Definition and Details of Flanges -

Torque Tightening
Torque tightening
To obtain a leak-free flange connection, a proper
gasket installation is needed, the bolts must be assign
on the correct bolt tension, and the total bolt strength
must be evenly divided over the whole flange face.

With Torque Tightening (the application of preload to a

fastener by the turning of the fastener's nut) the
correct bolt tension can be realized.

Correct tightening of a bolt means making the best use

of the bolt's elastic properties. To work well, a bolt
must behave just like a spring. In operation, the
tightening process exerts an axial pre-load tension on
the bolt. This tension load is of course equal and
opposite to the compression force applied on the
assembled components. It can be referred to as the
"tightening load" or "tension load"
 www.enerpac.com

Torque wrench
Torque Wrench is the general name for a hand-guided
screwing tool, and used to precisely set the force of a
fastening such as a nut or bolt. It allows the operator
to measure the rotational force (torque) applied to the
bolt so it can be matched to the specifications.

Manual and hydraulic wrench

The selection of the proper flange bolt tigtening
technique requires experience. The successful
application of any technique also requires qualification
of both the tools that will be used and the crew who
will do the work. The following summarizes the most
commonly used flange bolt tightening techniques.
Manual Wrench

Impact Wrench

Hammer Wrench

Hydraulic Torque Wrench

Manual Beam and Gear-Assisted Torque Wrench

Hydraulic Bolt Tensioner

Torque loss
Torque loss is inherent in any bolted joint. The
combined effects of bolt relaxation, (approximately
10% during the first 24 hours after installation), gasket
creep, vibration in the system, thermal expansion and
elastic interaction during bolt tightening contribute to
torque loss. When torque loss reaches an extreme, the
internal pressure exceeds the compressive force
holding the gasket in place and a leak or blow-out
occurs.

A key to reducing these effects is proper gasket

installation. By bringing the flanges together slowly
and parallel when installing a gasket and taking a
minimum of four bolt tightening passes, following the
correct bolt tightening sequence, there is a payoff in
reduced maintenance costs and increased safety.

Proper gasket thickness is also important. The thicker

the gasket, the higher the gasket creep which in turn
can result in torque loss. On standard ASME raised
face flanges a 1.6 mm thick gasket is normally
recommended. Thinner gasket materials can take a
higher gasket load and therefore higher internal
pressures.

Lubrication reduces friction

Lubrication reduces the friction during tightening,
decreases bolt failure during installation and increases
bolt life. Variation in friction coefficients affect the
amount of preload achieved at a specific torque.
Higher friction results in less conversion of torque to
preload. The value for the friction coefficient provided
by the lubricant manufacturer must be known to
accurately establish the required torque value.

Lubricant or anti-seizure compounds should be applied

to both the nut bearing surface and the male threads.

Tightening sequence
The first pass, lightly tighten the first bolt then move
directly across or 180 degrees for the second bolt,
then move1/4 turn around the circle or 90 degrees for
the third bolt and directly across for the fourth.
Continue this sequence until all bolts are tightened.
When tightening a four-bolt flange, use a criss-cross
pattern.
TIGHTENING SEQUENCE

Preparation flange bolt-up

In a flanged connection, all components must be
correct to achieve a seal. The most common cause of
leaky gasketed joints is improper installation
procedures.
Before beginning a bolting process, the following
preliminary steps will avoid future problems:
Clean the flange faces and check for scars; the

faces must be clean and free of defects (burrs,

pits, dents, etc.).

Visually inspect all bolts and nuts for damaged or

corroded threads. Replace or repair bolts or nuts

as necessary.

Remove burrs from all threads.

Lubricate the threads of the bolt or stud, and the

surface of the nut face adjacent to the flange or

washer. Hardened washers are recommended in

most applications.

Install the new gasket and be sure gasket is

properly centered. DO NOT REUSE old gasket, or

use MULTIPLE gaskets.

Check flange alignment ASME B31.3 Process

Piping:

...flange faces must be parallel within 1/16" per

foot of diameter, and flange bolt holes must be

aligned to within 1/8" maximum offset.

 Adjust the position of the nuts to insure that 2-3

threads is visible above the top of the nut.

Irrespective which method of tightening is used, above

determined checks and preparations always must be
done.
REMARK(S) OF THE AUTHOR...

MY OWN EXPERIENCES ABOUT...TORQUE WRENCHES

In the past I have assembled hundreds leak-free

flange connections, from NPS 1/2 to NPS 24 and

bigger. Rarely I have used therefore a Torque

Wrench.

In practice, "normal" pipe flange connections are

almost never assembled with a Torque Wrench. The

difficultest connections for me always were the

"little ones" and then especially the Raised Face

type above Class 300 (RF Height

= approximately 6.4 mm).

Relationable the flange faces from a NPS 1/2

flange are smaller then for example a NPS 6

flange, and the chance on misalignment, in my

view is much bigger.

In practice I encounter regularly flange

 connections, where the alignment do not in the

tolerance limit. If simply the order of Tightening

Procedure is followed the Mechanic is not well

busy. Possibly must be begun on bolt six instead of

on bolt one. Use your eyes during flange assembly,

it is very important and contributes very probably

to a leak-free connection

IMPROPER FLANGE CONNECTIONS - THE BOLTS ARE TOO

SHORT !

WHAT CAN YOU DO?

The picture show a improperly bolted flange,

because two bolts are too short, and the nuts are

not completely on the bolts. This means that the

joint may not be as strong as it should be. Flanges

 are designed so that the entire nut-bolt

combination holds the forces on the flange. If the

nut is only partially screwed onto the bolt, the

connection may not be strong enough.

If your job includes putting equipment together,

assembling flanged pipe, bolting manhole covers or

other bolted connections on equipment, or other

equipment assembly, remember that the job is not

complete until all of the bolts are properly

installed and tightened.

Some equipment requires special bolt tightening

procedures. For example, you may have to use a

torque wrench to correctly tighten the bolts to the

specification, or tighten the bolts in a special

order. Make sure that you follow the correct

procedure, use the correct tools, and that you are

properly trained in the equipment assembly

procedure.

Check pipes and equipment for properly bolted

flanges as part of your plant safety inspections. As

simple guidance, bolts that do not extend beyond

 the nuts should be reviewed by a plant piping

craftsman or engineer.

If you observe improperly bolted flanges in your

plant, report them so they can be repaired, and

make sure the required repairs are completed.

Inspect new equipment, or equipment which has

been re-assembled after maintenance, to make

sure it is correctly assembled and properly bolted

before starting up.

What is the proper length of a Stud Bolt?

As a rule, you can use: The free threads of the bolt
above the top of the nut is equals to 1/3 times the bolt
diameter.