D R A

IN
19-A
P R - 2 018
PRINT
ED
WHEN 1 / 19
LLED
NCONTRO
 Page 2 of 19

D R A
IN9-APR- 18
1
2 0
PRINT
ED
WHEN 2 / 19
LLED
NCO NTRO
 Page 3 of 19

ONSITE PROCEDURE
HYDRAULIC BOLT TENSIONING

Title: HYDRAULIC BOLT TENSIONING.

Document No: TS-MS-HBT-1.2-Rev1

1 28.03.2015 Revised KM JM PCA

0 26.09.2014 Original Issue MA JM PCA
Prepared Verified Approved
Rev No Date Description
ORGINATOR HSEQ MGMT

[Type here]
D R A
IN
19-A
P R - 2 018
PRINT
ED
WHEN 3 / 19
LLED
NCONTRO
 Page 4 of 19

TABLE OF CONTENTS
1.0 Scope

2.0 Introduction

3.0 References

4.0 Hydraulic Tensioning Kit

5.0 Technician Qualification

6.0 Safety

7.0 Pre-Job Check List

8.0 Tool Setup & Operation

9.0 Steps Explained

10.0 Tap Test

11.0 Typical Tensioning Methods

12.0 Joint Completion Report

13.0 Flange Tag

Appendix 1 – Joint Completion Report Format

Appendix 2 – Sample Pump Calibration Certificate
Appendix 3 – Typical Tensioning Calculation Sheet – BTS Software output
Appendix 4 – Technician Training Certificate Sample.
Appendix 5 – Data Sheet of CTST and Tensioning Pump.

1.0 SCOPE
D R A
IN
Doc no. TS-MS-HBT-1.2-Rev1 Page 2 of 17 Bolt Tensioning Method Statement
R - 2 018
P
19-A PRINT
ED
WHEN 4 / 19
LLED
NCONTRO
 Page 5 of 19

The purpose of this document is to describe the steps involved in controlled tightening of a joint using
Hydraulic Tensioning Method. All technicians must read and understand this document prior to the job for a
successful and safe completion of the tensioning activity.

2.0 INTRODUCTION
Tensioning is a controlled bolt tightening method in which the bolt stretch is achieved by directly stretching
the stud bolt & turning the nut down to retain the stress induced. This is done by a hydraulic Tensioning Tool.
In a hydraulic Tensioning Tool the load / stress induced to the bolt is controlled by the hydraulic pressure
applied and the type & size of the Tensioning Tool size.

In Bolt Tensioning there are two types of Load Loss will be experienced during the Tensioning process. The
first one is when the Load is Transferred from the Tensioning Tool to the Bolt – this is due to the deflection
of the threads between the bolt & nut and the embedment on Nut on seating surface. The second Load Loss
is dependent on the number of tools used simultaneously and this is termed as Cross-Loading. We can
reduce the impact of the first one (Load Transfer Loss) by repeating the tensioning process 3 times on each
setting. The Cross-Loading loss can be avoided by use of 100% Tensioning process (ie a tool on every bolt
tightening simultaneously). Practically 50% (ie a tool on every other bolt) is the preferred alternative and in
this case by using higher tool pressure for the first set of 50% bolts as compared to the second set of 50%
bolts will be able to compensate for the cross-loading loss. In our Procedure we therefore use A Pressure &
B Pressure . Tentec BTS Software takes these into account in the calculation protocol and provides the Tool
Pressure based on the Tensioning Method adopted.

3.0 REFERENCES
ASME PCC-1 Guidelines for pressure Boundary Bolted Flange Joint Assembly
SAEP-351 Saudi Aramco Bolted Flange Joints Assembly
ASME B16.5 Pipe Flanges and Standard Fittings
ASME B31.3 Process Piping
ASME B16.47 Large Diameter Steel Flanges
Tentec Training courses for MJI10, MJI18, MJI19

4.0 TENSIONING KIT

Normally a Typical Hydraulic Tensioning Kit consist of the below items.

a. Hydraulic Tensioning Pump - 25000 Psi – qty 1 per crew operation

b. CTST Tensioning Tool (Puller, Load Cell, Bridge, NTS) – qty (25% or 33% or 50% or 100% cover)
c. Inter Connecting Hoses – Tool qty – 1 (as minimum)
d. Link Hose to connect Pump to Tool Harness – qty 1 per crew operation
e. Tommy Bars to suit the Tool Model

D R A
IN
Doc no. TS-MS-HBT-1.2-Rev1 Page 3 of 17 Bolt Tensioning Method Statement
R - 2 018
P
19-A PRINT
ED
WHEN 5 / 19
LLED
NCONTRO
 Page 6 of 19

Tommy Bar - Puller

Tommy Bar - Socket

5.0 TECHNICIAN QUALIFICATION

Hydraulic bolt tensioning is a critical activity which should be carried out only by trained and certified
personnel. All Sendan Tentec technicians have undergone our internal training modules listed below.

Module 10 - Bolted Joint Integrity & Manual Torque Tightening

Module 18 - Bolted Joint Integrity & Hydraulic Tensioning
Module 19 - Bolted Joint Integrity & Hydraulic Torque Tightening

Sample training certificate attached on appendix.

6.0 SAFETY
D R A
IN
Doc no. TS-MS-HBT-1.2-Rev1 Page 4 of 17 Bolt Tensioning Method Statement
R - 2 018
P
19-A PRINT
ED
WHEN 6 / 19
LLED
NCONTRO
 Page 7 of 19

General Safety Precautions

 Always wear recommended PPE during the bolt tightening activity. (Suitable coveralls, Hard hat,
safety boot, hand gloves, earplugs and safety goggles as a minimum)
 Always make sure the technicians have sufficient training and experience on the specified job and
tool usage.
 Carefully read and understand the operation and maintenance manual of the equipments before
using them.
 Always ensure that all personnel in the near vicinity are aware that pressurisation of high pressure
equipment is about to take place. Cordon off the work area to avoid unauthorized entry of
personnel.
 Always make sure a Permit to Work is available before starting the work and check the PTW for
any special safety requirements.
 Make sure the technicians doing the job participate in the Tool Box Talk before starting the work
and proper records are maintained for the same.
 The technicians must read the Job Safety Analysis for the specific task before starting the job.
 Makes sure the technicians attend the site specific safety training and proper id cards are in place
before entering the site.

Task Specific Safety Precautions

 Never exceed the maximum working pressure of the bolt tightening system. 21,750 psi. (1500 bar)
 Do not sharply bend or kink the hose. Sharply bending or kinking hose can lead to premature hose
rupture. Try to avoid contact of the hose against any sharp objects.
 Do not drop sharp objects on to the hydraulic hose, do not drive any type of vehicle over hydraulic
hose. Doing so will cause internal hose damage and lead to premature hose failure.
 Never lift tools by the hydraulic hose or hydraulic connections.
 Always make sure correct tool pressure values are available for the joint to be tightened. If the value
is not supplied by the client then make sure to avail proper calculated value Data Sheet before
application of the tools.
 Before applying pressure make sure all the hydraulic hoses are properly connected. Check all the
coupling connections.
 While unbolting joints, always make sure there is no internal pressure in the line and the line is
purged and free from toxic gases.
 Make sure the equipment is tested and in working condition. The pump should have a valid
calibration certificate.
 Tool Setting - Ensure the Tool Bridge sit fully and securely on the surface around the nut. Puller
engagement should be minimum 1 x the bolt dia on the free thread while the other end of the bolt is
fully engaged to the reaction nut or threaded hole. Puller should fit on the thread snuggly – if in
doubt check the thread pitch and confirm. During operation never put body parts between the
moving component of the tool and stand in line of pressured direction.
 Working Crew – Normally one crew consist of two persons one handling the pump and the second
person handling the Tensioning Tool under pressure. Communication both verbal and visual must
be maintained at all times between the tool handler and remote control/pump operator. The tool
must not be energised without notification from the tool handler. Where the tools used is large size
or the qty of tools deployed is more than 24 per joint or the access around the joint demands it is
recommended to add 1 or 2 more persons to the crew. This is handled on case to case basis.

7.0 PRE-JOB CHECK LIST

D R A
IN
Doc no. TS-MS-HBT-1.2-Rev1 Page 5 of 17 Bolt Tensioning Method Statement
R - 2 018
P
19-A PRINT
ED
WHEN 7 / 19
LLED
NCONTRO
 Page 8 of 19

Tensioners

 The correct model & quantity of Tensioners with appropriate conversion kit to suit the flange and
bolt size have been selected for the application. Make sure the tools are in good usable condition
and tested.

Hydraulic Hose

 Make sure the Hoses are in good condition and is free from any damage. Look for any crushing,
cuts or kinks in the hose. Check the QD Fittings to ensure the self sealing points are in tact and the
threaded connections are tight and the fittings are clean, free of any dirt /dust.

Tensioning Pump

 Check the hydraulic oil level of the tank shows sufficient quantity of oil in good usable quality.
 Make sure the pump has a valid calibration certificate for its gauge.
 Make sure the availability of proper air or electric supply to the pump (as the case may be). If we
are using an air pump then make sure the air hoses are connected properly with whip checks and
Clips.

Joint to be Tightened

 The correct size of bolt is used for the flanges to be tightened and all the bolts are of same material.
 Correct gasket is used and the gasket is not damaged.
 Ensure both the mating flange faces are clean and free from any scars or damage.
 The correct length of Stud is protruding from the nut top surface. The side where the Tensioner Tool
is fitted the bolt should have minimum 1 x Dia protruding while the other side of the bolt should
maintain minimum protrusion of 2 to 3 threads past the nut top face.

D R A
IN
Doc no. TS-MS-HBT-1.2-Rev1 Page 6 of 17 Bolt Tensioning Method Statement
R - 2 018
P
19-A PRINT
ED
WHEN 8 / 19
LLED
NCONTRO
 Page 9 of 19

 Both the flanges are aligned properly with even gap on all sided and all the bolts are hand tight.
 There should be no undue separating external force on the flanges to be tightened.

Safety

 Make sure all the technicians have proper PPE for the job.
 Check PTW is available and is signed by all the relevant people.
 Check the work location and identify the nearest Muster point, fire alarm location, first aid point and
the wind direction.
 Make sure the line is free from any internal pressure, purged and free from any toxic gases.
 Make sure all connections are well secured
 Work area is cordoned off or adequately protected from direct exposure to other people in the
vicinity
 Correct Joint tensioning Data Sheet with calculated tool pressures are readily available

D R A
IN
Doc no. TS-MS-HBT-1.2-Rev1 Page 7 of 17 Bolt Tensioning Method Statement
R - 2 018
P
19-A PRINT
ED
WHEN 9 / 19
LLED
NCONTRO
 Page 10 of 19

8.0 TOOL SETUP & OPERATION

D R A
IN
Doc no. TS-MS-HBT-1.2-Rev1 Page 8 of 17 Bolt Tensioning Method Statement
R - 2 018
P
19-A PRINT
ED
WHEN 10 / 19
LLED
NCONTRO
 Page 11 of 19

9.0 STEPS EXPLAINED BELOW:

 Place Nut Rotating Socket over nut.

 Place Bridge + Load Cell assembly to go over & around the Nut Running Socket.
 Thread the Puller through the Load Cell and screw down onto bolt ensuring its free.
(If Puller gets struck or bottoms out on nut, then the bolt/nut assembly has issue – check and
correct before proceeding further.)
 Repeat above steps on every alternate bolt around the flange (for 50% tensioning
procedure).
 Connect one tool to another using Interconnecting hose to make a Harness setting around
the flange. The last tool and the first tool will not be connected using inter connecting hose.
 Connect the Link Hose to the open fitting end of the first tool.
 Connect Link Hose to Pump.
 Connect Pump to air after draining the air supply of any condensed water (min. pressure 60
psi. max pressure 90 psi at a min. 60 cfm).

OPERATING INSTRUCTIONS:
 Ensure the setup above is fully correct in all aspects.
 Set output hydraulic pressure using air regulator – increasing the sir pressure increases
output hydraulic pressure.
 Close STOP Valve to set the Pump for the required pressure. At this stage disconnect the
link hose from the Pump temporarily. Reconnect once the required Pump pressure is set.
 Ensure the tools are within view of Pump operator. Ensure no one stands in line with bolt
axis – which is called the pressured direction.
 Open Air Valve slowly and allow Pump start to build pressure.
 Apply a nominal pressure of 1000-1500 psi & hold. Check all hoses connections and tools
for any leaks and correct if there be any after depressurization.
 Note that Every Tool has limitation on the Maximum Stroke of its hydraulic ram. Check data
sheet and never exceed it,.
 If the tool stroke is close to maximum stroke, then hold the pressure at this level by closing
the air inlet valve. Please note that this need not happen on all tools. Even if the stroke limit
is reached on one of the multiple tools employed this step has to be followed. Using the
Tommy Bar, turn socket until nut is snug tightened on flange face. Go around the flange and
snug tighten all nuts. Following this open the STOP Valve. Using a Tommy Bar of the Puller
turn the Puller to mechanically force hydraulic Ram down so that the stroke is reset to 0.
Close the STOP Valve and the tensioning process has to be started again.
 Repeat the above steps until the nuts are tightened to the required Tool Operating A
Pressure (as mentioned in the Tensioning Calculation Data Sheet – refer Appendix 3 ).
 To reduce the Load Transfer Loss without taking the tools off the current set of bolts repeat
the tightening of the nuts 2 more times with Tool Operating A Pressure – at each stage
ensuring that the tools are not over-stroked.
 On completion of the above leaving the STOP valve open, using tommy bar turn the Puller to
force the Hydraulic Rams down, thereby setting the stroke to 0 level.
 Dismantle the Tensioners from the current set of bolts and transfer them to the remaining
50% of bolts which are to be tightened. It is typical to call the first set of bolts tightened as
odd bolts (ie 1, 3, 5 …) and the second set of bolts as even (2, 4, 6 …).
 Follow the tightening process as explained above until the 2 repeat tightening steps are
completed. This time using Tool Operating B Pressure (as mentioned in the Tensioning
Calculation Data Sheet – refer Appendix 3).
 After completing the 2 cycles of Tensioning – ie first cycle at A Pressure and Second at B
Pressure, dismantle 2 adjacent tensioner tools to expose one of the odd bolts tightened with
A Pressure. Choose the one where a Load Test on it would provide the most reliable result
for the joint configuration.

D R A
IN
Doc no. TS-MS-HBT-1.2-Rev1 Page 9 of 17 Bolt Tensioning Method Statement
R - 2 018
P
19-A PRINT
ED
WHEN 11 / 19
LLED
NCONTRO
 Page 12 of 19

ASSURANCE TEST (OR) BREAK LOOSE TEST

Cross-Loading loss results in the odd bolts to loose load when additional loads are induced on the
even bolts when 50% tensioning process is followed. To ensure the first 50% of bolts have retained
the required Residual Bolt Load (as per the Calculation Data sheet) an assurance test or a break
loose or is required. Follow the steps below:
 Assemble one tensioner tool to the exposed odd bolt & connect only this tool with the Link
hose to Tensioner Pump.
 Pressurize the tool slowly whilst the Nut Rotating Socket under this tool is subjected to
manual loosening force with the help of tommy bar. Do not exert more than the force used to
tighten in the first place. Do not hammer the tommy bar or use extensions on them. Increase
the tool pressure gradually until the nut triggers to turn. Hold the pressure and double check
the nut has come loose or not. It has to be loose before you record the Pressure at which
this trigger happened.
 At this point of nut movement, take a note of pump pressure.
 Before depressurization tighten down the nut with the socket under the same pressure.
 If the tool pressure is equal to or greater than B Pressure then break loose is achieved and
the assurance test is Passed.
 If the Tool Pressure recorded is lower than B Pressure then the Assurance Test has failed
and the Tensioning process has to be repeated on all bolts following the same procedure
explained above. This is not a common requirement unless the joints had to move prior to
gasket and bolt loading or in rare instances of RTJ or Lens Ring joints or joints with external
separating force where bulk of the bolt load applied might have been lost to overcome the
joint resistance.
10.0 TAP TEST
 This is a test to find out any lose bolts after the tensioning process. With a small peen
hammer tap all the bolts on its end and make sure we are getting uniform sound from all the
bolts. Any lose bolts will have a low/ different sound. Any lose bolts found out in this test
should be tightened again to the original value. It is always advisable to do the tap test in
the presence of client QC person and get it recorded on the final Joint Completion Report.
 Once the assurance test is Passed & the Tap Test confirms - the tools & equipment can be
removed from the flange.
11.0 TYPICAL TENSIONING METHODS

Typical 100% Tensioning Typical 50% Tensioning

For methods using less than 50% Tensioning Method contact Tentec.

D R A
IN
Doc no. TS-MS-HBT-1.2-Rev1 Page 10 of 17 Bolt Tensioning Method Statement
R - 2 018
P
19-A PRINT
ED
WHEN 12 / 19
LLED
NCONTRO
 Page 13 of 19

12.0 JOINT COMPLETION REPORT

See the Appendix for the Joint Completion Certificate Report. This is a full record of the joint details, torque
value used, equipment details and details of the technicians who carried out the job. The report should be
filled and get it signed from the client after the job. There is a unique identification number for each joint
completion certificate.

13.0 FLANGE TAG

After tightening the joint we need to put a metallic flange tag with the joint details, to show that the flange is
tightened. The joint completion certificate number will be marked on the tag for cross reference.

D R A
IN
Doc no. TS-MS-HBT-1.2-Rev1 Page 11 of 17 Bolt Tensioning Method Statement
R - 2 018
P
19-A PRINT
ED
WHEN 13 / 19
LLED
NCONTRO
 Page 14 of 19

APPENDIX - 1

D R A
IN
Doc no. TS-MS-HBT-1.2-Rev1 Page 12 of 17 Bolt Tensioning Method Statement
R - 2 018
P
19-A PRINT
ED
WHEN 14 / 19
LLED
NCONTRO
 Page 15 of 19

APPENDIX – 2

D R A
IN
Doc no. TS-MS-HBT-1.2-Rev1 Page 13 of 17 Bolt Tensioning Method Statement
R - 2 018
P
19-A PRINT
ED
WHEN 15 / 19
LLED
NCONTRO
 Page 16 of 19

APPENDIX - 3

APPENDIX - 4
D R A
IN
Doc no. TS-MS-HBT-1.2-Rev1 Page 14 of 17 Bolt Tensioning Method Statement
R - 2 018
P
19-A PRINT
ED
WHEN 16 / 19
LLED
NCONTRO
 Page 17 of 19

TECHNICIAN TRAINING CERTIFICATE SAMPLE

D R A
IN
Doc no. TS-MS-HBT-1.2-Rev1 Page 15 of 17 Bolt Tensioning Method Statement
R - 2 018
P
19-A PRINT
ED
WHEN 17 / 19
LLED
NCONTRO
 Page 18 of 19

APPENDIX 5

D R A
IN
Doc no. TS-MS-HBT-1.2-Rev1 Page 16 of 17 Bolt Tensioning Method Statement
R - 2 018
P
19-A PRINT
ED
WHEN 18 / 19
LLED
NCONTRO
 Page 19 of 19

APPENDIX – 5

D R A
IN
Doc no. TS-MS-HBT-1.2-Rev1 Page 17 of 17 Bolt Tensioning Method Statement
R - 2 018
P
19-A PRINT
ED
WHEN 19 / 19
LLED
NCONTRO