Doc. No.

: LINE-100-AM-4-0023

Job No. : AAID2102

WORK METHOD STATEMENT FOR

BOLT TIGHTENING WORK

PROJECT : LOTTE INDONESIA NEW ETHYLENE PROJECT

LOCATION : CILEGON, INDONESIA
OWNER : PT LOTTE CHEMICAL INDONESIA

0 Dec. 12, 2023 Issue for Construction M.G.In Y.M.Shim E.G.Park

A Sep. 05, 2023 Issue for Approval M.G.In Y.M.Shim E.G.Park

PREPARED REVIEWED APPROVED

REV. DATE DESCRIPTION
BY BY CM BY SM
 WORK METHOD Doc. No. : LINE-100-AM-0023
STATEMENT FOR BOLT Job No. : AAID2102
TIGHTENING WORK Rev. No. :0
Page : I OF II

REVISION LOG
REVISED
REV. NO. REV. DATE REVISION DESCRIPTION
PAGE
A Sep. 05,2023 Issue for Approval
0 Dec. 12, 2023 Issue for Construction
 WORK METHOD Doc. No. : LINE-100-AM-0023
STATEMENT FOR BOLT Job No. : AAID2102
TIGHTENING WORK Rev. No. :0
Page : II OF II

TABLE OF CONTENTS

1. PURPOSE ....................................................................................................... １
2. SCOPE ............................................................................................................ １
3. REFERENCE DOCUMENTS ........................................................................... １
4. DEFINITION..................................................................................................... ２
5. RESPONSIBILITY ........................................................................................... ２
6. GENERAL ....................................................................................................... ３
7. WORK METHOD ............................................................................................. ７
8. INSPECTION ................................................................................................ １４
9. SAFETY ........................................................................................................ １５
10. ATTACHMENT.............................................................................................. １５
 WORK METHOD Doc. No. : LINE-100-AM-4-0023
Job No. : AAID2102
STATEMENT FOR BOLT Rev. No. :0
TIGHTENING WORK Page : 1 of 15

1. PURPOSE

This method statement is to ensure that the bolt tightening, bolt torque tightening and bolt tensioning
for all flanged connections in a piping system and connections to equipment shall be carried out
safely and properly in accordance with good working practices as per the Project Specification.

2. SCOPE

This method statement is applicable to all flanged connections in piping systems including vendor
package equipment such as pipe to pipe, pipe to valve, pipe to pipe special items, pipe to instrument
and pipe to equipment connections regardless of sizes and classes
Out of Scope
Method statement for the following flange joint bolt tightening shall be provided separately.
1) For critical equipment flange joints, e.g. for heat exchanger channel/tube sheet, header box
cover plate and rotating equipment casing flange joints (Flange joint calculations, required bolt
stresses and method of tightening shall be provided by the equipment manufacturer).
2) Bolt tightening for non-metal flanges such as GRP flanges shall be applied by the Vendor
tightening procedure.
3) Insulated flanges and isolating flanges in cathodically protected pipe (Vendor specifications to
be provides separately)
4) Hot bolting to be executed at the stage of commissioning/start-up (Separate method statement
to be provided before starting the work)

3. REFERENCE DOCUMENTS

ANSI B1.1 Unified Inch Screw Threads

ANSI B16.5 Pipe Flanges and Flanged Fittings
ANSI B16.20 Ring Joint gaskets & grooves for steel pipe joints
ANSI B16.21 Non-metallic gaskets for pipe fittings
ASME B16.47 Large Diameter Steel Flanges : NPS 26 through NPS 60
ASME Section VIII Boiler and Pressure Vessel (Division 1 and 2)
ANSI B31.3 Chemical Plant and Petroleum Refinery Piping
ANSI B46.1 Surface Texture (surface Roughness, Waviness and Lay)
ASTM A105 Forgings, Carbon Steel, for Piping Components
 WORK METHOD Doc. No. : LINE-100-AM-4-0023
Job No. : AAID2102
STATEMENT FOR BOLT Rev. No. :0
TIGHTENING WORK Page : 2 of 15

ASTM A182 Forged or Rolled Alloy-Steel Pipe Flanges, Forged Fittings and Valves
and Parts for High-Temperature Service
ASTM A193 Standard Specification for Alloy Steel and Stainless Steel Bolting
Materials for High Temperature Service
ASTM A320 Standard Specification for Alloy Steel Bolting Materials for Low
Temperature Service
ASTM A350 Forgings, Carbon and Low Alloy Steel, Requiring Notch Toughness
Testing for piping Components
ASTM A453 Standard Specification for Bolting Materials, High Temperature 50 to 120
KSI (345 to 827 MPa) Yield Strength, with Expansion Coefficients
Comparable to Austenitic Steels
ASTM A694 Forging, Carbon and Alloy Steel, for Pipe Flange, Fittings, Valves,
and Parts for High-Pressure Transmission Service

4. DEFINITION

4.1 Bolt Tightening

A conventional manual bolt tightening method to be carried out by only the qualified pipe fitters
with spanners/wrenches on flange joints with stud bolt sizes 1/2” and 5/8” only but bolt torque
tensioning method is not applied.
4.2 Bolt Torque Tightening
A method for tightening flanged joints in which torsion loads are applied to the bolts causing
the bolts to stretch due to relative movement between internal and external thread.
Overcoming frictional force results in the initial bolt load.
4.3 Bolt Tensioning
A method for tightening flanged joints in which an axial force is applied to the bolts causing
them to stretch, at which time the nut is snagged and the local removed.

5. RESPONSIBILITY

5.1 Company
The Company means PT. Lotte Chemical Indonesia, the entity who is the owner and employer
of the project.
5.2 Contractor
The Contractor means PT. Hein Global Utama, the entity who has been selected as an EPC
contractor by Company to perform Lotte Indonesia New Ethylene Complex Project and who is
the employer for whom the subcontractor is working in the project.
 WORK METHOD Doc. No. : LINE-100-AM-4-0023
Job No. : AAID2102
STATEMENT FOR BOLT Rev. No. :0
TIGHTENING WORK Page : 3 of 15

5.3 Subcontractor
The Subcontractor is the organization who is performing Tie-in works on the project for a
Contractor.
Confirm all permanent materials with material specification
1. Execution all activities of pipe fitter qualification test and documentation
2. SUBCON. QC Engineer is responsible for the inspection according to ITP and check list.
5.4 Construction Discipline
1. A construction engineer is responsible for control of the bolt tightening works.
2. To make arrangement of the pipe fitter qualification test
5.5 Quality Control Discipline
1. A QC Engineer is responsible for the inspection according to ITP and check list.
2. Certify the qualified pipe fitter and maintain the qualified pipe fitter list

6. GENERAL

6.1 Pipe Fitter Training and Qualification

Before commencing work at the site, all pipe fitters shall be trained and qualified in accordance
with a separate method statement
6.2 Material Identification & Verification
All fitters must check as the referred specification for minimize errors in gaskets and bolts/nuts
installation and facilitate post installation checks.
6.2.1 Flanges
A flange face is clean from scratches, nicks, burrs, rust, grease or any other defects on the
gasket seating surface. If the scratches or pits are deeper than 0.2 mm and cover more
than half the width of the face, the flange will also have to be machined or replaced
(depending upon severity, an engineering assessment may be required When cleaning a
flange face, never use a tool that may damage the surface finish. A soft wire brush is
recommended
6.2.2 Bolts
Bolts are the correct length, diameter and material (including confirming color coding), are
undamaged, free of any burrs and corrosion.
Stud bolts or nuts which are not clearly marked with the correct material grade and color
code shall not be used as a wrong assumption could have serious consequences. (e.g.,
stud bolts marked with B7 and nuts with 2H in sweet services and studs marked with B7M
and nuts with 2HM in sour services in line with the pipe class).
Stud bolt/nut material grade and color code identification markings shall be easy accessible
 WORK METHOD Doc. No. : LINE-100-AM-4-0023
Job No. : AAID2102
STATEMENT FOR BOLT Rev. No. :0
TIGHTENING WORK Page : 4 of 15

for piping supervisors and MC punchers e.g. for flanged valves the markings shall all be
clearly visible from the back side of the pipe flange.
Nuts should not be assembled with the identification marking and color code against the
flange. The identification marking should always point outwards to allow for verification by
supervisor and MC punchers.
6.2.3 Gaskets
Check the type, class, size and material specification of the gasket before using it. Check
with the piping class to confirm that it is correct. Ensure that the color coding applied is rigid
enough to remain clearly visible during the project construction and commissioning phase
(more than 36 months). In case of any doubt the color coding shall be rigidly re-instated
before field issuing. Faded gasket color coding will result in gasket replacement during
mechanical completion punching. Check the gasket for damage, nicks, etc. Ensure that it
is clean and free from any contaminants before use.
Graphite Tinged, Spiral Wound, and Ring Joint gaskets can only be used once and shall
not be reused. Spiral Wound, Metal Groove and Ring Joint gasket that have no identification
shall not be used. It may appear to fit the flange, but this is not a guarantee. Do not cut or
deform a gasket to fit a flange. If the gasket does not fit, the wrong one has been chosen.
Blind gaskets shall not be used. Temporary gaskets and test gaskets shall be clearly
identifiable e.g. RED painted on the entire outer rim. Temporary gaskets have been installed
correctly rated to meet the expected test pressures.
6.2.4 Other Materials
Where applicable, any spectacle blind in the joint has been inspected to confirm that it is
undamaged (no burrs or scratches on the gasket contact surface), and that the closed
portion is coated with approved preservation material and a physical means of protection
such as a timber cover.
6.3 Flange Alignment and Parallelism Acceptance Criteria
6.3.1 Type of Alignment
Two types of alignment are recognized:
1) Lateral alignment that is the off-set of the aligned flange centerlines, applicable to the
complete flange set as well as the relative positioning of bolt holes.
2) Parallelism of the aligned flange faces, sometimes referred to as angular alignment.
6.3.2 Set up Prior to Measurement
1) The flanges shall be lined up so that the bolts can be inserted without force.
2) A gasket and 25 percent of the bolts (with at least four) shall be inserted. The bolts shall
be uniformly fastened using manual spanners to take out the free slack, to ensure the
real misalignment will be measured.
 WORK METHOD Doc. No. : LINE-100-AM-4-0023
Job No. : AAID2102
STATEMENT FOR BOLT Rev. No. :0
TIGHTENING WORK Page : 5 of 15

6.4 Bolt Torque Loads by Piping Class

The specific torque values to be applied for bolts are appended as shown below.
1) Flange Rating: ANSI B16.5, Class 150 for B7, B7M, B16, L7, L7M Bolts
2) Flange Rating: ANSI B16.5, Class 300 for B7, B7M, B16, L7, L7M Bolts
3) Flange Rating: ANSI B16.5, Class 600 for B7, B7M, B16, L7, L7M Bolts
4) Flange Rating: ANSI B16.5, Class 900 for B7, B7M, B16, L7, L7M Bolts
5) Flange Rating: ANSI B16.5, Class 1500 for B7, B7M, B16, L7, L7M Bolts
6) Flange Rating: ANSI B16.5, Class 150 for B8M Bolts
7) Flange Rating: ANSI B16.5, Class 300 for B8M Bolts
8) Flange Rating: ANSI B16.5, Class 600 for B8M Bolts
6.5 Bolt Tensioning
Controlled hydraulic jack bolt tensioning enables high integrity jointing to be achieved by
uniformly stretching the bolt shanks in the cold condition by means of hydraulic oil pressure.
The elongation produced in the bolts corresponds to the calculated load required to make the
flanged joint.
Whilst the bolts are elongated, the nuts can easily be run down the thread by hand, until they
bear against the flange. When the hydraulic pressure is released virtually all of the bolt
extension is retained over its active length between the nuts, and the required bolt load is
obtained.
A jacking tool screws onto one end of the bolt, therefore the bolt needs an additional length of
thread protruding out of the hexagonal nut at one end by about 1 to 1.5 times the bolt diameter.
After the tightening procedure is complete the extended thread lengths shall be protected
against corrosion and damage to allow the nuts to be subsequently unscrewed.
Grease filled rubber, aluminum or plastic caps are recommended for this purpose. In the
loosening procedure the bolts are stretched again and the nuts unscrewed easily providing the
threads has been protected.
The hydraulic pressure is supplied by a high-pressure oil pump via a distribution ring main to
a number of jacking tools. The number of tools used depends on the application or the total
number of bolts to be tightened.
Theoretically, the number of jacking tools should equal the number of bolts. However, for
accessibility reasons it is most unlikely that all stud bolts in a flange connection can be
tensioned simultaneously, even in those cases where bolts are accessible from both sides and
the tensioning tools can be placed on alternative sides of the flange: Therefore, completion of
tensioning in only one cycle is practically impossible. Tool manufacturers have developed
different tensioning schemes for stepwise tensioning. Principally they all aim to create an even
stress distribution over the stud bolts when not all tensioned in the same cycle (e.g. when half
 WORK METHOD Doc. No. : LINE-100-AM-4-0023
Job No. : AAID2102
STATEMENT FOR BOLT Rev. No. :0
TIGHTENING WORK Page : 6 of 15

of the bolts have been tightened they will suffer a decrease in preload when the rest are being
tightened).
Calculation of hydraulic pressure;
For a detailed calculation of loads to be applied to obtain the required bolt stresses, data shall
be obtained from the manufacturer of the selected tool.
For this reason, a practical example of calculation is not included, but the factors involved are
indicated
The required pressure required to operate the jacking tools is obtained by multiplying the
calculated load by a factor and dividing this by the effective lifting area of the jacking tool. The
factor is required to compensate for the loss of load, which occurs when the bolts take up the
strain after the hydraulic pressure is released and the bolts and nuts deform slightly as they
relax. The value of this factor is related to the bolt dimensions Land D. It can be seen in Figure
2 that long slender bolts have the lowest value for the factor, indicating that the loss of load
will be less. Short bolts of large diameter conversely have a high factor and therefore require
a high initial bolt load. Control over the final load is then less predictable and consequently bolt
tensioning of such bolts is not recommended. The required stress in the bolt will be obtained
from flange calculations, whilst the manufacturer of the tensioning equipment will provide tool
details and the load factor.
Additionally, if the flange joint will be subjected to high temperatures, the initial calculated bolt
load can be increased by the amount necessary to ensure an adequate working life for the
joint, considering loss of bolt load due to the effect of "creep" on the bolts. For these
connections bolts of adequate tensile strength combined with resistance to creep should be
selected to give a reasonable working life without the need for re-tightening or risk of
overstressing the flange. Gasket relaxation should be incorporated as well.
To compensate for the "neighbor unloading" effect during the first cycle and to minimize the
number of cycles required, the pressure "A" used during the first cycle will be higher than the
pressure "B" required for the theoretical case of 1 00% tools (where all bolts are simultaneously
at the required stress level). The initial "A" pressure is normally 15% to 20% higher than the
pressure "8" actually required. Hydraulic pressure 8 = f blf max x load factor x oil pressure at
max_ workload.
Where f b = actual stress required in bolts, f max = stress that would be applied to the bolts at
max. workload. The load factor can be found in next figure:
 WORK METHOD Doc. No. : LINE-100-AM-4-0023
Job No. : AAID2102
STATEMENT FOR BOLT Rev. No. :0
TIGHTENING WORK Page : 7 of 15

Controlled hydraulic jack bolt tensioning shall be carried out on the following flanged
connections (where inadequate space or availability of tooling restricts the use of tensioning,
then controlled torquing shall be used):

1) Bolt sizes 2 inches and larger in all services with pressure ratings 300#, 600# and 900#
2) Bolt sizes 1-1/2" and larger in all services with pressure ratings class 1500 and above
3) Bolt sizes 1-1/2" and larger in H2 service. With pressure ratings 600# and 900#
6.6 Clamp Connectors
This method statement does not contain bolt torques for clamp connector bolting. Using Dow
Molykote 1000 bolt thread lubricant with a coefficient of friction of 0.11, the bolt torques
required to achieve the required residual bolt stress, and acceptable flange alignment
tolerances, shall be obtained from the particular clamp connector manufacturer.

7. WORK METHOD

7.1 Alignment for Tightening (Flange Assembly)

During the flange assembly work, parallelism of flanges shall be checked by qualified fitter to
confirm they are within the tolerances specified above criteria.
7.2 Torque Values
Where bolt torque tightening is specified, a fitter must check torque values as per the referred
 WORK METHOD Doc. No. : LINE-100-AM-4-0023
Job No. : AAID2102
STATEMENT FOR BOLT Rev. No. :0
TIGHTENING WORK Page : 8 of 15

procedure to achieve joint tightness.

7.3 Selection of Tightness Tool
Before starting of tightening, a fitter must confirm the tightness method and all bolts shall be
lubricated with “Molykote 1000”
For each method of bolt tightening, flange ratings and bolt diameters are summarized as below.
(See attachment 3)
Guideline for Selection of Flange Tightening Tools for Hydrocarbon Services
Method Recommended Usage
*1.25", #900 or above applied
(Excluding tensioner work)
Torque Wrench
*All material below mentioned.
Ductile/Cast Iron, Glass Flake, HDPE, GRE/GRP, Bronze
*H2 (#600 or higher)
*2" #900 or above (ALL Service)
Hydraulic Torque Wrench
*1.5" or above (BFW/XS/HS) #900 or more LINE
*1" or above Toxic (H2S)
Note to the Table:
Where inadequate space or availability of tooling restricts use of hydraulic jack tensioner, hydraulic
torque wrench will be used.

7.4 Tightening Tensioning & Clamp Connector

7.4.1 Tightening Sequence
At each stage of tightening, bolts shall be tightened in a controlled sequence as shown
table. (Bolts numbered clockwise around the flange)

Bolts Tightening Sequence Table

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
1, 13, 7, 19, 4,16, 10, 22, 2, 14, 8,20, 5, 17, 11, 23, 6, 18, 12, 24, 3, 15,
24 bolt flange
9, 21
1, 15, 8, 22, 4, 18, 11, 25, 6, 20, 13, 27, 2, 16, 9, 23, 5, 19, 12, 26, 3,
28 bolt flange
17, 10, 24, 7, 21, 14, 28
1, 17, 9, 25, 5, 21, 13,29, 3, 19, 11, 27, 7, 23, 15, 31, 2, 18, 10, 26 ,6,
32 bolt flange
22, 14, 30, 8, 24, 16, 32, 4, 20, 12, 18
After tightening work at specified torque value (100%), fitter must be confirmed one by one
 WORK METHOD Doc. No. : LINE-100-AM-4-0023
Job No. : AAID2102
STATEMENT FOR BOLT Rev. No. :0
TIGHTENING WORK Page : 9 of 15

in clockwise direction (one round)

1) The above Table provides the typical sequences and numbering:

 WORK METHOD Doc. No. : LINE-100-AM-4-0023
Job No. : AAID2102
STATEMENT FOR BOLT Rev. No. :0
TIGHTENING WORK Page : 10 of 15

Note : For bolt tightening sequences for all flanges of 52 bolts and above advice should be sought to
provide an agreed tightening sequence.
2) Where bolt torque tightening is specified then the bolts shall be tightened to the initial
wrench torque value that applies 50% of the required bolt stress, either simultaneously
in pairs by two tradesmen working in tandem or in direct sequence. Care shall be taken
to prevent over-tightening one side of the flange and result in gasket crushing or flange
distortion. For torque wrench tightening, the bolts shall be tightened in wrench torque
value step that tighten the bolts to 80% then 100% of the bolts stress.
3) Thereafter, two diametrically opposite bolts located 90degree further round the
circumference shall be tightened, again being carefully not to distort the flanges. This
procedure shall be repeated until all bolts have been once. This sequence of tightening
pairs of bolts is to be applied irrespective of whether the tightening is by torque or hand
 WORK METHOD Doc. No. : LINE-100-AM-4-0023
Job No. : AAID2102
STATEMENT FOR BOLT Rev. No. :0
TIGHTENING WORK Page : 11 of 15

wrench/spanner.
4) Once all the bolts in the flanges have been initially tightened, the diametric tightening
process shall be repeated starting at the first bolts pair.
5) For flanges that are tightened with hand wrenched/spanners, the subsequent tightening
should take them to a tightness where the bolts are uniformly tight and the gasket evenly
compressed with the flange face parallel.
6) When performing the last two tightening sequences of all flange diameters, the pipe
surface temperature is to be 40-degree C. This is to minimize stress relaxation in the
bolts due to the high temperature gradients.
The thread projection on each end of the stud bolt of the flange joint which will be tightened
by manual wrench/spanner and torque wrench shall be between 1 and 3 threads. The tread
projection on one end on which the tensioning machine will be set shall be 1 1/2 bolt
diameter. Coat the stud, the nut thread, the nut and the flange bearing surfaces with
Molykote 1000.
7.4.2 Tensioning
To achieve joint tightness, it is important that the following sequence is adhered to:
1) Check and ensure that the general requirements of Section 5 have been satisfied.
2) Before starting work, check that the tensioning tool is not too large to fit on the nuts and
the flange.
3) The application of hydraulic jack bolt tensioning equipment shall be in a strict accordance
with the manufacturer's instructions and safety procedures.
4) A personnel using the equipment shall be properly trained in its application.
In preparation for the application of bolt tensioning equipment the following information for
each flange to be tightened;
1) The required bolt stress, from the flange calculation, load factor and hydraulic pressure(s)
2) The size and number of bolts to be applied.
3) The maximum workload that can be applied.
4) Provision of bolts with extra threaded length fitted with anti-corrosion caps.
All the relevant information and bolt-tensioning details should be recorded for each
application for subsequent reference and re-application. To facilitate loosening of the nuts
when required at some later date, it will be necessary to treat the thread of the bolts with
an anti-seize compound before fitting the nuts. The extended threaded part shall also be
covered with suitable caps to prevent damage during operation of the plant. The jacking
tool manufacturer's instructions shall always take preference. The tightening of bolts is
carried out in a number of stages or cycles, depending on the number of tools that can be
applied simultaneously.
 WORK METHOD Doc. No. : LINE-100-AM-4-0023
Job No. : AAID2102
STATEMENT FOR BOLT Rev. No. :0
TIGHTENING WORK Page : 12 of 15

A suggested sequence is given in next figure :

Suggested bolting-up sequence and number of tools to be applied

Sequence & Number

Flange Distortion(0.25mm

7.4.3 Clamp Connector Tightening Method

Note that clamp connectors are particularly sensitive to cleanliness. Check that the sealing
surfaces of the hubs and seal ring are perfectly clean and completely free from scratches,
corrosion or any other damage. Superficial marks or superficial corrosion on the hub sealing
surface may be removed by light application of emery cloth.
1) A light lubricant may be applied to the sealing surfaces immediately before assembly to
assist the correct location and alignment of the seal ring.
2) Apply Dow Molykote 1000 to the bolt threads, nut threads and the domed surface of the
nuts.
3) Assemble the joint fitting the nuts with the domed surface of the nuts facing the domed
 WORK METHOD Doc. No. : LINE-100-AM-4-0023
Job No. : AAID2102
STATEMENT FOR BOLT Rev. No. :0
TIGHTENING WORK Page : 13 of 15

seating area on the clamps. On horizontal piping the clamps should be orientated with
the bolts at the top and bottom of the joint to allow water to drain from the clamp to hub
interface.
4) To ensure even tightening of the two clamps, the bolts should be tightened diagonally in
a crisscross pattern. Apply the clamp manufacture's recommended bolt torque in 3
stages, setting the torque setting to 30%, 60% and 100% of the recommended torque at
each stage. Finally apply the 100% bolt torque value to each bolt in a clockwise direction.
The gap between the clamp lugs should be the same at each set of bolts
7.5 Flange Joint Identification Tagging
Joints when the pipe fitter is satisfied that all the above is in accordance with the requirement
and material specifications and this method statement, the pipe fitter will “sign off” the joint and
“tag” as below. The Flange Tag form can be changed by the Project.

Material:

1. Tag plate shall be made from 0.6mm

Raptor Poly.
2. Binding wire shall be of a plastic cable
tie or stainless steel wire.

7.6 Disassembly and Reassembly

When disassembly of a joint is required, the bolts shall be in the same sequence as per above
for tightening. Each nut shall be loosed one-twelfth turn in the proper sequence and the
loosening sequence repeated at least once before any bolts is completely loosened.
The retightening of bolts on reassembly shall follow the original sequence for tightening and
inspection.
Used gasket shall be replaced with new one; reuse of old gasket is not permitted.
 WORK METHOD Doc. No. : LINE-100-AM-4-0023
Job No. : AAID2102
STATEMENT FOR BOLT Rev. No. :0
TIGHTENING WORK Page : 14 of 15

8. INSPECTION

8.1 Recorded Joints

1) All recorded joints must be inspected & recorded by subcontractor inspector for confirm
the condition of the flange (undamaged, clean etc.) followed by a check of alignment and
witness of torqueing at the tightening stage
2) Flange tightening reports should be used in accordance with Attachment 3: Flange
Tightening Report
3) A contractor QC Engineer must do spot check and confirmation signature on 10% of
flanges.
8.2 Non Recorded Joints

1) During pipe erection phase, Subcontractor’s QC Engineer must be spot check and
confirmation signature on 10% of flanges.
2) During punching out of piping systems prior to their release for pressure testing,
Contractor shall confirm that every joint has been signed off by a qualified pipe fitter and
that 10% of the joints have been counter signed by the Subcontractor’s QC Engineer. In
addition, Contractor should check that each joint that will not be disturbed has been
completed by confirming the pipe fitter identification tag with yellow label
 WORK METHOD Doc. No. : LINE-100-AM-4-0023
Job No. : AAID2102
STATEMENT FOR BOLT Rev. No. :0
TIGHTENING WORK Page : 15 of 15

9. SAFETY

All work related to flange integrity and tensioning shall be executed strictly in accordance with
Contractor’s Construction HSE Management Plan and it’s referred safety rules and regulations.
HSE hazards are identified prior to flange integrity and tensioning activities. The identified HSE
hazards shall be risk assessed. Base on the results of risk assessment, counter measures and
mitigation action shall be conducted.
Specific HSE requirements for activities shall as a minimum be:
1) Permit to work, specific procedure and method statement and Job Safety Analysis (JSA).
2) Material safety data sheet(MSDS) for specified hydraulic fluids shall be available at site when
handling, storing or using the material.
3) Before executing activities a Tool Box Talk shall be conducted.
4) Appropriate Personal Protective Equipment(PPE) as determined by the JSA and Risk
Assessment shall be worn by all personnel assigned to execute these activities.
5) Approved/tested/certified tools and equipment.
6) Appropriate Spill Kit and first aid equipment is available at job site.
7) Working Area is adequately illuminated at all times.

10. ATTACHMENT

[Attachment 1] Calculation of Target Torque-1

[Attachment 2] Calculation of Target Torque-2
[Attachment 3] Bolt Torquing/Tensioning Chart & Calculation of Target Torque
[Attachment 4] Piping Activity Flow Sheet
[Attachment 5] Flange Tightening Report
[Attachment 6] Hydraulic Torque Wrench Operation & Maintenance Manual
[Attachment 1] Calculation of Target Torque-1

Bolting Materials : ASTM A193 grades B7 and B7M, ASTM A320 grades L7, L7M and L43.
Target Pre-stress : 52500 psi
Nominal Bolt root Target Target Target Torque Target Torque
bolt size area (inch²) Bolt Load Bolt Load (ft-lb) (N-m)
(Inch) (lb) (N) Non-Coated Coated Non-Coated Coated
Bolt Bolt Bolt Bolt

1/2" 0.126 6615 29425 56 42 76 57

5/8’’ 0.202 10605 47173 111 83 151 113

¾’’ 0.302 15855 70527 199 149 270 202

7/8’’ 0.419 21998 97850 321 241 435 327

1’’ 0.551 28928 128676 483 362 655 491

1’’1/8 0.728 38220 170011 717 538 972 370

1’’1/4 0.929 48773 216951 1017 763 1379 1035

1’’3/8 1.115 60638 269729 1390 1043 1885 1414

1’’1/2 1.405 73763 328112 1845 1384 2502 1877

1’’5/8 1.68 88200 392333 2389 1792 3240 2430

1’’3/4 1.98 103950 462393 3032 2274 4112 3084

1’’7/8 2.3 120750 537123 3774 2831 5118 3839

2’’ 2.65 139125 618859 4638 3479 6290 4718

2’’1/4 3.42 179550 798678 6734 5050 9132 6849

2’’1/2 4.29 225225 1001851 9385 7039 12728 9546

2’’3/4 5.26 276150 1228377 12657 9493 17165 12874

3’’ 6.32 331800 1475920 16590 12443 22499 16875

3’’1/4 7.49 393225 1749152 21300 15975 28886 21665

3’’1/2 8.75 459375 2043402 26797 20098 36341 27256

4’’ 11.57 607425 2701961 40495 30372 54918 41190

[Attachment 2] Calculation of Target Torque-2

Bolting Materials : ASTM A193 grade B8M

Target Pre-stress : 32500 psi
Nominal Bolt root Target Target Target Torque Target Torque
bolt size area (inch²) Bolt Load Bolt Load (ft-lb) (N-m)
(Inch) (lb) (N) Non-Coated Coated Non-Coated Coated
Bolt Bolt Bolt Bolt

1/2" 0.126 4095 18215 35 26 47 35

5/8’’ 0.202 6565 29203 69 52 94 71

¾’’ 0.302 9815 43659 123 93 167 126

7/8’’ 0.419 13618 60574 199 149 270 202

1’’ 0.551 17908 79657 299 224 405 304

1’’1/8 0.728 23660 105245 444 333 602 452

1’’1/4 0.929 30193 134303 630 472 854 640

1’’3/8 1.155 37538 166975 861 646 1168 876

1’’1/2 1.405 45663 203117 1142 857 1549 1162

1’’5/8 1.68 54600 242873 1479 1110 2006 1505

1’’3/4 1.98 64350 286243 1877 1408 2546 1909

1’’7/8 2.3 74750 332505 2336 1752 3168 2376

2’’ 2.65 86125 383103 2871 2154 3894 2921

2’’1/4 3.42 111150 494420 4169 3127 5654 4241

2’’1/2 4.29 139425 620193 5810 4358 7879 5910

2’’3/4 5.26 170950 760424 7836 5877 10627 7970

3’’ 6.32 205400 913665 10270 7703 13928 10447

3’’1/4 7.49 243425 1028808 13186 9890 17882 13413

3’’1/2 8.75 284375 1264963 16589 12442 22498 16873

4’’ 11.57 376025 1672643 25069 18802 33998 25499

 [Attachment 3] Bolt Torquing/Tensioning Chart & Calculation of Target Torque

Bolt Torquing / Tensioning Chart

ASME B16.5 Flange Rating

Flange
Size 150 lb 300 lb 600 lb 900 lb 1500 lb 2500 lb
NPS No. Bolt Not No. Bolt Not No. Bolt Not No. Bolt Not No. Bolt Not No. Bolt
Note
(in) of Dia e of Dia e of Dia e of Dia e of Dia e of Dia
No.
Bolt (in) No. Bolt (in) No. Bolt (in) No. Bolt (in) No. Bolt (in) No. Bolt (in)
1/2 4 1/2 1 4 1/2 1 4 1/2 1 4 3/4 1 4 3/4 1 4 3/4 1
3/4 4 1/2 1 4 5/8 1 4 5/8 1 4 3/4 1 4 3/4 1 4 3/4 1
1 4 1/2 1 4 5/8 1 4 5/8 1 4 7/8 1 4 7/8 1 4 7/8 1
1 1/2 4 1/2 1 4 3/4 1 4 5/8 1 4 1 1 4 1 1 4 11/8 1
2 4 5/8 1 8 5/8 1 8 5/8 1 8 7/8 1 8 7/8 1 8 1 1
3 4 5/8 1 8 3/4 1 8 3/4 1 8 7/8 1 8 11/8 1 8 11/4 1
4 8 5/8 1 8 3/4 1 8 7/8 1 8 11/8 1 8 11/4 1 8 11/2 1
6 8 3/4 1 12 3/4 1 12 1 1 12 11/8 1 12 13/8 1 8 2 2
8 8 3/4 1 12 7/8 1 12 11/8 1 12 13/8 1 12 15/8 1 12 2 2
10 12 7/8 1 16 1 1 16 11/4 1 16 13/8 1 12 17/8 1 12 21/2 2
12 12 7/8 1 16 11/8 1 20 11/4 1 20 13/8 1 16 2 2 12 23/4 2
14 12 1 1 20 11/8 1 20 13/8 1 20 11/2 1 16 21/4 2
16 16 1 1 20 11/4 1 20 11/2 1 20 15/8 1 16 21/2 2
18 16 11/8 1 24 11/4 1 20 15/8 1 20 17/8 1 16 23/4 2
20 20 11/8 1 24 11/4 1 24 15/8 1 20 2 2 16 3 2
24 20 11/4 1 24 11/2 1 24 17/8 1 20 21/2 2 16 31/2 2
26 24 11/4 1 28 15/8 1 28 17/8 1 20 23/4 2
28 28 11/4 1 28 15/8 1 28 2 2 20 3 2
30 28 11/2 1 28 13/4 1 28 2 2 20 3 2
32 28 11/2 1 28 17/8 1 28 21/4 2 20 31/4 2
34 32 11/2 1 28 17/8 1 28 21/4 2 20 31/2 2
36 32 11/2 1 32 2 2 28 21/2 2 20 31/2 2
42 36 11/2 1

Notes
1. Flange bolting to be tightened by hydraulic torque wrench for all services in these sizes as
recommended torque value Table-1 & 2
(Available Manual Torque Wrench If applicable torque value < 730 Nm)
2. Flange bolting to be hydraulic tensioned for all services in these sizes. The bolt lengths specified
included an additional length of 1 bolt diameter to facilitate the use of bolt tensioning equipment.
[Attachment 4] Piping Activity Flow Sheet
[Attachment 5] Flange Tightening Report

FLANGE JOINT
INSPECTION REPORT
Project : Report No :

Subcon : System :

Date : Sub-system :
Tightening Method Torque Wrench or Equipment No. Calibration Date

Gasket / Flange Bolt Tightening

Sr. ISO DWG Rev Joint
Bolt Spec. Req. Acc
Type Size Rating Sign
/ Grade Value / Rej

Note :

Inspection by Subcontractor Contractor OWNER

Name

Signature

Date

Form No. : ITR-PI-008

Attachment #6
Attachment #6
Attachment #6
Attachment #6
Attachment #6