High-Pressure Flange Integrity for Oil Refinery Bolting Application
The Basrah Oil Refinery, commissioned in the early 1970s, is a key part of Iraq’s refining infrastructure. Originally designed with a capacity of around 170,000 barrels per day (bpd), its output has declined due to war damage and aging facilities. Currently, it operates at approximately 210,000 bpd. A major modernization effort, known as The Basrah Refinery Upgrading Project is a major modernization effort, transforming the refinery by constructing new units adjacent to the existing facility and updating existing flange assemblies to enhance Iraq’s oil production ensuring long-term operational safety. These upgrades will increase gasoline and diesel production and quality as well as improving oil refinery efficiency of the complete facility.
INTRODUCTION
Boltight® engineers were consulted on the precise bolting of large metal flanges operating under high-pressure conditions. The project also faced other significant challenges such as following stringent technical requirements, limited local bolting expertise, and the necessity for coordination among key stakeholders, such as the Iraq Ministry of Oil, the EPC contractor JGC-Hyundai Engineering & Construction Consortium, and various subcontractors.
By providing advanced equipment, tailored training, and expert technical support, Boltight became an integral part of this upgrade project. Boltight supplied standard hydraulic bolt tensioners (T-Series) ranging from 1” to 2½”, hydraulic hoses, and air-driven pumps to meet technical requirements. They also hosted a custom on-site training program focused on theoretical sessions on bolting principles and safety. It also included hands-on exercises using 44” NPS flanges. Additionally, inclusive technical support covered Flange Management System (FMS) reviews, procedural documentation for tensioning, and precise load calculations.
The Boltight engineers corrected inaccurate load calculations by determining the exact residual loads required for the flanges and the appropriate loads to be applied during tensioning, also ensuring accuracy and efficiency in project execution. They also streamlined communication among stakeholders, eliminating delays and ensuring smooth project progress.
MORE ABOUT BOLTIGHT
Boltight standard hydraulic tensioners provide a quick, easy, and safe method for tightening large diameter bolts to high and accurate preloads. They feature high wear and corrosion-resistant surface treatment as well as internal pieces that compensate for joint misalignment.
Product benefits:
- Easy to install and remove
- Extremely durable due to surface coating of components (nitride)
- Tools can be connected in sequence to improve operation speed and ensuring even joint compression
At Nord-Lock Group, we also provide extensive training for distributors and end users to ensure successful implementation. Utilizing theoretical knowledge and hands-on practice, Boltight employees conducted an intensive training session for the operators, including a theoretical understanding of preload and operating principles; hands-on training to install and pressurize and tensioners; and how to troubleshoot any application-specific needs in the future.
CONCLUSION
The Basrah Oil Refinery is undergoing a major modernization effort to boost gasoline and diesel output, improve fuel quality, and ensure long-term operational safety. Boltight played a key role in the project by handling the precise bolting of large high-pressure flanges – an area challenged by strict technical standards, limited local expertise, and the need for coordination among major stakeholders and subcontractors.