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FUNDAMENTALS OF BOLT
TIGHTENING
NO
PROCEDURE
PROCEDURE
LOAD/EXTENSION
MEASUREMENT
NO
PREPARATION
PREPARATION
RESULT
RESULT?
KNOWN
a e
Uncontrolled
Tightening f
h
g
0 tsi 17 tsi 25 tsi 38 tsi 50 tsi
Optimum Gasket
Seating Stress
Under-load Over-load
LEAKAGE ! LEAKAGE !
Insufficient
Gasket
Gasket Result of Permanent
Compression Uncontrolled Deformation
Tightening
Uncontrolled Tightening
Partially Controlled
Hand or Hydraulic Torque Wrenches,
Bolt Tensioners, Angle of Turn etc.
What is
Controlled Tightening?
a e
Controlled
Tightening
h f
g
Controlled Tightening
• All Bolts Within Specified Tolerance
• Not Physically Demanding
• Time Saving
• Good Working Practice
• Safe
• Environmentally Friendly
• Hydro-test Conformance
• Minimal Probability of Leaks
• Very Low Probability of Re-Work
• Cost Effective
• Minimal Down Time
• Maintains a Leak Free Joint
Bolt Torquing
15 1 13
1 7 5
7 5
12 9
4 3 4 3
10 11
6 8
2 6 8
14 16
2
Comparator
Ultrasonic bolt measuring equipment measures the time of flight of a shock wave as
it travels through the bolt.
CORRECT LOADING OF BOLTED JOINTS
When tightening a flanged joint the object is to :
a. Achieve the correct load in the bolt, therefore, the joint .
b. Evenly distribute that load across the joint.
To achieve this correct loading the three factors above are employed in formula
used in Pressure Vessel codes BS5500 and ASME VIII.
Approximately 20 years behind Whitworth, William Sellers in America carried out a similar exercise and
the American National Thread was established.
P
Effective (Pitch)
Note: The effective Diameter is obtained from the relevant British Standard.
Diameter
Elastic Behaviour of Bolting Material
All methods of tightening result in stretching the bolt. If the bolt is not stretched it will not provide any clamping force
on the components being bolted together. In fact the bolt acts like a spring. After being stretched by whatever method
of tightening, the bolt material then tries to return to its original length, it is this behaviour of the material that provides
the clamping force.
Steel bolting material behaves elastically, when loaded bolt returns to its original length after removing the load, the
material is known as being elastic. However this property of elasticity holds good up to such a point called the elastic
limit of the material. If the load applied takes the material beyond its elastic limit the material will remain extended
when the load is removed. At this point the material is said to have permanent set.
The amount a bolt extends depends on the load on the bolt. It can be seen from the following graph that there is a
direct relationship between the amount of extension and the load producing that extension. For example if a certain
load causes a bolt to stretch 0.01mm, then that load is doubled, the extension will also be doubled to 0.02mm, when
the load is trebled, the extension will be trebled to 0.03mm and so on until the material is loaded beyond its elastic
limit.
Elastic Behaviour of Bolting Materials
Steel bolting material behaves elastically, when a particular bolt is loaded it extends in length. The amount the
bolt extends depends on the load on the bolt and the relationship between the bolt load and its extension is of
straight form. This can be shown in a load extension graph or a stress - strain graph. Stress is the load per unit
area and Strain is the extension per unit length.
The Stress-strain diagram is of straight-line form within the elastic limit of the material. The gradient of this graph is
a constant known as the Modulus of Elasticity (E). Modulus of Elasticity (E) = Stress / Stain
and for steel this is approximately 30,000,000 lbf./in2, or 207,000 N/mm2.
Therefore, if E = stress / strain
then Strain = Stress / E
= 55,000 / 30,000,000 = 0.0018 inches / inch.
This is often expressed in bolt tightening specifications as a percentage as 0.18% strain which implies in steel a
stress of 55,000 lbf. / in2.
Typical Load - Extension Graph for Steel
Yield Point - bolt remains elastic up to this point
Load
Elastic
Region
Extension
0.2%
If the load applied takes the material beyond the elastic region into the plastic region, the material would then
remain permanently extended, which is known as permanent set. If the permanent extension is 0.2% of the original
length of the bolt then the load producing it is known as 0.2% of proof load, which sometimes can be accurately
established than the load at yield.
The load applied to the bolt must be within the elastic region of the bolt material and is determined as a percentage
of either.
• The proof load, or
• Load at yield
Bolt Material 0.2% Proof Stress
Tonf/in2
B7 47
B8 13.5
B16 56 47 0 520 4
B7
2H
Spot face area
to be in contact
with flange
Gaskets
Spiral Wound Gasket
Winding Metal
and Filler
Material
Inner
Ring
Outer
Ring
Manufacturer
Nominal pipe
size
Manufactured
to ASME
B16.20
Pressure
class
Winding metal
and filler
material
Spiral Wound Gaskets
Outer Ring
Filler Material
Filler Material
Nominal Bore
Outer Ring Material
Piping Class
HOW DO SPIRAL WOUND GASKETS WORK?
Upon compression, the soft graphite filler material flows
into the flange imperfections and creates a tight seal.
Flange
Imperfections Graphite
Scratches
Missing Graphite
Don’ts
Do not re-use old gaskets-fit new
Do not use a gasket that has no identification
Do not alter or cut a gasket to fit a flange
Particular care is required during assembly of the flanges to avoid misalignment. Misalignment not only detrimentally
affects the bolt load, but may also damage the gasket, bend studbolts, unseat nut spot face, and overload flange
stresses, all of which will adversely affect the joint integrity that will almost certainly promote joint leakage.
Flanges
Flange Standards
For process and utilities pipework, the two most
commonly used flange standards are ANSI B16.5 and
BS1560.
A third standard, API 6A specifies flanges for wellhead
and Christmas tree equipment.
Types of Flange
Two of the most common flange
types in use, as illustrated below
are:
1. WELD NECK - the WN flange is butt
welded to the pipe. This type of flange
is normally used for high pressure
systems often involving hazardous
systems products
The combined bolt load from all the bolts in a joint must carry out three main functions.
2. To carry sufficient residual bolt load after the hydro-static end load is applied to clamp any gasket enough to
prevent system pressure pushing the gasket out of the joint.
3. Produce sufficient stress in the gasket to seat the gasket.
Produces
Gasket Stress
Sufficient force must be exerted on the faces to plastically distort the layers of the gasket material into the
contours of the contours of the faces of the joint and form a seal.
But this force must not be so great that it overstresses the gasket material to the extent that it looses its
elasticity and, therefore, its ability to recover and follow the contours of the flange as conditions of pressure and
temperature change.
GASKET SEATING STRESS
(BEAM DIAGRAM)
Underload Overload
Leakage Leakage
Safety Safety
Factor Factor
Reliability Zone of Stress
Minimum Maximum
Seating Stress Seating Stress
JOINT PREPARATION
CHECK LIST : JOINT ASSEMBLY :
Flange faces are clean, free Ensure flange faces are
from grease & undamaged. aligned correctly
Spot faces of flanges are Ensure correct lubricant is
clean & free from paint used
Gasket is clean, undamaged Apply Lubricant to :
& free from grease - Spot Face of Nut
- Nut & Bolt Threads
Ensure all Nut & Bolt Grades
are correct
Ensure Bolt Protrusion on all
bolts is correct
Torque Tightening
Theory
What is torque?
Turning
Moment
Force
Torque Theory
T = W P + Re. + Rs.
2 Cos
T = Torque
W = Bolt Load (Stress x c.s.a.)
P = THREAD PITCH
= 1
/2 THREAD INCLUDED ANGLE
Re = EFFECTIVE THREAD RADIUS
Rs = NUT SPOT FACE MEAN RADIUS
= CO-EFFICIENT OF FRICTION
T = W P + Re. + Rs.
2 Cos
50% of the applied torque is used to overcome the nut spot face friction
40% of the applied torque is used to overcome the bolt and nut thread friction
Torque required to
turn the nut
=P/2π
Thread friction at
effective radius
= Re. µ / Cos. Ø
Example
1” dia UN8 Force W = Bolt Load = 45000 lb/in2 x 0.563 in2
Bolt Stress : 45000 lb / in2 W = 25335 Lbf.
Area of bolt Minor dia : 0.563 in2
Thread Pitch :P = 0.125 in
1/2 Thread Included angle Cos =30o (0.866)
Effective Thread Radius : Re = 0.4595 in.
Nut Spot Face Mean Radius : A/F + Hole Dia (in) / 4 = 1.626 + 1.125 / 4 = 0.6875 in
Coefficient of Friction : µ 0.08 to 0.15
1in UN8 Bolt Force W = Bolt Load = 45000 lbf/in2 x 0.563 in2
Bolt Stress: 45000 lbf/in2 W = 25335 lbf
Area of bolt Minor Dia.: 0.563 in2
Thread Pitch: P = 0.125 in
T=W P + Re μ + Rs μ lb.in
2π Cos Ө
Torque Calculator
(Slide Rule)
NOTES FOR HAND TORQUE WRENCH OPERATION
As soon as your wrench indicates that the pre determined torque has been achieved
by for example ‘clicking’ or ‘ breaking’ stop pulling immediately.
Continuing to pull past this indicated point may cause a higher than required torque to be
applied, and may over stress the components of the bolted joint.
Always wind the torque wrench setting back to zero after use.
Failure to do so will eventually cause damage to the internal spring, causing it to weaken.
A hand torque wrench should be kept clean, and handled with care
If it is dropped or knocked then calibration of the wrench should be carried out.
The USE OF
IKM Testing (UK) Ltd
TORQUE SLIDE RULE.
----------------------------------
Bolt Tensioning
• Induces the load axially, by stretching the stud bolts within the elastic range of the material to
supply the required bolt loading.
• Bolt Loads are uniformly applied and controlled, the joint is effectively ‘clamped’ with minimal
movement.
• Joints normally have 50% tool cover but can in some cases have 100% tool coverage.
• The hydraulic pressure to ensure the required bolt stress is calculated to include a load loss
factor to compensate for load loss in the joint, following release of the pressure from the tool.
The bolt is therefore subjected to a stress higher than that desired, referred to as Gross Load
applied. The Residual Load is left after release of the tool pressure.
TOOL OPERATED
CONNECT HOSES
PULLER SLEEVE “
PS3 - 11
HYPUR-MATE
LOAD CELL
PS3
70000
60000
FLLF
50000
TLLF
Bolt Stress (lb/in2)
40000
30000
RESIDUAL
20000
10000
0
12" 600# - B7 Bolting
Target residual bolt stress of 45 ksi
90000
80000
70000
60000
50000 torque
tension 50%
40000 tension 100%
85%bolt yield
30000
20000
10000
80000
70000
60000
50000
torque
tension 50%
40000
tension 100%
85%bolt yield
30000
20000
10000