Skills and Practices Flyer # 60

A document for sharing learnings about caring for equipment

Bolted Flanges
Flange bolts resist pressure & separating forces and uniformly clamps the joint/ gasket surfaces. The major cause of flange leaks, loose bolts and bolt fatigue is incorrect bolting practices but problems will often not occur till well after initial instillation.

Flange Bolting Preparation Check List

Ensure the correct specification bolts & nuts are used (S&P flyer #33) Its OK to reuse old bolts and nuts as long as they are not distorted or damaged If not specified, use a bolt diameter to torque chart for bolt type used and a generic tightening sequence (see right) or get specialist advice. Tightening sequence helps minimise flange distortion and achieving uniform clamping. For non-pipe flanges, work from the area of greatest stiffness out or from a central area spiralling out. Number at least two of the flange hole positions to define tightening starting point & direction. Bolt tension may need to be reduced for lower compressive strength gaskets or where significant flange distortion is observed or is considered likely. Flange Flatness Flange joint surface must be clean and within 0.15mm flatness. This maximum out-of-flatness must not occur in less than 20o of arc. Check using a flat plate, torch and feeler gauge. Repair any localised high spots. Flange Alignment The two mating flanges must be within 1mm in 200mm of parallel and the centrelines of each flange must be within at least 3mm. Check using a straight edge and taper gauge (eg Starrett 270) or similar method. Ensure the flange gap is free to close up without changing flange alignment. If drift pins are required for alignment, remove only after other bolts are first stage tightened. Flat washers are recommended under a nut or bolt head where there is a slightly uneven seating surface, where compressive loads need to be more widely spread or when the hole clearance is twice the clearance of a standard flat washer. Ensure there is no angle between nut or bolt head seating surface. Check the problem is not a Drunk Nut where there is an angle between nut seat & the bolt. For threaded holes check depth and bolt length to ensure bolts dont bottom out. Position the nut rather than the bolt head in the best position for later inspection.
#60 Bolted Flanges V1 - A4.doc - 6/07/2009 Controlled by peter.todd@sirfrt.com.au - Prepared by Peter Todd Prepared for SIRF Roundtable member purpures. It is not a substitute for professional advice.

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Tensioning Bolts - Torque Specifications

You need to be aware that a number of things can affect the torque specification for correct tensioning of a bolt. This includes bolt diameter, bolt material, galvanising (or other coatings), fineness of the threads and especially thread lubrication. Tests have shown that lubricated bolts require about 40% less torque to tighten then solvent cleaned bolts. Stainless steel, aluminium and other bolt materials that are susceptible to galling will often seize before full tightening if lubrication is not applied. High tensile galvanised bolts may not achieve full tension during tightening if lube is not applied.

High Pressure Piping Bolting Procedure

1. Ensure the flanges meet the flatness & alignment specification (see above). 2. Liberally lubricate the bolts, both on the threads and the underside of the bolt or nut that will be rotated. Install bolts and ensure the gasket is correctly positioned. 3. Lightly snug the bolts to ensure good alignment and flange seating (no clearance) 4. Tighten the bolts in the specified sequence to 60% of the maximum torque, then to 80% and then to 100%. 5. Repeat the tightening sequence at 100% of the required torque. 6. Go around the flange twice, this time in a clockwise sequence to 100% torque. This repetition of the final bolt tightening is required because as one bolt tightens and the gasket compresses, the tension is reduced on adjacent bolts. A bolt that was initially tensioned to 100% of the required torque may end up with only 10% of the required tension if no repetition is applied. This bolting practice has been used in general chemical & petroleum plants successfully for over 50 years.

Less Critical and Gasket-less Bolted Flanges

1. Same steps 1 to 3 for high pressure flange applications. 2. Tighten the bolts in the specified sequence to 70% of the maximum torque and then to 100%. 3. Go around the flange in a clockwise sequence to 100% of torque specification.

Bolting Quality Assurance

Even the most professional tradesperson can forget to fully tighten bolts when distracted. A bolt tightened snug looks identical to a fully tightened bolt. An error proofing method is shown at right. Immediately nuts are tightened snug then a white line is painted on one of the nut flats and radially on the bolt end aligning with the flat. When each bolt is fully tightened the line on the bolt head is extended through. The relative positions of old & new lines should be similar on all bolts.
#60 Bolted Flanges V1 - A4.doc - 6/07/2009 Controlled by peter.todd@sirfrt.com.au - Prepared by Peter Todd Prepared for SIRF Roundtable member purpures. It is not a substitute for professional advice. Page 2 of 2