BOLTRIGHT Tightening Procedure

file:///C:/Program Files/Hi-Force/BOLTRIGHT/TensioningProcedure.HTM

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BOLTRIGHT RESULTS SUMMARY

and

TIGHTENING PROCEDURE

Date: 5/4/2011 at 05:43 PM

Name:

Organisation: TR-CCC

Joint Tag:

Remarks: Hi-Force Tool STS3-200 used.

Flange and Gasket Details

Flange Standard: ANSI Flange Nominal Size: 6 Design Pressure: 425 bar (6170 psi) Number of Bolts in Flange: 8 Bolt Material: ASTM A193 - B7M Gasket Type: Spiral Wound Gasket Gasket m Factor: 2.50 Effective Gasket Seating Width: 7.43 mm (0.293 inches) Flange Class: 2500 Operating Temperature: 20 C Test Pressure: 638 bar (9255 psi) Bolt Thread Size: 2 - 8 UN Bolt Minimum Yield Strength: 552 N/mm (80000 Lbf/in) Gasket Material: Graphite Gasket y Factor: 69 N/mm (10000 Lbf/in) Gasket Load Reaction Diameter: 194.6 mm (7.66 inches)

Tensioning Procedure
This tensioning procedure is a guide and may be needed to be adapted to suit the specific situation and circumstances. This procedure is designed to produce a residual load in each bolt of 493.0 kN (110825 Lbf) This represents 50% of the minimum yield strength of the bolt. The bolts will be tensioned during the tightening process to a higher load initially to allow for elasticity effects. The maximum loading sustained by the bolts during the tightening process represents 78%. of their minimum yield strength. Prerequisites : All personnel involved in implementing this procedure are competent in the use of the tightening equipment and joint tightening procedures. If assistance is needed, please contact Hi-Force. Important Note: This tensioning procedure is based upon using the Hi-Force hydraulic tensioner model number STS3-200 and a Pressure A = 1406 bar (20387 psi) and a Pressure B = 1125 bar (16310 psi) A. Pre-Bolting Inspection A.1 Gasket. Make sure the material is as specified, look for any possible defects or damage in the gasket such as folds or creases. A2. Flange. Inspect the gasket seating surfaces. Check for corrosion pitting, cracks, and tool marks. Any radial tool marks can directly lead to leakage regardless of the gasket material or the amount of bolt tightening. Make sure that the gasket seating surface is appropriate for the type of gasket being used. Check the areas on the flange where the nuts will seat. These should be flat and free from pitting and excessive wear. A3. Flange Alignment. It is important that the flange faces are parallel and aligned. The flange bolt holes should be lined up so that the bolts will not be bent when tightened. A4. Bolts. The bolt material specified is ASTM A193 - B7M and the thread size is 2 - 8 UN . Check each bolt to ensure that this is the case and that each bolt, nut and washer (if used) do not shown signs of corrosion, damage or excessive paint . Note : Any defects noted during the inspection must be rectified prior to starting the tensioning procedure. B. 50% Tensioning Procedure B1. Square up the Flanges. Hand tighten the bolts to square up the joint. Ensure that the flange faces are kept parallel to each other by partially tightening the bolts so that there is metal to metal contact around the full periphery of the joint. B2.1 Tensioning. The 8 bolts in the flange are to be tightened using a 50% tensioning procedure i.e. tensioners will be fitted to 4 bolts eqi-spaced around the flange. These are tightened to a high pressure (pressure A) before the remaining 4 bolts are tightened to a lower pressure (pressure B). The sequence and pressures applied are critical to achieving a leak free joint, carefully follow the instructions detailed below:

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BOLTRIGHT Tightening Procedure

file:///C:/Program Files/Hi-Force/BOLTRIGHT/TensioningProcedure.HTM

B2.2 Tensioner Installation. Fit the hydraulic tensioners ( Hi-Force Model Number STS3-200) to 4 bolts eqi-spaced around the flange. B2.3 Pressure A Tensioning. Apply Pressure A (i.e. 1406 bar (20387 psi)) and tighten the nuts using a tommy bar. Release the pressure. B2.4 Pressure B Tensioning. Transfer the hydraulic tools to the 4 bolts that are yet to be tightened. Apply pressure B (i.e. 1125 bar (16310 psi)) and tighten. Release the pressure and then re-apply the pressure and ensure that the 4 nuts are tight. B2.5 Break Loose Tensioning Check. Transfer the hydraulic tools back to the 4 bolts that had been previously tightened. Increase the tensioner pressure slowly whilst attempting to rotate the tommy bar in the socket in the loosening direction of the nuts. Turn the pump off as soon as the nut first starts to rotate and make a note of the pressure (the "break loose" pressure) . If this is equal to or greater than pressure B (i.e. 1125 bar (16310 psi)) then the tensioning is complete. If this "break loose" pressure is less than pressure B then repeat steps B2.3 to B2.5. Final Check. As a final check, use a hammer to "ring" each bolt to ensure that none are slack.

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