METHOD STATEMENT

Title : Method Statement for Flange Tightening

Date : 21-12-2009. Revision -04

Client :

Consultant:

Contractor:

Project:

Rev:03- 1. Page 2: Para 2 is added

15-06-11 2. Page 2: Para 3 is amended
3. Page 2 Para4 is amended and cautions has been added
4. Page 2 Para5 , sketch has been added.
5. Page 3 Para 11 is removed.

Rev04 1 Torque Level has been added for Flat face flanges as well with TF gasket or Krol / Ziller
2-07-2012 Gasket.

Prepared by: Ali Assi, Technical Manager

Document No: AQAP-MS-002

Ref: AQAP-MS-002 Page 1 of 5

 METHOD STATEMENT FOR
FLANGE TIGHTENING
1 Scope:

This method statement covers the instructions for flange tightening at site for all diameters
and both grooved face flanges (with O ring gasket) and flat face flanges (with EPDM /
Compressed Asbestos Gasket). Moreover, this document outlines also the maximum
recommended torque value that can be applied on the GRP flanges.

2 Instructions:

1. Thoroughly clean the flange and the O ring groove or EPDM/ CA gasket.
2. Check if the gasket has been stored in a manner that prevents creases or warp
3. Check that during both storage and handling, the sealing surfaces of the gasket are
not damaged and are free of debris or surface contamination.
4. Position the gasket in the groove or on the face of the flange for EPDM/CA gasket
and secure in position, if necessary, with small strips of adhesive masking tape.
Caution1: DO Not tape the gasket in place in such a way that the tape runs across
the sealing surface. This leaves potential leak paths across the gasket face.
Caution2: DO NOT glue or stick the gasket in place with a material that will
contaminate the sealing surfaces once the gasket is put into operation.
Caution3: DO NOT assume that gasket, put in place before the flange is positioned,
will automatically stay in position.
5. Make sure that the two flanges or connecting flange with valve or expansion joint is
well aligned with GRP flanges. Make sure that the two mating flanges touch each
other from inside or a gap of maximum 2-3mm should be allowed. Any
misalignment or more gaps would require high bolt torque and could lead to high
stress at flange and could cause damage.

Ref: AQAP-MS-002 Page 2 of 5

 6. Insert bolts, washers, and nuts. All hardware must be clean and lubricated to avoid
incorrect tightening. Washers must be used on all GRP flanges.
7. Using a torque wrench, tighten all bolts to 35 N-m (20 N-m for small dia pipes <= 250)
torque, following standard flange bolt tightening sequences shown in figure 2.0.
8. The below table is showing the minimum and maximum torque level. Minimum level
is required to achieve the sealing, maximum level is the maximum allowable for
flange.

GRP Flanges Groove Face with O Ring Gasket

DN Min Torque Level (N.m) Max Allowable Torque
Level
25 100 20 30
150 300 20 40
350 - 600 34 70
650 -1000 34 80
1050 - 1200 34 110
1250 - 1800 68 125
1250 - 1800 68 125

GRP Flanges Flat Face with TF Gasket or EPDM (Krol & Ziller) Gasket
DN Min Torque Level (N.m) Max Allowable Torque
Level
25 80 20 30
100 20 35
150 200 30 50
250 30 55

Ref: AQAP-MS-002 Page 3 of 5

 300 35 70
350-500 60 100
600-800 100 170
900-1100 160 220
1200-1400 200 300

9. Repeat this procedure, raising the bolt torque until the flanges almost touch at their
inside edges or maximum bolt torque. Do not exceed this torque without consulting
AQAP for advice.
10. Uniform pressure should be established over the flange face by tightening bolts in 7
N.m increments according to the sequence shown in figure 2.0. For flanges with
more than 20 bolts, similar altering bolt tightening sequences shall be used. (As per
ASTM D 4024-00)
11. Check bolt torque one hour later and adjust as seen necessary to the maximum
torque.
Figure 1: Flange Joints Grooved Face

Figure 2: Flange Joints Flat Face

Ref: AQAP-MS-002 Page 4 of 5

 Figure 3: Bolt Tightening Sequence

Ref: AQAP-MS-002 Page 5 of 5