside Bolt Circle) gaskets must not be used.
Bolting to Gray Cast Iron Flanges

The bolt material would be a low strength bolt (“Black bolt”) however these are
not used on the Stanlow site therefore B7’s can be used with a reduced a
residual stress of 30000psi or 207MPa. For both 125#/150# and 300#/250#
connections.
Title :
Appendix C : Flange Bolting Diagram
Title :
Appendix D : Nickeleez Torques Values

Table 3 : Imperial Torque Values for Nickeleez

Imperial
30 000 psi 35 000 psi 45 000 psi 50 000 psi
Bolt Dia
Torque (ft. Lbs) Torque (ft. lbs) Torque (ft. Lbs) Torque (ft. lbs)
(Inch)
1
/2 29 34 44 49
5
/8 57 67 86 95
3
/4 100 117 150 167
7
/8 160 187 240 267
1 240 280 360 400
1 1/8 348 405 521 579
1
1 /4 484 565 726 807
1 3/8 651 759 976 1085
1
1 /2 853 995 1280 1422
1 5/8 1165 1359 1748 1942
1 3/4 1372 1601 2058 2287
1 7/8 1696 1979 2544 2827
2 2071 2416 3106 3452
Table 3 figures have been derived from the following data source and calculation :
handbook.
 “An Introduction to the Design and Behaviour of Bolted Joints” by John. H.
Bickford this references the same long equation. Endorsed by N. Motosh 1976.
Note : A local factor is not required for this product.
Title :
Table 4 : Metric Torque Values for Nickeleez


Imp/Metric
207 Mpa 241 Mpa 310 MPa 345 Mpa
Bolt Dia
Torque (Nm) Torque (Nm) Torque (Nm) Torque (Nm)
(Inch)
1
/2 40 46 59 66
5
/8 78 91 116 129
3
/4 136 158 204 226
7
/8 217 253 326 362
1 325 380 488 542
1 1/8 471 550 707 785
1
1 /4 656 766 984 1094
3
1 /8 883 1030 1324 1471
1 1/2 1157 1350 1735 1928
5
1 /8 1580 1843 2370 2633
1 3/4 1860 2171 2791 3101
7
1 /8 2299 2683 3449 3832
2 2808 3276 4212 4680
Table 4 figures have been derived from the following data source and calculation :
handbook.
 “An introduction to the design and behaviour of bolted joints” by John. H.
Bickford this references the same long equation. Endorsed by N. Motosh 1976.
 ASME PCC-1 Guidelines for pressure boundary bolted flange joint assembly.
Note : A local factor is not required for this product.
Title :
Appendix E: Joint Assembly Record QA Sheet
Joint Assembly Joint Assembly

Record Record.docx
The following table shows who completes each field in the document and at what stage the
information is populated:
Field Responsible person When

WO Essar Planner/Coordinator At the planning stage
FLOC Essar Planner/Coordinator At the planning stage
Drawing Essar Planner/Coordinator At the planning stage
Joint Description Essar Planner/Coordinator At the planning stage
Flange Essar Planner/Coordinator At the planning stage
Bolt Properties Essar Planner/Coordinator At the planning stage
Gasket Essar Planner/Coordinator At the planning stage
Method Essar Planner/Coordinator At the planning stage
Tightness Essar Planner/Coordinator At the planning stage
Flange Condition Contractor Supervisor Prior to rebuilding the heat exchanger
Tool Serial Number Contractor Supervisor Once the joint is completed
Installer by Contractor Supervisor Once the joint is completed
Supervisor Contractor Supervisor Once the joint is completed
Date Contractor Supervisor Once the joint is completed
Title :
Appendix F: Additional Requirements
Appendix F
For ODP equipment see the embedded spreadsheet (above).
For other units see ENG-Mech-050
Note : other Units are in the process of being added to the Appendix F spreadsheet and so
the two documents will be combined in due course.
Title :
Appendix G : Gr660 Stamping
Purpose & Scope

Gr 660 bolting has been identified as having a limited life due to creep at high temperature.
This procedure is to define how remaining life is to be arrived at and to specify a procedure for
date stamping of bolts to facilitate the control of this.
Definition
Gr 660 ASTM A453 Gr 660 material.
References
SJM/Gr 660 Technical report on allowable bolt life of Gr 660 bolting at elevated temperature.
Procedure
1. When a new Gr 660 bolt is fitted & bolt tensioned for the first time both ends shall be die
stamped with the month of initial tensioning, e.g. 7th April 94 would be 4/94.
2. At each subsequent tensioning of the bolt the month of the tensioning shall be stamped on
each end of the bolt.
3. Prior to each planned shutdown a survey shall be made of each joint where grade 660
bolting is used and an assessment shall be made of which bolts will need to be replaced.
4. A bolt shall be replaced at a shutdown if the remaining bolt life after tightening is
insufficient to last until the next planned maintenance on that joint.
5. Remaining bolt life in years, Tb, as derived in technical report SJM/Gr 660, is given by :
Tb = 18.25 - 2.57N - Te.
Where N = number of times tensioned excluding initial commissioning tightening.
Te = time elapsed in years since first tensioned, excluding unit shutdown time.
Example
If a bolt is stamped 4/88, 7/89, 3/91 and 3/94 and next planned shutdown is 9/97 at the
end of September 1994 :
N= 3
Te = 5.75 years (assumes 8 months of shutdown duration)
Tb = 18.25 - (2.57*3) - 5.75
= 4.8 years
Thus the bolt will have sufficient remaining life to remain in service until July 1999 based
on continuous running. It will, however, require to be replaced at the next major
shutdown.

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Stanlow Engineering Procedures Document No.

BOLT TIGHTENING & JOINT MAKING

REV DESCRIPTION DATE AUTHORISER SIGN

F See Revision Log Feb 21 Russell Sparks

Next Review date: Feb 2025

Date Rev Document Revision Log

Rollout of Procedure / Work Instruction

Affected Departments All Engineering / Engineering ETS distribution / CMG

Method of Communicating Roll Out of Document

4.0 BOLT TIGHTENING

4.2 Tightening Patterns

(bolts numbered clockwise around the flange)

4.2.2 Torqueing Method for Rectangular Flanges

4.3 Quality Assurance (QA) of Bolted Joints

Hand Default Tool

Controlled Default Tool

All Services: Default Tool

Appendix B : Values of Bolt Stress and Torque to be Applied

GASKETS : Klinger : Maxiflex™(SPW) All windings and fillers.

Required Residual Bolt Stress (pre-load)

Required residual bolt stress

Table 2 : Metric Torque Values using Belzona 8211 Anti-Seize

Required residual bolt stress

B2. Non Standard Flanges

Flange diameter Maximum misalignment at OD of flange

Bolting to Gray Cast Iron Flanges

Appendix C : Flange Bolting Diagram

Appendix D : Nickeleez Torques Values

Required residual bolt stress

Note : A local factor is not required for this product.

Table 4 : Metric Torque Values for Nickeleez

Required residual bolt stress

Note : A local factor is not required for this product.

Appendix E: Joint Assembly Record QA Sheet

Joint Assembly Joint Assembly

Field Responsible person When

Appendix F: Additional Requirements

Appendix G : Gr660 Stamping

Purpose & Scope

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