BOLT TIGHTENING

PROCEDURE

CONTRACT NO:
DOCUMENT NUMBER: HEX-HTC-…… REV: 01 Page 1 of 15

OWNER: LONG SON PETROCHEMICALS CO., LTD

CONTRACTOR: HUTHACO COMMERCIAL SERVICE AND

CONSTRUCTION CO., LTD

DOCUMENT TITLE: PROCEDURE OF BOLT TIGHTENING

Rev Issued Date Prepared Reviewed Approved

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Table of contents
1. Objective ..................................................................................................................3
2. Scope ........................................................................................................................3
3. Reference Document ............................................................................................... 3
4. Forms .......................................................................................................................3
5. Definition .................................................................................................................3
6. Responsibility ..........................................................................................................3
7. Procedure steps ..................................................................................................... 4`
7.1. Machine operation safety ...................................................................................4
7.2. Danger to personnel ...........................................................................................4
7.3. Best practices when working on-site .................................................................5
7.4. Best practices when working on-site .................................................................5
7.5. Hazards of the Reaction Arm and how to use it safely. ...................................11
7.6. Hazards of the Reaction Arm and how to use it safely. ...................................12
8. Process flow chart .................................................................................................14

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1. Objective
To set an operational standard in accordance with the company's policies and
guidelines for practical work. This document will act as a guideline to ensure that
the task is performed safely with no impact on personnel and environment.
2. Scope
This work instruction covers the procedure for Bolt Tightening (Bolt Torque) and
applies to HTC companies

3. Reference Document
Note
4. Forms
CRAT-F-WI-SS01-01

Bolt Tightening Site

Survey Report CRAT-F-WI-SS01-02 Special

Service Work Sheet

CRAT-F-WI-SS01-03

Flange Tightening Report

5. Definition
Force applied to Nut/ Bolt which is set using a Torque wrench. Program
measuring the force acting on the Bolt and recommends tightening procedure,
tools to use, torque and pressure.

6. Responsibility
6.1. Division Manager is responsible for controlling and reviewing the cost,
the design and the technical documentation.
6.2. Engineer is responsible for the project and flange data collected from the
customer and uploaded in our software program. Data provided by the

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customer will be verified and the Engineer will report any issue or
concerns to the customer.
6.3. QC is responsible for the final inspection of the flange connection and
upload status of flanges into our system.
6.4. Supervisor/Foreman is responsible for the jobsite and to supervise
subordinates to ensure thatall work is carried out according to the
tightening procedure and flange management system..
6.5. Equipment Supervisor is responsible for the in and out going equipment
inspections and operation checks, Maintenance, and repairs.
6.6. Technician is responsible for strictly following each step of this
instruction, perform the work assigned by their supervisor and to look
after and maintain the equipment.
7. Procedure steps
7.1. Machine operation safety
Hydraulic tools are able to produce much higher torque easily, safely and
more efficiently. Tools which produce a large amount of pressure will
normally have a pneumatic or electrical system to help drive the pressure,
but this will also add safety factors and documentation depending on
which system is used. Whichever way is used; the operator must be aware
of safety when using hydraulic machines. In order to assess the risk, the
operator must study and use their knowledge and understanding of the
equipment to work safely. Hydratight will set up a training program for
any operator that requires knowledge on how to operate the equipment
and use it safely. Operators must read the working procedure, safety
precautions and maintenance procedure in order to increase their safety
awareness when working on-site.
7.2. Danger to personnel
Doing correct maintenance and using the tools correctly will not cause any
danger to the operator, the same can be said when working with hydraulic
equipment. If the tools are used incorrectly, thenthere may be a risk of
injury to the operator. Therefore, a risk assessment must be in place before
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using the equipment so that the operator can use the equipment safely and
reduce the risk of injury to safe level.
7.3. Best practices when working on-site
Personnel using the tools must work safely by following the best practices
below
1. Workers must read and understand the work procedure and tool
manual, and also pass the training course before being able to use the
tool.
2. Experienced and ECITB trained personnel must be in control of the
equipment.
3. Don't use electrical pumps in wet or explosive environments. If an
electrical pump has to be used, then make sure that it is properly
grounded and that a warning sign is in place
4. Watch out for pinch points on and around the reaction arm and flange.
5. Be aware of the dangers of pressures above 10000PSI/690 bar
5.1. Use tools, hydraulic hoses, connections and safety equipment
correctly.
5.2. Watch out for hydraulic leaks
5.3. Never use pressures above the maximum pressure of the RSL
6. Do not use hydraulic hoses which are damaged or kinked
7. Do not connect the power cord before completing the checks.
8. During maintenance, use Molycole 503 for lubrication.
9. Do not modify any tools and equipment.
7.4. Best practices when working on-site
1. Check whether the flange and gasket are in good condition. If either
the flange or gasket is not in good condition, then repair or replace
them before reassembling it.

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2. Insert the gasket in between the flanges while making sure that all
alignments are correct.
3. Check the condition of the stud bolt and nut by spinning the but on the
stud bolt to see whetherit spins smoothly. If the stud bolt and nut is not
in good condition, inform the client before replacing them.

4. Use an appropriate lubricant such as ANTI SEIZE.

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5. Use the right size and number of stud bolts to assemble the flange
according to the ANSI standard.

6. Mark the TORQUE TIGHTENING SEQUENCE onto the flange.

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7. Set up the torque pump by connecting the hydraulic hose to the Torque
Wrench, while making sure that the appropriate torque wrench is
chosen. Once complete, start tightening the bolts inthe TORQUE
TIGHTENING SEQUENCE using a torque of 30%.

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Note: If the Hydraulic Oil seal is worn out or damaged, it may cause
the hydraulic oil to leak out from the quick coupling. Make sure that
rags are in place to clean up any potential spills
8. Adjust the Torque to 60%, and tighten the nut as shown in step 7.

9. Adjust the Torque to 100%, and tighten the nut as shown in step 7 and
8

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10. Tighten the stud again at 100%, this time going around the flange. Do
not tighten in sequence.

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Note: - Once the job is complete, store all the tools and do
housekeeping. Complete the flange report and timesheet, and send it
the client along with the performance evaluation form.
7.5. Hazards of the Reaction Arm and how to use it safely.
The dangers points on the reaction arm are the space next to the reaction
arm and the gaps between the bolts (do not put hands or fingers in these
spots).

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7.6. Hazards of the Reaction Arm and how to use it safely.

1. Pump
Always check the hydraulic oil level before starting work. If the
hydraulic oil level is low, fill itup using the appropriate oil grade (ISO
#22 and #32).
Change the engine oil every 300 hours or whenever the oil is dirty.
Always check the Air Lubricator oil level before starting work. If the
oil level is low, fill it up using the appropriate oil grade (ISO #10).
2. Hoses, fittings and connections
1) As it is used in high pressure applications, keep away from
contamination and dust. After use, coat in oil to prevent rusting.
2) If a leak is found or there is damage to the hoses, fittings or
connectors, immediately stop work and fix it.
3. Torque wrench
1) Check the cleanliness and apply lubricant to reduce rust after every
use

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2) After 300 hours of usage; take apart, clean and apply grease to all
components

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8. Process flow chart

Site Survey

Arrange Tools and Check Bolt Tightening Site

Tension Value Survey Report & generated
work instruction

Tool Installation with Stud Bolt

Tightening 30% of Torque Value

Tightening 60% of Torque Value

Tightening 100% x 2 times

Inspection

House Keeping

Complete

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-Special Service Work

Sheet
-Flange Tightening
Report

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