The bolted flange joint assembly (BFJA) guidelines described in this document apply to pressure-boundary flanged joints with ring-type gaskets that are entirely within the circle enclosed by the bolt holes and with no contact outside the circle. By selection of those features suitable to the specific service or need, these guidelines may be used to develop effective joint assembly procedures for the broad range of sizes and service conditions normally encountered in industry. Guidance on troubleshooting BFJAs not providing leak-tight performance is also provided in this document (Appendix P). PCC-1-2019 replaces the previous edition, published in 2013. These guidelines are unique in the world for addressing issues with the assembly of pressure vessel and piping bolted joints from a standards perspective. They address subsequent advances in gasket technology, bolting assembly procedures, and calculation methods that have enabled the improvement of both the integrity and efficiency of bolted-joint assembly. PCC-1-2019 assembles current industry best practice into one easily-referenced location. Appendix A, “Training and Qualification of Bolted Joint Assemblers”, for example, provides guidelines for establishing uniform criteria for training and qualifying bolted joint assembly personnel, as well as guidelines for quality control of the program. In addition, Appendix F, “Alternative Flange Bolt Assembly Patterns”, adds faster methods of assembly that will achieve equal or better joint integrity than legacy methods. Applying such lessons learned could offer significant benefits in BFJA safety, efficiency and cost-reduction. Intended for assemblers, designers, supervisors, inspectors and instructors in all industries that employ pressure boundary bolted flange joints.

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PDF Pages	PDF Title
4	CONTENTS
7	FOREWORD
8	COMMITTEE ROSTER
9	CORRESPONDENCE WITH THE PCC COMMITTEE
11	ASME PCC-1–2019 SUMMARY OF CHANGES
14	1 SCOPE 2 INTRODUCTION 3 TRAINING AND QUALIFICATION OF BOLTED JOINT ASSEMBLY PERSONNEL 4 CLEANING AND EXAMINATION OF FLANGE AND FASTENER CONTACT SURFACES
15	5 ALIGNMENT OF FLANGED JOINTS 6 INSTALLATION OF GASKET
16	7 LUBRICATION OF “WORKING” SURFACES 8 INSTALLATION OF BOLTS 8.1 Bolt/Nut Specifications 8.2 Bolt Lengths
17	9 NUMBERING OF BOLTS 9.1 Numbering of Bolts When a Single Tool Is Used 9.2 Numbering of Bolts When Multiple Tools Are Used 10 TIGHTENING OF BOLTS 10.1 Tightening Method/Load-Control Technique
18	10.2 Bolt Elongation (Bolt Stretch) Determination Tables Table 1 Torque Increments for Legacy Cross-Pattern Tightening Using a Single Tool
19	Figures Figure 1 Indicator-Type Bolting for Through-Bolted Joints
20	Figure 2 Indicator-Type Bolting for Studded Joints
21	10.3 Tightening Method/Load-Control Technique Selection 10.4 Start-Up Retorque Table 2 Recommended Tool, TighteningMethod, and Load-Control Technique Selection Based on Service Applications
22	11 TIGHTENING SEQUENCE 11.1 Single-Tool Usage 11.2 Multiple-Tool Usage 11.3 Measurement of Gaps 12 TARGET TORQUE DETERMINATION 13 JOINT PRESSURE AND TIGHTNESS TESTING
23	14 RECORDS 14.1 Documentation of Authorized Agent 14.2 Joint Assembly Records Table 3 Legacy Cross-Pattern Tightening Sequence and Bolt-Numbering System When Using a Single Tool
24	Table 3.1 Alternative to Legacy Cross-Pattern Tightening Sequence and Bolt-Numbering System When Using a Single Tool
25	Figure 3 Example Legacy and Alternative to Legacy Numbering Sequences for 12-Bolt Joint
26	15 JOINT DISASSEMBLY Figure 4 Example of 48-Bolt Flange Bolt Grouping
27	15.1 Disassembly Load Control 16 REFERENCES 16.1 General 16.2 API Publications 16.3 ASME Publications 16.4 ASME Boiler and Pressure Vessel Code Figure 5 Example Short Assembly Record
28	16.5 ASTM Publications Figure 6 Example Medium-Length Assembly Record
29	Figure 7 Example Long Assembly Record
30	16.6 AWS Publication 16.7 European Committee for Standardization Publication 16.8 ISO Publications 16.9 U.S. Department of Labor/Occupational Safety and Health Administration Publication 16.10 Japanese Standards Association Publication 16.11 MSS Publication 16.12 PIP Publication 16.13 TEMA Publication 16.14 WRC Publications 16.15 VDI Publication 16.16 Other Publications
32	APPENDICES APPENDIX A TRAINING AND QUALIFICATION OF BOLTED JOINT ASSEMBLY PERSONNEL A-1 INTRODUCTION
33	Figure A-1 Appendix Procedure Flowchart
35	A-2 REQUIREMENTS FOR QUALIFIED BOLTING SPECIALISTS
36	Table A-1 Guidance for Work-Site Experience
37	Forms Form A-1 Example Reference Sheet
43	A-3 REQUIREMENTS FOR QUALIFIED SENIOR BOLTING SPECIALISTS
44	A-4 REQUIREMENTS FOR QUALIFIED BOLTING SPECIALIST INSTRUCTORS
45	A-5 QUALITY ASSURANCE
48	APPENDIX B DESCRIPTION OF COMMON TERMS B-1 TIGHTENING TERMS
49	B-2 GASKET TERMS B-3 TENSIONER LOAD/BOLT STRESS TERMS
50	Table C-1 Recommended Gasket Contact Surface Finish for Various Gasket Types APPENDIX C RECOMMENDED GASKET CONTACT SURFACE FINISH FOR VARIOUS GASKET TYPES
51	APPENDIX D GUIDELINES FOR ALLOWABLE GASKET CONTACT SURFACE FLATNESS AND DEFECT DEPTH D-1 FLANGE FACE FLATNESS TOLERANCES D-2 FLANGE FACE IMPERFECTION TOLERANCES D-3 RTJ GASKETS
52	Figure D-1 Flange Circumferential Variation Tolerance, T1 Table D-1M Flange Seating Face Flatness Tolerances (Metric) Table D-1 Flange Seating Face Flatness Tolerances (U.S. Customary)
53	Figure D-2 Flange Radial Variation Tolerance, T2 Table D-2M Allowable Defect Depth vs. Width Across Face (Metric) Table D-2 Allowable Defect Depth vs. Width Across Face (U.S. Customary)
54	Figure D-3 Flange Surface Damage Assessment: Pits and Dents Figure D-4 Flange Surface Damage Assessment: Scratches and Gouges
55	Figure D-5 RTJ Gasket Seating Surface Assessment
56	APPENDIX E FLANGE JOINT ALIGNMENT GUIDELINES E-1 GENERAL E-2 GUIDELINES FOR ALIGNING FLANGES
57	Figure E-1 Centerline High/Low Figure E-2 Excessive Spacing or Gap Figure E-3 Parallelism Figure E-4 Rotational-Two Hole
58	APPENDIX F ALTERNATIVES TO LEGACY TIGHTENING SEQUENCE/PATTERN F-1 EXISTING PROCEDURES
59	Table F-1 Summary Instruction on the Use of Alternative Assembly Procedures
61	Figure F-1 Legacy Pattern Numbering System Figure F-2 Alternative Assembly Pattern #1 (Modified Legacy Pattern)
62	Figure F-3 Alternative Assembly Pattern #2 (Quadrant Pattern)
63	Figure F-4 Alternative Assembly Pattern #3 (Circular Pattern) Figure F-5 Alternative Assembly Pattern #4 (Multibolt Legacy Pattern)
64	Figure F-6 Alternative Assembly Pattern #5 (Multibolt Quadrant Pattern) F-2 DEVELOPING NEW PROCEDURES F-3 RTJ AND LENS-TYPE GASKETS
65	Figure F-7 Alternative Pattern #1: Modified Legacy Pattern (Single Tool)
66	Figure F-8 Alternative Pattern #2A: Quadrant Pattern: Star Sequencing (Single Tool)
67	Figure F-9 Alternative Pattern #3: Circular Pattern (Single Tool)
68	Figure F-10 Alternative Pattern #4: Simultaneous Multibolt Pattern (Four Tools)
69	Figure F-11 Alternative Pattern #5: Simultaneous Multibolt Pattern Example (Two Tools)
71	APPENDIX G USE OF CONTRACTORS SPECIALIZING IN BOLTING SERVICES
72	Table H-1M Bolt Root and Tensile Stress Areas (Metric Threads) APPENDIX H BOLT ROOT AND TENSILE STRESS AREAS
73	Table H-1 Bolt Root and Tensile Stress Areas (Inch Series)
74	APPENDIX I INTERACTION DURING TIGHTENING I-1 ELASTIC INTERACTION I-2 COUNTERING THE EFFECTS OF ELASTIC INTERACTION
75	APPENDIX J CALCULATION OF TARGET TORQUE
77	APPENDIX K NUT FACTOR CALCULATION OF TARGET TORQUE
78	Table L-1 ASME B16.5 Flange Bolting Information APPENDIX L ASME B16.5 FLANGE BOLTING INFORMATION
79	Table M-1 Recommended Washer Temperature Limits APPENDIX M WASHER USAGE GUIDANCE AND PURCHASE SPECIFICATION FOR THROUGH-HARDENED WASHERS M-1 WASHER USAGE GUIDANCE
80	M-2 PURCHASE SPECIFICATION FOR THROUGH-HARDENED WASHERS
81	Table M-2 Chemical Requirements Table M-3 Dimensional Requirements for Metric Washers
82	Table M-4 Dimensional Requirements for U.S. Customary Washers
83	Table M-5 Dimensional Tolerances for Metric Washers Table M-6 Dimensional Tolerances for U.S. Customary Washers Table M-7 Sampling
84	APPENDIX N DEFINITIONS, COMMENTARY, AND GUIDELINES ON THE REUSE OF BOLTS N-1 TERMS AND DEFINITIONS N-2 GENERAL COMMENTARY
85	N-3 GUIDELINES
86	APPENDIX O ASSEMBLY BOLT STRESS DETERMINATION O-1 INTRODUCTION
87	O-2 ASSEMBLY BOLT STRESS SELECTION O-3 SIMPLE APPROACH O-4 JOINT COMPONENT APPROACH
89	O-5 DETERMINING FLANGE LIMITS
90	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)
91	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)
92	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.)
93	Table O-4.1-2M Bolt Stress Limit for SA-105 Steel Flanges Using Elastic–Plastic FEA (MPa) ASME B16.5 and ASME B16.47 Series A — Weld Neck Table O-4.1-2 Bolt Stress Limit for SA-105 Steel Flanges Using Elastic–Plastic FEA (ksi) ASME B16.5 and ASME B16.47 Series A — Weld Neck
94	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) ASME B16.5 and ASME B16.47 Series A — Weld Neck Table O-4.1-4M Bolt Stress Limit for SA-105 Steel Flanges Using Elastic Closed Form Analysis (MPa)
95	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 to Table O-4.1-4M/Table O-4.1-4 Bolt Stress Using Elastic Closed Form Analysis (deg)
96	Table O-4.1-6M Bolt Stress Limit for SA-182 F304 Steel Flanges Using Elastic–Plastic FEA (MPa) ASME B16.5 and ASME B16.47 Series A — Weld Neck Table O-4.1-6 Bolt Stress Limit for SA-182 F304 Steel Flanges Using Elastic–Plastic FEA (ksi) ASME B16.5 and ASME B16.47 Series A — Weld Neck
97	Table O-4.1-7 Flange Rotation for SA-182 F304 Steel Flanges Loaded to Table O-4.1-6M/Table O-4.1-6 Bolt Stress Using Elastic–Plastic FEA (deg) ASME B16.5 and ASME B16.47 Series A — Weld Neck
98	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) ASME B16.5 and ASME B16.47 Series A—Weld Neck
99	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) ASME B16.5 and ASME B16.47 Series A — Weld Neck
100	APPENDIX P GUIDANCE ON TROUBLESHOOTING FLANGED JOINT LEAKAGE INCIDENTS P-1 INTRODUCTION P-2 SCOPE P-3 INVESTIGATIVE AND DIAGNOSTIC EVALUATION GUIDE
101	P-4 CHECKLIST OF FLANGE DESIGN AND ACCEPTABLE PRACTICE CONSIDERATIONS
102	Form P-3.4 Sample Flange Joint Leak Report
104	Figure P-1 Tapered-Hub-Type Flange Figure P-2 Slip-On-Type Flange
105	Figure P-3 Lap Joint Flange P-5 LEAKAGE PROBLEMS AND POTENTIAL SOLUTIONS P-6 REFERENCES
106	Table P-1 Leak During Hydro-Test (LHT)
107	Table P-2 Leak During Heat-Up or Initial Operation (LIO)
108	Table P-3 Leak Corresponding to Thermal or Pressure Upset (LCU) Table P-4 Leak After Long-Term (Months of) Operation (LTO) Table P-5 Leak During Shutdown (LDS)
109	APPENDIX Q CONSIDERATIONS FOR THE USE OF POWERED EQUIPMENT Q-1 GENERAL GUIDANCE Q-2 PNEUMATIC AND ELECTRIC TORQUE WRENCHES Q-3 HYDRAULIC TORQUE WRENCHES
110	Q-4 HYDRAULIC TENSIONERS
112	Figure Q-4.5-1 24-Bolt, 24-Tool Example Q-5 REFERENCE
113	Figure Q-4.5-2 24-Bolt, 50% (12-Tool) Example

Published By	Publication Date	Number of Pages
ASME	2019	114


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Standard Title	ASME PCC-1-2019 – Guidelines for Pressure Boundary Bolted Flange Joint Assembly
Published Code	ASME
Publication Date	2019
Pages Count	114

ASME PCC 1 2019

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