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ASME PCC-1-2022 Guidelines for Pressure Boundary Bolted Flange Joint Assembly, 2022
- CONTENTS
- FOREWORD
- ASME PRESSURE TECHNOLOGY POST-CONSTRUCTION COMMITTEE ROSTER
- CORRESPONDENCE WITH THE PCC COMMITTEE
- ASME PCC-1–2022 SUMMARY OF CHANGES
- 1 SCOPE
- 2 INTRODUCTION
- 3 TRAINING AND QUALIFICATION OF BOLTED JOINT ASSEMBLY PERSONNEL
- 4 CLEANING OF GASKET SEATING SURFACES OF FLANGES
- 5 EXAMINATION OF FLANGE AND FASTENER CONTACT SURFACES [Go to Page]
- 5.1 Examination of Gasket Seating Surfaces for Surface Finish
- 5.2 Examination of Gasket Seating Surfaces for Flatness
- 5.3 Examination of Fastener Contact Surfaces and Washers
- 5.4 Examination of Flange Nut or Washer Bearing Surfaces
- 6 ALIGNMENT OF FLANGE JOINTS
- 7 INSTALLATION OF GASKET
- 8 LUBRICATION
- 9 INSTALLATION OF BOLTS
- 10 TIGHTENING PROCEDURE
- 11 OPTIONAL PRACTICES
- 12 JOINT PRESSURE AND TIGHTNESS TESTING
- 13 RECORDS
- 14 JOINT DISASSEMBLY
- 15 REFERENCES [Go to Page]
- 15.1 API Publications
- 15.2 ASME Boiler and Pressure Vessel Code (BPVC)
- 15.3 ASME Standards
- 15.4 ASTM Publications
- 15.5 European Committee for Standardization Publication
- 15.6 ISO Publications
- 15.7 Japanese Standards Association Publication
- 15.8 MSS Publication
- 15.9 PIP Publication
- 15.10 SAE Publication
- 15.11 TEMA Publication
- 15.12 U.S. Department of Labor, Occupational Safety and Health Administration Publication
- 15.13 VDI Publication
- 15.14 WRC Publications
- 15.15 Other Publications
- Figures [Go to Page]
- Figure 8-1 Examples of Lubrication Application
- Figure D-2-1 Flange Circumferential Variation Tolerance, T1
- Figure D-2-2 Flange Radial Variation Tolerance, T2
- Figure D-3-1 Flange Surface Damage Assessment: Pits and Dents
- Figure D-3-2 Flange Surface Damage Assessment: Scratches and Gouges
- Figure D-4-1 RTJ Gasket Seating Surface Assessment
- Figure E-2-1 Centerline High/Low
- Figure E-2-2 Excessive Spacing Gap
- Figure E-2-3 Parallelism
- Figure E-2-4 Rotational Two-Hole
- Figure F-6.1.1.2.1-1 Pattern #1 (Star Pattern): 24-Bolt Basic Example
- Figure F-6.1.1.2.2-1 Pattern #1 (Star Pattern): 24-Bolt Modified Star Example
- Figure F-6.1.1.2.2-2 Modified Star Pattern With Multiple Tools
- Figure F-6.1.2.1-1 Pattern #2 (Quadrant Pattern): 24-Bolt Examples
- Figure F-6.1.2.2-1 Pattern #2 (Quadrant Pattern): 24-Bolt Accelerated Cross Example
- Figure F-6.1.3.1-1 Pattern #3 (Circular Pattern): 24-Bolt Example
- Figure F-6.1.3.2-1 Pattern #3 (Circular Pattern): 24-Bolt Step-by-Step Example
- Figure F-6.1.3.3-1 Pattern #3 (Simultaneous Multibolt Circular Pattern): 24-Bolt Step-by-Step Example (Two Tools)
- Figure J-5-1 Example of Bolt Grouping for a 48-Bolt Flange
- Figure P-4.6.1-1 Tapered-Hub-Type Flange
- Figure P-4.6.2-1 Slip-On-Type Flange
- Figure P-4.6.3-1 Lap Joint Flange
- Figure Q-4.5-1 24-Bolt, 24-Tool Example
- Figure Q-4.5-2 24-Bolt, 50% (12-Tool) Example
- Figure R-2.2-1 Example Long Assembly Record
- Figure R-2.2-2 Example Short Assembly Record
- Figure R-2.2-3 Example Medium-Length Assembly Record
- Figure R-2.2-4Example Multipart Tear-Off Tag
- Tables [Go to Page]
- Table A-1.4-1 Training Matrix
- Table A-2.1-1 Training of Fundamentals Curriculum
- Table A-2.2-1 Piping Endorsement Curriculum
- Table A-2.3-1 Powered-Equipment Endorsement Curriculum
- Table A-2.4-1 Heat Exchanger Endorsement Curriculum
- Table C-1 Recommended Gasket Seating Surface Finish for Various Gasket Types
- Table D-2-1M Flange Seating Face Flatness Tolerances (Metric)
- Table D-2-1 Flange Seating Face Flatness Tolerances (U.S. Customary)
- Table D-3-1M Allowable Defect Depth vs. Width Across Face (Metric)
- Table D-3-1 Allowable Defect Depth vs. Width Across Face (U.S. Customary)
- Table E-2-1 Common Alignment Tolerances
- Table F-4-1 Example Tightening Practices Based on Service Application
- Table F-6.1.1.1-1 Star and Modified Star Pattern Sequencing
- Table F-6.1.2.1.1-1 Quadrant Pattern Cross Sequence
- Table F-6.1.2.1.2-1 Quadrant Pattern Circular Sequence
- Table H-1M Bolt Root and Tensile Stress Areas (Metric Threads)
- Table H-1 Bolt Root and Tensile Stress Areas (Inch Series)
- Table J-6-1 Legacy Cross-Pattern Tightening Sequence and Bolt-Numbering System When Using a Single Tool
- Table L-1 ASME B16.5 Flange Bolting Information
- Table M-1.3-1 Recommended Washer Temperature Limits
- Table M-2.4-1 Chemical Requirements
- Table M-2.6.1-1 Dimensional Requirements for Metric Washers
- Table M-2.6.1-2 Dimensional Requirements for U.S. Customary Washers
- Table M-2.6.1-3 Dimensional Tolerances for Metric Washers
- Table M-2.6.1-4 Dimensional Tolerances for U.S. Customary Washers
- Table M-2.8.2-1 Sampling
- Table O-3.2-1M Reference Values (Target Torque Index) for Calculating Target Torque Values for Low-Alloy Steel Bolting Based on Unit Prestress of 1 MPa (Root Area) (Metric Series Threads)
- Table O-3.2-1 Reference Values (Target Torque Index) for Calculating Target Torque Values for Low-Alloy Steel Bolting Based on Unit Prestress of 1 ksi (Root Area) (Inch Series Threads)
- Table O-4.1-1M Pipe Wall Thickness Used for Following Tables (mm)
- Table O-4.1-1 Pipe Wall Thickness Used for Following Tables (in.)
- Table O-4.1-2M Bolt Stress Limit for SA-105 Steel Flanges Using Elastic–Plastic FEA (MPa)
- Table O-4.1-2 Bolt Stress Limit for SA-105 Steel Flanges Using Elastic–Plastic FEA (ksi)
- Table O-4.1-3 Flange Rotation for SA-105 Steel Flanges Loaded to Table O-4.1-2M/Table O-4.1-2 Bolt Stress Using Elastic–Plastic FEA (deg)
- Table O-4.1-4M Bolt Stress Limit for SA-105 Steel Flanges Using Elastic Closed Form Analysis (MPa)
- Table O-4.1-4 Bolt Stress Limit for SA-105 Steel Flanges Using Elastic Closed Form Analysis (ksi)
- Table O-4.1-5 Flange Rotation for SA-105 Steel Flanges Loaded toTable O-4.1-4M/Table O-4.1-4 Bolt Stress Using Elastic Closed Form Analysis (deg)
- Table O-4.1-6M Bolt Stress Limit for SA-182 F304 Steel Flanges Using Elastic–Plastic FEA (MPa)
- Table O-4.1-6 Bolt Stress Limit for SA-182 F304 Steel Flanges Using Elastic–Plastic FEA (ksi)
- Table O-4.1-7 Flange Rotation for SA-182 F304 Steel Flanges Loaded toTable O-4.1-6M/Table O-4.1-6 Bolt Stress Using Elastic–Plastic FEA (deg)
- Table O-4.2-1 Example Bolt Stress for SA-105 Steel Weld-Neck Flanges, SA-193 B7 Steel Bolts, and Spiral-Wound Gasket With Inner Ring (ksi)
- Table O-4.2-2 Example Assembly Bolt Torque for SA-105 Steel Weld-Neck Flanges, SA-193 B7 Steel Bolts, and Spiral-Wound Gasket With Inner Ring (ft-lb)
- Table P-5-1 Leak During Pressure Test
- Table P-5-2 Leak During Heat-Up or Initial Operation
- Table P-5-3 Leak Corresponding to Thermal or Pressure Upset
- Table P-5-4 Leak After Long-Term Operation
- Table P-5-5 Leak During Shutdown
- Form [Go to Page]
- Form P-3-1 Sample Flange Joint Leak Report
- MANDATORY APPENDIX I DEFINITIONS
- NONMANDATORY APPENDICES [Go to Page]
- NONMANDATORY APPENDIX A TRAINING AND QUALIFICATION OF BOLTED JOINT ASSEMBLY PERSONNEL [Go to Page]
- A-1 INTRODUCTION
- A-2 ACADEMIC TRAINING PROGRAM
- A-3 EXAMINATION PROGRAM
- A-4 QUALITY ASSURANCE
- NONMANDATORY APPENDIX B DESCRIPTION OF COMMON TERMS
- NONMANDATORY APPENDIX C RECOMMENDED GASKET SEATING SURFACE FINISH FOR VARIOUS GASKET TYPES
- NONMANDATORY APPENDIX D GUIDELINES FOR ALLOWABLE GASKET SEATING SURFACE FLATNESS AND DEFECT DEPTH [Go to Page]
- D-1 INTRODUCTION
- D-2 FLANGE FACE FLATNESS TOLERANCES
- D-3 FLANGE FACE IMPERFECTION TOLERANCES
- D-4 RTJ GASKETS
- D-5 REFERENCE
- NONMANDATORY APPENDIX E FLANGE JOINT ALIGNMENT GUIDELINES [Go to Page]
- E-1 CHECKS, MEASUREMENTS, OR VERIFICATIONS
- E-2 VERIFICATION METHODS AND TOLERANCES
- E-3 ALIGNMENT METHODS AND TOOLS
- E-4 ENGINEERING EVALUATION
- NONMANDATORY APPENDIX F JOINT-TIGHTENING PRACTICES AND PATTERNS [Go to Page]
- F-1 INTRODUCTION
- F-2 BOLT-LOAD CONTROL
- F-3 BOLT-LOAD VERIFICATION
- F-4 TIGHTENING PRACTICES
- F-5 TOOL SELECTION FOR LOAD CONTROL
- F-6 TIGHTENING PATTERNS
- F-7 DEVELOPING NEW PROCEDURES
- F-8 RTJ AND LENS-TYPE GASKETS
- F-9 HIGHLY COMPRESSIBLE SOFT GASKETS VULNERABLE TO UNEVEN COMPRESSION
- F-10 REFERENCES
- NONMANDATORY APPENDIX G SINGLE-STUD REPLACEMENT
- NONMANDATORY APPENDIX H BOLT ROOT AND TENSILE STRESS AREAS
- NONMANDATORY APPENDIX I INTERACTION DURING TIGHTENING
- NONMANDATORY APPENDIX J OPTIONAL PRACTICES FOR FLANGE JOINT ASSEMBLY [Go to Page]
- J-1 INTRODUCTION
- J-2 MEASUREMENT OF GAPS
- J-3 BOLT ELONGATION (BOLT STRETCH) MEASUREMENT
- J-4 START-UP RETORQUE
- J-5 GROUPED BOLTING FOR LARGE FLANGES
- J-6 ALTERNATIVE LEGACY CROSS-PATTERN TIGHTENING SEQUENCE AND BOLT-NUMBERING SYSTEM
- J-7 CONTROLLED DISASSEMBLY
- NONMANDATORY APPENDIX K NUT FACTOR CALCULATION OF TARGET TORQUE [Go to Page]
- K-1 COMMON TARGET TORQUE FORMULA
- K-2 ADDITIONAL INFORMATION ON TARGET TORQUE FORMULAS
- K-3 REFERENCES
- NONMANDATORY APPENDIX L ASME B16.5 FLANGE BOLTING INFORMATION
- NONMANDATORY APPENDIX M WASHER USAGE GUIDANCE AND PURCHASE SPECIFICATIONS FOR THROUGH-HARDENED WASHERS [Go to Page]
- M-1 WASHER USAGE GUIDANCE
- M-2 PURCHASE SPECIFICATION FOR THROUGH-HARDENED WASHERS
- NONMANDATORY APPENDIX N DEFINITIONS, COMMENTARY, AND GUIDELINES ON THE REUSE OF BOLTS [Go to Page]
- N-1 TERMS AND DEFINITIONS
- N-2 GENERAL COMMENTARY
- N-3 GUIDELINES FOR REUSE OF BOLTS AND NUTS
- N-4 GUIDELINES FOR REUSE OF GASKETS
- NONMANDATORY APPENDIX O ASSEMBLY BOLT STRESS DETERMINATION [Go to Page]
- O-1 INTRODUCTION
- O-2 ASSEMBLY BOLT STRESS SELECTION
- O-3 SIMPLE APPROACH
- O-4 JOINT COMPONENT APPROACH
- O-5 DETERMINING FLANGE LIMITS
- NONMANDATORY APPENDIX P TROUBLESHOOTING FLANGE JOINT LEAKAGE [Go to Page]
- P-1 INTRODUCTION
- P-2 SCOPE
- P-3 INVESTIGATIVE AND DIAGNOSTIC EVALUATION GUIDE
- P-4 FLANGE DESIGN AND ACCEPTABLE PRACTICE CONSIDERATIONS
- P-5 LEAKAGE PROBLEMS AND POTENTIAL SOLUTIONS
- P-6 REFERENCES
- NONMANDATORY APPENDIX Q CONSIDERATIONS FOR THE USE OF POWERED EQUIPMENT [Go to Page]
- Q-1 GENERAL GUIDANCE
- Q-2 PNEUMATIC AND ELECTRIC TORQUE WRENCHES
- Q-3 HYDRAULIC TORQUE WRENCHES
- Q-4 HYDRAULIC TENSIONERS
- Q-5 ESSENTIAL ELEMENTS OF TORQUE TOOL PERFORMANCE
- Q-6 REFERENCE
- NONMANDATORY APPENDIX R ASSEMBLY RECORDS MANAGEMENT [Go to Page]
- R-1 PURPOSES OF JOINT ASSEMBLY RECORDS
- R-2 MAINTENANCE OF JOINT ASSEMBLY RECORDS [Go to Page]
