BOLTRIGHT Tightening Procedure

BOLTRIGHT RESULTS SUMMARY

and Date:
06/24/2009 at
TIGHTENING PROCEDURE 03:31 PM

Bolt Tension Procedure for 20" # 900 Flange

Name: Saad Abou-Zeid Organisation: TRO Joint Tag:
Remarks:

Flange and Gasket Details

Flange Standard: ANSI Flange Class: 900
Flange Nominal Size: 20 Operating Temperature: 20 C
Design Pressure: 153 bar (2220 psi) Test Pressure: 230 bar (3330 psi)
Number of Bolts in Flange: 20 Bolt Thread Size: 2 - 8 UN
Bolt Minimum Yield Strength: 724 N/mm² (105000
Bolt Material: ASTM A193 - B7
Lbf/in²)
Gasket Type: Spiral Wound Gasket Gasket Material: Graphite or Soft Steel
Gasket m Factor: 2.50 Gasket y Factor: 69 N/mm² (10000 Lbf/in²)
Gasket Load Reaction Diameter: 553.5 mm (21.79
Effective Gasket Seating Width: 8.98 mm (0.354 in)
in)

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 402.4 kN (90475 lbf) . This represents 31% 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 49%. 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 STS4-200 and a Pressure A = 746 bar (10818 psi) and a
Pressure B = 597 bar (8655 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

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BOLTRIGHT Tightening Procedure

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 - B7 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. 25% 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 20 bolts in the flange are to be tightened using a 25%
tensioning procedure i.e. tensioners will be fitted to 5 bolts eqi-spaced around the
flange. These are tightened to a high pressure (Pressure A) before the next 5 bolts are
tightened to this pressure (Pressure A). This is repeated until all the 20 bolts in the
flange have been tightened. A "break loose" pressure is then determined for the
tightened bolts which should be greater than Pressure B (which is lower than the
original tightening Pressure A). The sequence and pressures applied are critical to
achieving a leak free joint, carefully follow the instructions detailed below:
B2.2 Tensioner Installation. Fit the hydraulic tensioners (Hi-Force Model Number
STS4-200) to 5 bolts eqi-spaced around the flange.
B2.3 Pressure A Tensioning. Apply Pressure A i.e. 746 bar (10818 psi) and tighten
the nuts using a tommy bar. Release the pressure and remove the tensioners from the
bolts. Place the tensioners on the next 5 bolts ensuring that the tensioners are eqi-
spaced. Apply Pressure A i.e. 746 bar (10818 psi) and tighten using a tommy bar.
Repeat this procedure until all 20 bolts have been tightened using Pressure A.
B2.4 Break Loose Tensioning Check. Transfer the hydraulic tools back to the 5 bolts
that had been first 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. 597 bar (8655
psi) then the required tensioning value as been achieved on this bolt. Repeat this
Pressure B check on all the bolts in the flange. If it is found that the "break loose"
pressure on any of the bolts is less than pressure B then it is necessary to repeat steps
B2.3 to B2.4 to ensure a leak free joint.
Final Check. As a final check, use a hammer to "ring" each bolt to ensure that none
are slack. On high-pressure, high-temperature applications, it is suggested that the
flanges be retightened to the required stress after 24 hours at operating pressures and
temperatures to compensate for any relaxation or creep that may have occurred.

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