Flange Bolt-Up Torque Sequence Log Worksheet
Bolt-up records prove each flanged joint was tightened to procedure. This worksheet lets you list joints, set a final target torque and see the staged pass values calculated automatically, then export the whole log to Excel.
| Joint / flange tag | Size and class | Number of bolts | Final target torque (ft-lb) | Pass 1 (30%) (ft-lb) | Pass 2 (60%) (ft-lb) | Pass 3 (100%) (ft-lb) | Technician | Date | Status | |
|---|---|---|---|---|---|---|---|---|---|---|
27 | 54 | 90 | ||||||||
27 | 54 | 90 | ||||||||
36 | 72 | 120 | ||||||||
53 | 105 | 175 | ||||||||
135 | 270 | 450 |
The 30, 60 and 100 percent passes follow a common star-pattern practice, often followed by a circular check pass. Always use the target torque from your approved procedure, gasket manufacturer or ASME PCC-1 calculation for the actual bolt, lubricant and gasket. The default values are examples only.
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How to use this worksheet
Add a row per flanged joint, pick the size and class, enter the number of bolts and the final target torque from your procedure. The worksheet calculates the 30, 60 and 100 percent pass values for the technician to follow. Update the technician, date and status as work progresses, then export the sheet to Excel or PDF for the commissioning dossier. Add a row note in the joint tag if a joint has a special gasket.
Why bolt-up uses several passes
A flange gasket compresses unevenly when bolts are tightened to full torque in one pass, which can leave the joint prone to leakage. Industry guidance such as ASME PCC-1 describes tightening in stages using a cross or star pattern, followed by sequential circular passes until the nut stops turning at final torque. Torque is only a proxy for bolt load, so friction, lubricant and nut condition change the real preload.
- Clean threads and lubricate nut faces as per procedure
- Follow the star pattern for each pass
- Finish with a circular check pass at final torque
- Record the lubricant and torque wrench serial number
Common mistakes
Using one torque value for every flange size, ignoring the lubricant's effect on the nut factor and skipping the final circular pass are the most frequent faults. Another is reusing damaged gaskets or fasteners. Compare the log to the hydrotest schedule so any joint marked as retorque is corrected before pressure is applied.
Frequently Asked Questions
Where do I get the target torque?
From a bolt load calculation per ASME PCC-1, the gasket manufacturer or your company procedure. It depends on bolt size, material, gasket type and lubricant, so no single table fits every joint.
Why 30, 60 and 100 percent?
It is a common staged pattern that brings the flange faces together evenly. Some procedures use different steps, such as 20, 50 and 100 percent, so change the multipliers in your procedure if needed.
Is torque enough to verify a joint?
Torque is an indirect measure. For critical joints, hydraulic tensioning or bolt stretch measurement gives better control, and a leak test confirms the result.
Can I export this for the customer?
Yes. Export to Excel or PDF from the tool. Add torque wrench calibration references and signatures in the document your customer expects.
If bolt-up and leak test records are rekeyed from paper into your ERP or CMMS, we can help set up a private workflow that captures them once.
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