Tentec

PROC-102662-005
23rd March 2011

www.tentec.net

TEST PROCEDURE AND RESULTS REPORT FOR.

DETERMINING RESIDUAL BOLT LOAD SCATTER USING
HYDRAULIC NUT HTT.9190.000B
FOR ENOVATE SYSTEMS LTD.
TEST REQUIREMENT
To determine variations (scatter) in residual bolt load values for bolting up joints using Tentec hydraulic nut
HTT.9190.000B (See Appendix 3 for drawing).
TEST SET-UP
Refer to attached Enovate drawing, EN-ASSY-00288 Revision A (Ref Appendix 3). This drawing illustrates a
special test jig which will be manufactured and supplied by Enovate Systems Ltd. The test jig simulates the part
of the Pressure Balance Breakaway Joint (PBBJ) where the tension retaining flange is mated with the main
housing. The pitch between the stud-bolts in the jig is at the same spacing as the stud-bolt used in the flanged
joint of the PBBJ. The jig enables simultaneous load testing of two hydraulic nuts fitted to 1 8-UNC break
stud-bolts.
Bolt elongations due to the load applied by the hydraulic nuts will be digitally measured. The results will be
recorded in tabulated and graphical form.
Testing will be performed at room temperature using digital dial test indicators (DTIs) mounted independently
from the test jig (Ref Appendix 5 to see set-up test jig and DTIs). Testing will be performed dry i.e. without
the use of thread lubricant on the 1st pair of stud-bolts albeit, both stud-bolts will be supplied with a Phosphate
and oil dip finish.
Testing will be performed with Xylan (1427) coating applied i.e. with the PTFE coated on threads of the 2nd
pair of stud-bolts
PROCEDURE
Stage 1; Preliminary set up.
1. Confirm 2 off hydraulic nuts to be used for the test, supplied by Enovate, have unique identification numbers
EN-COMP-91907 Rev A ESN-002and EN-COMP-91907 Rev A ESN-003.
2. Assemble test rig blocks as illustrated in drawing EN-ASSY-00288 Rev A, (drawing items
1 and 3).Ensure that 1st pair of stud bolts (Parts EN-COMP 12276 Rev D ESN-002 and EN-COMP 12276
Rev D ESN-003) are fully engaged into lower block (drawing item 1).
3. Assemble hydraulic nut EN-COMP-90907 Rev A ESN-002 complete with stud measuring pin and magnet
on to the free end of stud-bolt ; EN-COMP 12276 Rev D ESN-002. Record the unique part number of the nut
and the respective part number of the stud-bolt to which it was mated. Ensure that the bearing surfaces are
clean and free from debris. Screw the hydraulic nut onto the bearing surface until hand tight.
4 Assemble hydraulic nut EN-COMP-90907 Rev A ESN-003 complete with stud measuring pin and magnet
on to the free end of stud-bolt ;EN-COMP 12276 Rev D ESN-003. Record the unique part number of the nut
and the respective part number of the stud-bolt to which it was mated. Ensure that the bearing surfaces are
clean and free from debris. Screw the hydraulic nut onto the bearing surface until hand tight.
5. Place the assembled test jig into a vice, ensuring the jaws locate on and grip the representation on the PBBJ
upper housing of the test jig, (Part EN-COMP-12695).
Page 1 of 14

6. Using an in-line calibrated electronic pressure gauge, adjust the hydraulic air pump to stall at 1121.15 barg.
This will ensure that an equal hydraulic pressure is consistently applied to both nuts.
7. Using a 3 hose harness arrangement of suitable length, connect one end to each hydraulic nut and the other
end to the air pump.
Operations 8 through 10 are required to initially embed all surfaces and screw threads prior to testing
proper. Do not measure bolt elongation at this stage.
8. Pressurise the system to the pre-set stall figure. Screw the hydraulic nut collars hand tight against the nut
bodies. Using a Norbar torque handle complete with special fitting, tighten the collar to 10 Nm. Release the
retained hydraulic pressure and allow the nuts to rest for 2 minutes.
9. Re-pressurise the system to the pre-set stall figure and hold. Using the torque arm or a simple Tommy bar,
unscrew the hydraulic nut collar away from the nut body.
10. Release the retained hydraulic pressure. Disconnect the hydraulic hose from each nut.
Stage 2; Commence Testing joint with non-coated stud-bolts.
11. Mount a digital DTI onto the side of the vice and adjust its position so it is directly above the stud-bolt ENCOMP 12276 Rev D-ESN-003 (fitted with nut EN-COMP-90907 Rev A ESN-003). Ensure the DTI needle
is positioned centrally on the stud measuring pin.
12. Mount a digital DTI onto the side of the vice and adjust its position so it is directly above the stud-bolt ENCOMP 12276 Rev D-ESN-003 (fitted with nut EN-COMP-90907 Rev A ESN-003). Ensure the DTI needle
is positioned centrally on the stud measuring pin.
13. Ensure the hydraulic nuts are screwed hand tight against the bearing surface. Re-connect the hydraulic hose
harness to each hydraulic nut, before zeroing both of the DTIs.
14. Pressurise the system to the pre-set stall value of 1121.15 Barg. Screw the hydraulic nut collars hand tight
against the nut bodies. Using a Norbar torque handle complete with special fitting, tighten the collar to 10
Nm.
15. Measure the initial Elongated length of each stud-bolt (stud-bolt mated to nuts nos. ESN-002 and ESN-003
respectively). Record measured elongated lengths in table. Row: Nut 002, Nut 003, before releasing the
retained hydraulic pressure..
16. Measure the residual Elongated length of each stud-bolt (stud-bolt mated to nuts nos. ESN-002 and ESN003 respectively). Record measured elongated lengths in table. Row: Nut 002, Nut 003.
17. Re-pressurise the system to the pre-set stall figure and hold. Using the torque arm or a simple Tommy bar,
unscrew each hydraulic nut collar away from the nut body.
18. Release the retained hydraulic pressure.
19. Repeat operations 13 through 18 a further four times, recording each subsequent initial stud-bolt / residual
stud elongation length in table row 2, 3, 4, and 5.
20. When the pressure test has been repeated five times and the resulting initial stud-bolt / residual stud-bolt
elongations recorded, release the retained hydraulic pressure. Disconnect the hydraulic hose harness from
each hydraulic nut. Remove both the DTIs and each hydraulic nut from the stud-bolts.
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Stage 3: Set-up and Commence Testing joint with Xylan-coated stud-bolts

21. Confirm 2 off hydraulic nuts to be used for the test, supplied by Enovate, have unique identification
numbers EN-COMP-91907 Rev A ESN-010and EN-COMP-91907 Rev A ESN-011.
22. Assemble test rig blocks as illustrated in drawing EN-ASSY-00288 Rev A, (drawing items 1 and 3). Ensure
that 1st pair of stud bolts (Parts EN-COMP 12276 Rev D ESN-010 and EN-COMP 12276 Rev D ESN011) are fully engaged into lower block (drawing item 1).
20. Assemble hydraulic nut EN-COMP-90907 Rev A ESN-002 complete with stud measuring pin and magnet
on to the free end of stud-bolt; EN-COMP 12276 Rev D ESN-010. Record the unique part number of the
nut and the respective part number of the stud-bolt to which it was mated. Ensure that the bearing surfaces
are clean and free from debris. Screw the hydraulic nut onto the bearing surface until hand tight.
21. Assemble hydraulic nut EN-COMP-90907 Rev A ESN-003 complete with stud measuring pin and magnet
on to the free end of stud-bolt; EN-COMP 12276 Rev D ESN-011. Record the unique part number of the
nut and the respective part number of the stud-bolt to which it was mated. Ensure that the bearing surfaces
are clean and free from debris. Screw the hydraulic nut onto the bearing surface until hand tight
22. Repeat steps 5 through to step 18 but, now record the results for new tests, 11, 12, 13, 14 & 15 in the
respective rows numbered 11 ~ 15 accordingly.
Stage 4 & 5: Collating Results Data
Refer to document result sheets 1 & 2 attached to see summary of results for tests done on both the uncoated
and coated stud-bolts.
The elongation measurements are all recorded in tabulated form.
From the tabulated results, 4 data items are collated for each configuration with both the uncoated and the
coated sets of stud-bolts.
a) A graph for the joint configuration with uncoated and coated stud-bolts. Each graph illustrates the scatter
range (tested over 5 repeats, per each hydraulic nut / stud set) for a specific joint configuration.
b) Calculation of the bolt-up scatter range value.
c) Calculation of the bolt-up residual pre load scatter about the average pre load for each bolt.
d) Calculation of the average residual bolt load.
e) Calculation of specific Load Loss Factor using average residual bolt load.

APPENDICES.

A1.
A2.
A3.
A4.
A5.
A6.

Result Sheet 1 (Stage 4) Uncoated Stud-bolts

Results Sheet 2 (Stage 5) Xylan Coated Stud-bolts
Enovate drawing, EN-ASSY-00288 Revision A.
Tentec Drawing; Hydraulic Nut HTT.9190.000B (Envoate Part EN-COMP-91907 Rev A)
Photographs of Test Set-up and measuring equipment
Calibration Certificates
Page 3 of 14

HTT.9190.000B. RESIDUAL STUD/BOLT ELONGATION MEASUREMENTS

Appendix 1. Results Sheet 1 (Stage 4) Uncoated Stud Bolts.

Applied Hydraulic Pressure: 1121.15 bar

Maximum Applied Load: 101.885 kN
Collar Tightening Torque: 10 Nm
Target residual Load: 82.414 kN

BOLT
(ESN)

INITIAL BOLT
LENGTH ( mm )

NUT

RESIDUAL
RESIDUAL BOLT
INITIAL BOLT
LOAD TRANSFER
BOLT LOAD
EXTENSION ( mm ) EXTENSION (mm)
FACTOR
(kN)

002

0.234

0.294

1.256

81.092

002

0.235

0.295

1.255

81.163

002

0.238

0.298

1.252

81.371

002

0.235

0.296

1.260

80.888

002

0.236

0.294

1.246

81.785

003

0.216

0.272

1.259

80.909

003

0.217

0.275

1.267

80.397

003

0.219

0.276

1.260

80.844

003

0.216

0.272

1.259

80.909

003

0.216

0.272

1.259

80.909

002

003

133.582

133.431

Stage 4a: Joint Configuration EN-ASSY-00288 (Uncoated stud bolts)

82.000

81.800

81.600

81.400

RESIDUAL STUD-BOLT LOAD (kN)

TEST

81.200

STUD-BOLT ESN 002

81.000

STUD-BOLT ESN 003

80.800

80.600

80.400

80.200

80.000
1

TEST REPEAT No.

TEST RESULTS.
Stage 4b.Residual Pre load Scatter ( kN )

Stage 4c.Residual Pre load scatter about average Residual Stud-Bolt pre load

Stage 4d.Residual Stud/bolt load ( kN )

Stage 4e. Specific Load Loss

Factor

BOLT ESN 002

0.897

+0.526 kN (0.65%) / -0.371 kN (0.46%)

81.259

1.254

BOLT ESN 003

0.512

+0.116 kN (0.14%) / -0.396 kN (0.49%)

80.793

1.261

COMBINED
RESULTS

1.389

+0.760 kN (0.95%) / -0.628 kN (0.78%)

81.025

1.257

Tentec

NOTES:
1) 1" 8UN Tensile Stress Area is 394.84 mm ( 0.612 in )

www.tentec.net

2) E = 207x10 N/mm

Page 4 of 14

HTT.9190.000B. RESIDUAL STUD/BOLT ELONGATION MEASUREMENTS

Appendix 2. Results Sheet 2 Xylan Coated Stud-Bolts

Applied Hydraulic Pressure: 1121.15 bar

Maximum Applied Load: 101.885 kN
Collar Tightening Torque: 10 Nm
Target residual Load: 82.414 kN

INITIAL BOLT
LENGTH ( mm )

INITIAL BOLT
EXTENION (mm)

002

0.210

0.269

1.281

79.538

002

0.214

0.274

1.280

79.574

002

0.217

0.276

1.272

80.105

002

0.209

0.269

1.287

79.160

002

0.213

0.274

1.286

79.203

003

0.209

0.268

1.282

79.455

003

0.211

0.271

1.284

79.327

003

0.213

0.273

1.282

79.493

003

0.208

0.269

1.293

78.781

003

0.210

0.270

1.286

79.244

010

011

133.452

133.513

Stage 5a: Joint Configuration EN-ASSY-00288 (Coated stud bolts)

80.500

80.300

80.100

79.900

RESIDUAL STUD-BOLT LOAD (kN)

RESIDUAL BOLT
EXTENSION ( mm )

BOLT
(ESN)

RESIDUAL
LOAD TRANSFER
BOLT LOAD
FACTOR
(kN)

NUT

TEST

79.700

79.500

Stud-Bolt ESN 010

79.300

Stud-Bolt ESN 011

79.100

78.900

78.700

78.500
1

TEST REPEAT No.

TEST RESULTS.
Stage 5b.Residual Pre load Scatter ( kN )

Stage 5c.Residual Pre load scatter about average Residual Stud-Bolt pre load

Stage 5d.Residual Stud/bolt load ( kN )

Stage 5e. Specific Load Loss

Factor

BOLT ESN 010

0.946

+0.591kN (0.75%) / -0.355 kN (0.45%)

79.515

1.281

BOLT ESN 011

0.712

+0.234 kN (0.30%) / -0.478 kN (0.60%)

79.259

1.285

COMBINED
RESULTS

1.324

+0.718 kN (0.90%) / -0.606 kN (0.76%%)

79.387

1.283

Tentec

NOTES:
1) 1" 8UN Tensile Stress Area is 394.84 mm ( 0.612 in )

www.tentec.net

2) E = 207x10 N/mm

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Appendix 3; Enovate drawing, EN-ASSY-00288 Revision A.

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Appendix 4; Tentec Drawing; Hydraulic Nut HTT.9190.000B

Page 7 of 14

Appendix 5; Photos of Test set-up and measuring equipment.

Photo 1 showing test jig, hydraulic nuts DTIs and hydraulic harness assembly
mounted in vice.

Photo 2 showing DTIs positioned directly above the hydraulic nuts fitted with
elbow adaptors to allow ease of measurement.

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Photo 3 shows DTIs mounted onto magnetic stands secured to vice

Photo 4 shows a DTI measuring the stud bolt elongation via a measuring pin
secured by a magnet to the top of the stud bolt.

Page 9 of 14

Appendix 6: Calibration Certificates

Pressure Gauge Certificate

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DTI Certificates

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