Flange Bolt Tightening Procedures PDF

TRANSCANADA OPERATING PROCEDURE (PROCEDURE)
Title: Flange Bolt Tightening Procedures

Revision: 04 Effective Date: 2009/03/11 Status: Issued Driver: Best Practice Page 1 of 11
TOP Contact: Trent Bertholet
1.0 PURPOSE
The purpose of this TOP is to identify the appropriate method and process for tightening flanges ranging
from NPS 2 to NPS 48.
2.0 SCOPE
This procedure applies to tightening of flange bolts in TransCanada pumping stations, compressor
stations, meter stations, and pipelines, diameters NPS 2 to NPS 48 and pressure classes ANSI 600 and
ANSI 900.
The procedures in this TOP will be followed during regular business activities as well as throughout an
emergency (if the TOP is applicable) to ensure the employees health and safety and the environment are
not compromised. For information on roles and responsibilities during an emergency, please refer to
TransCanada's Emergency Management System (IMS Manual / Section 2).
3.0 REFERENCES
Related CS&E TOPs (Pre-Job, Work Authorization and Job Safety Analysis, Lockout/Tagout, Waste
and Hazardous Materials Management, etc.)
Asbestos Management Procedures (Canada, Mexico) (EDMS No. 003671361)
Asbestos Management Procedures (U.S.) (EDMS No. 003864096)
Specific Manufacturers Manuals
Appendix A: Tightening Methods - Class 600 Flanges
Appendix B: Tightening Methods - Class 900 Flanges
Appendix C: Typical Stud Tightening Sequence
Appendix D: Hydraulic Pressures - Class 600 (PN 100) Flanges
Appendix E: Hydraulic Pressures - Class 900 (PN 150) Flanges
Applicable TCPL Drawing(s)
Z662-07 5.2 Steel Material and Gaskets 5.2.7 Bolting, 5.2.8 Gaskets
10.3 Operating and Maintenance Procedures
CFR 195 Subpart C Design Requirements 195.118 Fittings, 195.126 Flange Connections
Subpart F Operations and Maintenance 195.422 Pipeline Repairs
4.0 PROCEDURE:
4.1 Pre-Job Meeting

4.2 General and Torquing Sequence
4.3 Tool Selection
4.4 Hammer Wrench
4.5 Hydraulic or Pneumatic Torque Wrench
4.6 Hydraulic Tensioner
Note: Prior to use, please validate paper copies against the official version (Doc ID 003863194) in EDMS (General Library).
4.7 Disassembly of Flanged Connections
Notes:
1. Each Activity should be performed after reviewing the appropriate CS&E TOPs (Procedures).
Special Resource: Flange tightening crew should have available to them flange spreaders when
disassembling connections or changing out gaskets on existing connections.
Qualification Requirement(s): For large diameter flanged connections using hydraulic tensioners
workers must have knowledge of the tools and the operation of the pneumatic pump.
4.1 Pre-Job Meeting

Responsibilities/Accountabilities: Designated Pre-Job Representative, Pipeline, Mechanical, Bolt
Tensioning Technician
Discuss the flange tightening project during the pre-job and review appropriate drawings to identify
the flanges which will be installed or maintained
Verify the following:
o Flange size
o Flange pressure class
o Number of studs and stud grade
o Stud diameter and stud lengths (flanges being tightened with a hydraulic tensioner require
extra long studs as identified in Appendix A or B)
o Nut Size
o Preferred tightening method (manual or hydraulic torque wrench, hydraulic tensioning)
o Torque values
o Type of gasket to be used
4.2 General and Torquing Sequence
Responsibilities/Accountabilities: Pipeline, Mechanical, Contractor

Use a wire brush and/or gasket remover to ensure the flange faces are clean.
Inspect flange faces for damage i.e. dents, scratches
Only new gaskets of the correct type, material and size for the application should be used. Check for
obvious damage to new gaskets.
Gaskets must conform to TransCanada specifications.
Do not lubricate gaskets as this will prevent them from sealing properly.
Gaskets that contain asbestos must be handled using appropriate safety procedures and personal
protective equipment. Refer to the Asbestos Exposure Control Procedures for more information on
working with gaskets that contain asbestos.
! NOTE: Use of grinders or other power tools to remove asbestos gaskets is prohibited, due to
potential health hazard by emitting asbestos fibers into the air.
Prior to installing the studs:
o Clean used bolts/studs with a wire brush and/or preferred cleaning product and inspect the
threads for mechanical damage, debris, paint and rust. Studs may be re-used provided the
thread shows no damage and are free of debris, paint and rust. Discard any bolts/studs and
nuts that are damaged or elongated.
Appropriate lubrication must be used (e.g. molybdenum-disulfide grease e.g. Hydrotight,
Sweeney 503 or Loctite moly paste) with a coefficient of friction equal to 0.067.
o Ensure both flange faces are clean and free from defects.
o With the use of line up pins, ensure flange faces are lined up in all directions (axial with the
pipe, planar, and torsional).
Install studs and nuts in the lower end of the flange to support the pre-selected gasket.
Install gasket.
Install the remaining studs and nuts.
Gradually and evenly tighten studs to bring flange faces together.
Tighten at least four of the studs approximately 50% of the required torque.
Remove line up pins and install last two studs and their nuts.
Using the procedure for the selected tooling, proceed to tighten the studs.
! NOTE: Lubrication of the studs enables proper torque and consistent tension on each stud.
Insufficient stud tension will result if lubricant is not used.
4.3 Tool Selection

Refer to Appendix A or Appendix B to determine the proper tightening tool for 600# and 900#
flanges.
4.4 Hammer Wrench

Hammer wrenches should only be used for snugging up flanges or loosening studs. They are not an
acceptable method for completing the final tightening.
Visually inspect hammer wrench and hammer for any damage prior to use. Ensure the wrench is
fully engaged and properly positioned before impact. Proper personal protective equipment and body
positioning techniques are required.
4.5 Hydraulic or Pneumatic Torque Wrench

Tighten each of the studs using the sequence shown in Appendix C**. Mark each stud with chalk or a
grease pencil as it is tightened so it is easy to verify that all studs have been tightened.
Repeat the torque pattern again to ensure studs are torqued to the proper value.
Torque wrenches can be heavy and bulky to handle. Consider using mechanical assistance /
additional personnel particularly when working in awkward positions.
! NOTE: Manual torque wrenches are designed only for tightening studs, NOT for loosening
them. Use of torque wrench for loosening studs could put it out of calibration.
Torque wrenches should be calibrated annually or more often if recommended by the manufacturer.
Calibration records, including before and after readings, must be provided by the company
performing the calibration, and must be kept on file to assist with determination of future calibration
schedules.
Torque wrenches should be re-set to zero when finished with as this will prolong the life of the spring
and assist to maintain calibration of the tool.
** Initially set wrench to 50% of specified torque and repeat sequence at 100%.
4.6 Hydraulic Tensioner

U.S. / Cdn. Sites:
Hydraulic Tensioners are preferred for tightening Class 600 and Class 900 flanges NPS 16 and larger.
The Hydraulic Tensioner Contractor shall participate in pre-job meeting prior to tightening flanges, as
detailed in section 4.1
Contact Asset Reliability if additional information on Hydraulic Tensioners is required.
a) Assemble the extra long studs (see Appendix A or Appendix B to determine the correct stud length)
through the flanges, leaving the extra length of each stud protruding on the same side of the flange.
! Note: When installing studs, the end of the stud with the extra threads should be accessible for
tensioner installation.
b) Referring to Appendix D or Appendix E, determine the correct tool for the stud diameter and fit one
tool to every second stud and assemble the interconnecting hoses as per the manufacturer's
instructions.
c) Find the value for pressure A (Appendix D or Appendix E) for the type of tensioning machine being
used.
d) Apply the specified hydraulic pressure to the tool.
e) Tighten down the hexagon nuts with an even hand pressure applied to the tommy bar.
f) Release the hydraulic pressure.
! Note: It is important not to exceed the maximum allowable ram stroke of the tool. Follow the
manufacturer's instructions to push back the rams into the tools before proceeding.
g) Repeat steps (d) to (f) again.
h) Transfer the tools to the second half of the studs (those not yet tightened).
i) Find the value for pressure B (Appendix D or Appendix E) for the type of tensioning machine being
used.
j) Repeat steps (d) to (g) again (All studs should now have been tightened twice).
4.7 Disassembly of Flanged Connections

Check that there is no pressure behind the flange. If there is, bleed off any gas or oil as applicable
before disassembly. Ensure proper Tag and Lockout procedures.
Unbolt the bolts and nuts in the reverse order of the numbering sequence shown in Appendix C.
Relieve tension in all the bolts/studs before removing the nuts to prevent an overstressing of the studs.
5.0 DEFINITIONS
Hydraulic Torque Wrench A machine that utilizes hydraulic pressure to rotate the nuts on studs or
bolts. The pressure shown on the gauge can be converted to a torque
value by utilizing the chart that accompanies the machine.
Hydraulic Tensioner A machine which utilizes hydraulic pressure to put longitudinal
pressure onto (stretch) studs. While the pressure is applied at the value
indicated on the accompanying chart, the stud nuts are hand tightened
against the flanges. When the pressure is released, the tension
remaining on the stud is equivalent to the pressure that would have
been created by rotating the nut to the pre-determined torque value.
6.0 LATEST REVISION

Rev. No. Description Date TOP Contact
(yyyy/mm/dd)
04 Review done by Lloyd McFadden, Trent Bertholet and Bruce Dupuis for 2009/03/11 Trent Bertholet
this TOPs applicability to LVP Oil Pipeline Systems (Keystone Pipeline)
line of business with only minor edits required.
7.0 APPROVAL
Name (Print) Signature Date
(yyyy/mm/dd)
TOP Trent Bertholet
Contact Specialist
Pipeline Integrity - Engineering Governance
Approver Dave Taylor
(Mgmt. Manager
Rep.) Pipeline Integrity - Engineering Governance
APPENDIX A
Tightening Methods
Standard Flanges, ANSI 600# Raised Face
Flange Size Stud Bolts Nut Flange Tightening Method Practical
Nominal Size Size X = preferred method Torque Values
(O.D.) x = acceptable method (lubricated)
NPS No. Diameter Min.Length Nominal Torque Hydraulic Hydraulic Min. Max.
of (inches) (inches) Size Wrench Torquing Tensioning Torque Torque
Bolts (inches) (ft./lb.) (ft./lb.)
2 8 5/8 4-1/4 1 1/16 X 92 108
3 8 3/4 5 1-1/4 X 166 185
4 8 7/8 6 1-7/16 X 258 297
6 12 1 7 1-5/8 X x 331 445
8 12 1-1/8 8 1-13/16 X x 515 641
10 16 1-1/4 8-3/4 2 X x 552 884
12 20 1-1/4 9 2 X x 589 884
16 20 1-1/2 12 2-3/8 x X 994 1551
20 24 1-5/8 13-3/4 2-9/16 x X 1306 1984
24 24 1-7/8 15-1/2 2-15/16 x X 2023 3087
30 28 2 17 3-1/8 x X 2686 3759
36 28 2-1/2 19-1/2 3-7/8 x X 4600 7435
42 28 2-1/2 23 3-7/8 x X 5887 7435
48 32 2-3/4 26-1/4 4-1/4 x X 7359 9926
Notes: 1) Extra long stud bolts are used for NPS 16 to NPS 48 to accommodate hydraulic tensioning
2) Torque values are based on ASME BPV Code Section VIII
3) Stud bolt material ASTM A320 Grade L7
4) Lubricant molybdenum disulphide grease (black/grey grease; trade name e.g. Felpro C670)
Gaskets
Application Type / Material Trade Names
Regular Flange Sealing Spiral Wound / Metal Ring + Flexitallic Style CG-304 / Flexite
non-asbestos winding
Insulation Kit Flat Ring (type F) / Fiber PSI Linebacker and Pikotek PGE
Reinforced Epoxy
APPENDIX B
Tightening Methods
Standard Flanges, ANSI 900# Raised Face
Flange Size Stud Bolts Nut Flange Tightening Method Practical
Nominal Size Size X = preferred method Torque Values
(O.D.) x = acceptable method (lubricated)
NPS No. Diameter Min.Length Nominal Torque Hydraulic Hydraulic Min. Max.
of (inches) (inches) Size Wrench Torquing Tensioning Torque Torque
Bolts (inches) (ft./lb.) (ft./lb.)
2 8 7/8 5-3/4 1 1/16 X 166 270
3 8 7/8 5-3/4 1-1/4 X 276 358
4 8 1-1/8 6-3/4 1-7/16 X 478 586
6 12 1-1/8 7-3/4 1-5/8 X x 534 586
8 12 1-3/8 8-5/8 1-13/16 X x 1030 1268
10 16 1-3/8 9-1/4 2 X x 1030 1268
12 20 1-3/8 10 2 X x 1086 1262
16 20 1-5/8 13-5/8 2-3/8 x X 1601 1878
20 20 2 16-1/2 2-9/16 x X 2870 3598
24 20 2-1/2 20-7/8 2-15/16 x X 4765 7183
30 20 3 23-7/16 3-1/8 x X 8242 12555
36 20 3-1/2 26-3/4 3-7/8 x X 13192 20143
42 24 3-1/2 29-1/2 3-7/8 x X 14369 20143
48 24 4 33-1/2 4-1/4 x X 23090 30296
Notes: 1) Extra long stud bolts are used for NPS 16 to NPS 48 to accommodate hydraulic tensioning
2) Torque values are based on ASME BPV Code Section VIII
3) Stud bolt material ASTM A320 Grade L7
4) Lubricant molybdenum disulphide grease (black/grey grease; trade name e.g. Felpro C670)
Gaskets
Application Type / Material Trade Names
Regular Flange Sealing Spiral Wound / Metal Ring + Flexitallic Style CG-304 / Flexite
non-asbestos winding
Insulation Kit Flat Ring (type F) / Fiber PSI Linebacker and Pikotek PGE
Reinforced Epoxy
APPENDIX C
Typical Stud Tightening Sequence
(Used for initial snug-up and/or when using a manual or hydraulic torque wrench)
1 9
13 5
7 16
11 3
4 12
15 8
6 14
10 2
Typical Flange Tightening Sequence

for an NPS 10, ANSI 600# (16 holes) Flange
NOTE: This is an example only. Continue until all studs have been tightened and re-checked.
APPENDIX D
Hydraulic Pressures Class 600 (PN 100) Flanges
(FOR USE WITH HYDRAULIC TENSIONERS)
Flexitallic Hydratight Tensioner Sweeny Slect-A-Torq H.T.I.

Tensioner Tensioner
Flange Tool Pressure Pressure Tool No. Pressure Tool Pressure Pressure
Size No. A B No. A B
NPS 16 3 12500 9600 SHTV 3 10100 VC150 14000 10800
NPS 20 3 14000 11000 SHTV 3 13500 VC162 17200 13200
NPS 24 4 13000 10000 SHTV 4 12600 VD188 14000 10800
NPS 30 4 15200 12000 SHTV 4 15400 VD200 17600 13500
NPS 36 6 14000 11000 SHTV 5 13500 VE250 17200 13200
NPS 42 6 16500 13000 SHTV 5 15400 VE250 22000 16900
NPS 48 7 16000 12300 SHTV 6 15400 VE275 17900 13800
1. Pressures in table based on maximum allowable tool pressure.
2. Values in Pressure B in table based on: Pr essure( B ) Pr essure( A)

1.3
3. All pressures are expressed in psi(g).
APPENDIX E
Hydraulic Pressure Class 900 (PN 150) Flanges
(For use with Hydraulic Tensioners)
Flexitallic Hydratight Tensioner Sweeny Slect-A-Torq H.T.I.

Tensioner Tensioner
Flange Tool Pressure Pressure Tool No. Pressure Tool Pressure Pressure
Size No. A B No. A B
NPS 16 3 11500 8600 SHTV 3 13000 FD150 17600 13500
NPS 20 3 15200 11800 SHTV 3 16000 FE162 15000 11500
NPS 24 4 14000 11000 SHTV 4 16000 FF188 15600 12000
NPS 30 4 16000 12300 SHTV 4 17000 FF200 19400 14900
NPS 36 6 17200 13000 SHTV 5 17000 FH250 15300 11800
NPS 42 6 17200 13000 SHTV 5 17000 FH250 19500 15100
NPS 48 7 17800 13700 SHTV 6 15400 FJ275 19600 15100
1. Pressures in table based on maximum allowable tool pressure
2. Values in Pressure B in table based on Pr essure( B ) Pr essure( A)

1.3
3. All pressures are expressed in psi(g)

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TRANSCANADA OPERATING PROCEDURE (PROCEDURE)

Title: Flange Bolt Tightening Procedures

TOP Contact: Trent Bertholet

4.1 Pre-Job Meeting

4.7 Disassembly of Flanged Connections

4.1 Pre-Job Meeting

4.2 General and Torquing Sequence

Responsibilities/Accountabilities: Pipeline, Mechanical, Contractor

4.3 Tool Selection

Responsibilities/Accountabilities: Pipeline, Mechanical, Contractor

4.4 Hammer Wrench

Responsibilities/Accountabilities: Pipeline, Mechanical, Contractor

4.5 Hydraulic or Pneumatic Torque Wrench

Responsibilities/Accountabilities: Pipeline, Mechanical, Contractor

4.6 Hydraulic Tensioner

Responsibilities/Accountabilities: Pipeline, Mechanical, Contractor

4.7 Disassembly of Flanged Connections

Responsibilities/Accountabilities: Pipeline, Mechanical, Contractor

6.0 LATEST REVISION

Typical Flange Tightening Sequence

Flexitallic Hydratight Tensioner Sweeny Slect-A-Torq H.T.I.

NPS 20 3 14000 11000 SHTV 3 13500 VC162 17200 13200

NPS 24 4 13000 10000 SHTV 4 12600 VD188 14000 10800

NPS 30 4 15200 12000 SHTV 4 15400 VD200 17600 13500

NPS 36 6 14000 11000 SHTV 5 13500 VE250 17200 13200

NPS 42 6 16500 13000 SHTV 5 15400 VE250 22000 16900

NPS 48 7 16000 12300 SHTV 6 15400 VE275 17900 13800

1. Pressures in table based on maximum allowable tool pressure.

2. Values in Pressure B in table based on: Pr essure( B ) Pr essure( A)

Flexitallic Hydratight Tensioner Sweeny Slect-A-Torq H.T.I.

NPS 20 3 15200 11800 SHTV 3 16000 FE162 15000 11500

NPS 24 4 14000 11000 SHTV 4 16000 FF188 15600 12000

NPS 30 4 16000 12300 SHTV 4 17000 FF200 19400 14900

NPS 36 6 17200 13000 SHTV 5 17000 FH250 15300 11800

NPS 42 6 17200 13000 SHTV 5 17000 FH250 19500 15100

NPS 48 7 17800 13700 SHTV 6 15400 FJ275 19600 15100

1. Pressures in table based on maximum allowable tool pressure

2. Values in Pressure B in table based on Pr essure( B ) Pr essure( A)

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