assembly and tightening of bolted connections
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7/25/2019 Assembly and Tightening of Bolted Connections
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Team ECC is a joint venture between
CB&I Lummus and Toyo Engineering Corporation
Assembly & Tightening ofBolted Connections
hell ECC !roject " #ovember $%%
I# ACC'()A#CE *IT+ !(',ECT !ECI-ICATI'# E.%%%%%.!I.//0/.%%%
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Course 'bjectives
Everyone will leave this class understanding1
-lange Identification2
3as4et Inspection2 Correct Lubricant 5sage2
Application of Correct Tor6ue Load2
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Legislation
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7uote1. “Flange torque tightening/bolt
tensioning is a specialist skill”.
'nly trained, certified and competent
personnel should underta4e tor6ue
tightening8carry out bolt tensioning and use
e6uipment which is correctly maintained andcalibrated
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'bjectives
Competence In The 5se 'f A 9anual Tor6ue *rench
“Right First Time”
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The Bolted ,oint
A bolted joint has the following components1 -langes
tudbolts with #uts
3as4ets or eal2
The purpose of these components when used correctly is
to join two pieces of pipewor4 together without lea4age
of the contained product
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Behaviour of #uts and Bolts
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#uts & Bolts
Bolt is :li4e a spring;
pring creates compression
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Behaviour 'f #uts & Bolts
#ut Tightened " Bolt tretches " Tries To (eturn
C(EATE C'9!(EI'#
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Behaviour 'f #uts & Bolts
Bolt 9aterial %2$< proof stress =!I> =#8mm$>
B/?%@%%% /$
L/ ?%@%%% /$
B.class ?$%%%
$%%
B. class $ %%%.%%% 00./
3rade 2 ?%%% 00
3rade ?%2 ?0%%% %
3rade ?$2 ?@%%% ?%
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Identification of #uts & Bolts
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Types of 3as4et in ECC !roject
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piral *ound 3as4ets
Application1?2 (aised face flanges2
$2 +igh temperature & pressure service2
02 Corrosive or toDic medium2
Can be Retightened
B5T #'T (E.5E)
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piral *ound 3as4ets
piral *ound 3as4et =*3>
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piral *ound 3as4et
!roduct 7uality 8 Inspection
It is relatively easy to scratch or score graphite based sealing products
during handling2 mall scratches scores or indents are acceptable
on *3 provided that the graphite is not removed2 5pon
compression of the gas4et the scratches will be removed2
C(ATC+E '# 3(A!+ITE A(E ACCE!TABLE
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piral *ound 3as4et
!roduct 7uality 8 Inspection
If graphite is removed from the gas4et then the product should not be
used2 The area of the gas4et where the graphite has been removed
could become a lea4 path or may alter the product seating
characteristics2
9II#3 -ILLE( I #'T ACCE!TABLE
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9issing 3raphite
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C#A- 3as4ets
Compressed #on Asbestos -ibre
Can be Retightened
Cannot be RE-USED
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C#A- 3as4ets
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3raphite Coated
3as4ets
3raphite coated to aid sealing
Can be Retightened
B5T #'T (E.5E)
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3as4et torage & +andling
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The :; teps
The teps to 3as4et Installation1?2Chec4 correct surface finish2
$2Chec4 no flange face damage2
02Chec4 flange flatness22Chec4 it is the correct gas4et2
@2Chec4 the gas4et is not damaged2
2)o not force the gas4et into position2/2)o not use any grease2
2)o not use compounds " unless specified2
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-lange Assembly
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-lange Assembly Chec4s
Chec4 that joint faces are clean and free fromcuts indentations and other mar4s2 #ote
particular the presence of eDcessive
corrosion pitting and or radial mar4s crossing
the joint sealing surface2
The surface finish shall be within the
tolerances specified in B?2@ or B?2/
Chec4 that flange faces are parallel or that
pipewor4 is flexible to allow flanges to bepulled parallel and concentric without
undue bolt loads2
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-lange Assembly
The bolts provide the clamping force to seal the joint2
Tightening induces a bolt load8stress to provide
this force2
*e need to 4now what this load 8 stress is
otherwise1 Bolt load 8 stress is either too low or too high2
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-lange Assembly
Bolt load 8 stress is too low1?23as4et does not seal and joint lea4s
$23as4et seals but lea4s in service due to many
load loss factors including vibration thermal
eDpansion cyclic loading eDternal loading bolt
relaDation etc2
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-lange Assembly
Bolt load 8 stress too high1?23as4et crushed and lea4s due to over
compression
$2Bolts ta4en beyond yield strength
02-lange ta4en beyond yield strength
2-lange rotation
@2-lange faces damaged
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3raphite Coated
3as4ets
3as4et eating tress )iagram
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-lange Assembly
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Tightening
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9ethods of Tightening
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9ethods of Tightening
Uncontrolled olting-logging & +and spanners Impact wrenches etc
5ncontrolled tightening is often performed with1
5n.calibrated e6uipment
#o procedure
#o safety
#o accuracy
#o control
#o competency
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9ethods of Tightening
!ontrolled olting+and Tor6ue *renches
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Tor6ue Tightening
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afety -irst
Manual torque tightening tools enable the users tomore easily accomplish bolting tasks with accuracy
and efficiency
!he user must accept the primary responsibility of
safety when using torque tightening tools by
carrying out site related risk assessments" reading"
understanding" and complying with all operatinginstructions prior to and during operation
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Tor6ue Tightening
"##$%&' T(R)U&9inus
FR%!T%(*"$ $(++&+E6uals
R&+%'U"$ ($T $("'
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Tor6ue Tightening
There are 0 main factors to ta4e into account inorder that the bolt forces determined are produced
by the tor6ue applied to the nut or bolt2
?2Tor6ue to overcome friction at the bolt threads
!L5
$2 Tor6ue to overcome friction at the nut spot
face
!L5
02 Tor6ue to stretch the bolt
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Tor6ue Tightening
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Lubricant
Lubricant =9'LFG'TE !0/> must be
applied by a suitable brush to the1
#ut seating face &
Along the portion of the threaded
part of the bolt which is to be
tightened2
Ensure lubricant =9'LFG'TE !0/> is
spread evenly along the thread2
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Effects of Lubrication
Bolt Tension & Tor6ue Table Bolt 9aterial " +igh trength alloy steel bolting A?0 or B$ 3rade B/
Bolt tress " The table below gives tor6ue values re6uired to achieve an average bolt stress
e6uivalent to @%< of the bolt yield stress
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Tor6ue Tightening
#reparation of Flanges:panner tight; :6uare -langes; :?.0 threads above nut;
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Tightening e6uence
?2 +and tighten all nuts ensuring mating flangesare parallel and bolt holes are aligned2
$2 elect the correct bolt tor6ue value for the bolt
diameter and material to be tightened2
02 Tighten two bolts diametrically opposite each
other to @%, of the re6uired bolt stress2
2 Tighten another pair of bolts approDimately %,
further around the circumference2@2 Continue until all bolts have been tightened to
@%, of the re6uired stress2
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2 (epeat steps 0 and @ to %,
of the re6uiredbolt stress2
/2 (epeat steps 0 and @ to ?%%, of the re6uired
bolt stress2
2 Chec4 all bolts at ?%%, of recommended value2
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ECC Tor6ue Table
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!riss-cross tightening sequence examples bolt flange ?.0.$.
bolt flange [email protected]./.$...
?$ bolt flange [email protected]./.??.$..?%...?$
? bolt flange ?.@.?0.0.??./.?@.$.?%..?..?$..?
$% bolt flange ?.?0.@.?/..0.?@./.?.??.$.?..?.?%..?..$%.?$
$ bolt flange ?..?/.@.?0.$?.0.??.?./.?@.$0.$.?%.?..?.$$..
?$.$%..?.$
$ bolt flange ?.?@..$$..?.??.$@..$%.?0.$/.$.?..$0.@.?.?$.
$.0.?/.?%.$./.$?.?.$ 0$ bolt flange ?.?/..$@.@.$?.?0.$.0.?.??.$/./[email protected]?.$.?.?%.
$..$$.?.0%..$%.?$$..$.?.0$
0.bolt flange ?.$?..$.?/.@.$@.?0.00.0.$0.??.0?.?./.$/[email protected]@.$.
$$.?%.0%.?..$.?.0..$.?$.0$.$%..$.?.0
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Tor6ue *rench
Tightening e6uence
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Tor6ue Tightening
+and tor6ue wrench operation !ull the tor6ue wrench steadily using its handgrip2
An uncontrolled pull may result in a false reading8 tor6ue being
produced2
As soon as your wrench indicates that the pre determined tor6ue has
been achieved by for eDample Hclic4ing or H brea4ing stop pullingimmediately2
Continuing to pull past this indicated point may cause a higher than
re6uired tor6ue to be applied and may over stress the components of
the joint2
Always wind the tor6ue wrench setting bac4 to Jero value on the scalefailure to do so will eventually cause damage to the internal spring
A hand tor6ue wrench should be 4ept clean and handled with care2 If it
is dropped or 4noc4ed then re.calibration of the wrench 95T be
carried out2
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Inspection of Tor6ue *rench
Tor6ue wrench must have a valid calibration stic4er be in
good condition and in good wor4ing order before use2
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!lease note
the wrench isset to Kero
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Loc4ing crew
The loc4ing screw is located at the bottom of thewrench and should be loc4ed off every time2
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Tor6ue etting
*rench set at ?$ #m
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(emember to
loc4 off thetor6ue wrench
The #m is
located onthe top of the
window
t f T * h
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torage of Tor6ue *rench
If the wrench is damaged in any way you must
inform your supervisor2
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After completion
of the job the
wrench must
always be set toKero
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The ?% )'s
?2 Ensure that you are fully conversant with the safe use of the tools
and their operating procedures
$2 Chec4 that the tor6ue values re6uired are applicable for the tools
being used and for the joint or bolt material being tightened2
02 #umber the studs as an aid for applying the correct criss.cross
tightening se6uence2
2 9a4e sure that the full thread engagement of the nut on the bolt
has been achieved2
@2 5se 9'LFC'TE !0/ this is the only approved lubricant for the
ECC project2
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?% '
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The ?% )'s
2 +and tighten the nuts first ensuring that the correct face of the nut
is seated s6uarely onto the flange surface2 (emember small bolts
when lubricated do not need high tor6ue vales do not over tighten2
/2 Ensure that the bac4ing spanner if being used is ade6uately
engaged2
2 Ensure that there is sufficient room around the joint being tightened
to pull the wrench safely2
2 *ear suitable protective clothing2
?%2 (eset manual tor6ue wrench to Kero prior to storage2
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Th )'#T
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The )'#Ts
#ever tor6ue damaged or corroded bolts2
#ever tor6ue flanges that have visible damage 8corrosion to the sealing
area of the flange face2
)o not draw the joint up tight on one or two bolts as this will cause local
gas4et crushing or pinching of the gas4et2
)o not over tighten boltsM ta4e particular care with small bolts i2e2 less
than ?; diameter2
#ever pull the manual tor6ue wrench any further once the clic4 or
lin4age has activated2
#ever use a wrench that has been dropped or 4noc4ed without chec4ing
the calibration2
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"dantage
'ne wrench N range of soc4ets
can cover number of bolt siKes2
imple to operate2
Low profile tooling overcomes
application access problems2
(ight first time2
'isadantage
Control of lubrication critical2
Time consuming2
(eaction point is re6uired
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-l l t t
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-lawless tartup
7uality
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