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.

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orque 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"

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.
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.

safety

documents

materials

societies

pipes

flanges

fittings

valves

bolts

gaskets

equipment

specials

steel

steam

civil

others

Question and Answer

 Piping related Abbreviations

Making the environment better

Advertisements

Explore the World of Piping

© Werner Sölken 2008 - 2022

All rights reserved.
www.wermac.org uses Google Analytics