Assembly and Tightening of Bolted Connections

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/.%%%



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



'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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http://slidepdf.com/reader/full/assembly-and-tightening-of-bolted-connections 9/55Comparison of bolt material yield strengths

Behaviour 'f #uts & Bolts

Bolt 9aterial %2$< proof stress =!I> =#8mm$>

B/?%@%%% /$

L/ ?%@%%% /$

B.class ?$%%%

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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



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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Adobe Acrobat

Document



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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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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!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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Adobe Acrobat

Document



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



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



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



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

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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



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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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



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



-lawless tartup

7uality

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Assembly and Tightening of Bolted Connections

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