BOLTRIGHT Tightening Procedure file:///C:/Program Files/Hi-Force/BOLTRIGHT/TensioningProcedure.

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Hi-ForceLogo BOLTRIGHT RESULTS SUMMARY Date: 05/04/2011 at

and
11:50 AM
TIGHTENING PROCEDURE

Name: Organisation: TR-CCC Joint Tag:

Remarks: Hi-Force Tool STS2-125 used.

Flange and Gasket Details

Flange Standard: ANSI Flange Class: 2500
Flange Nominal Size: 3 Operating Temperature: 20 C
Design Pressure: 425 bar (6170 psi) Test Pressure: 638 bar (9255 psi)
Number of Bolts in Flange: 8 Bolt Thread Size: 1 1/4 - 8 UN
Bolt Material: ASTM A193 - B7 Bolt Minimum Yield Strength: 724 N/mm 2 (105000 Lbf/in 2)
Gasket Type: Spiral Wound Gasket Gasket Material: Graphite
Gasket m Factor: 2.50 Gasket y Factor: 69 N/mm 2 (10000 Lbf/in 2 )
Effective Gasket Seating Width: 6.71 mm (0.265 inches) Gasket Load Reaction Diameter: 107.2 mm (4.22 inches)

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 196.1 kN (44087 Lbf)
This represents 42% 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 66%. 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 STS2-125 and a Pressure A = 1005 bar (14570 psi) and a Pressure B = 804 bar (11656 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 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 1 1/4 - 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. 50% 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 8 bolts in the flange are to be tightened using a 50% tensioning procedure i.e.
tensioners will be fitted to 4 bolts eqi-spaced around the flange. These are tightened to a high pressure
(pressure A) before the remaining 4 bolts are tightened to a lower pressure (pressure B). The sequence and
pressures applied are critical to achieving a leak free joint, carefully follow the instructions detailed below:

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BOLTRIGHT Tightening Procedure file:///C:/Program Files/Hi-Force/BOLTRIGHT/TensioningProcedure.HTM
B2.2 Tensioner Installation. Fit the hydraulic tensioners ( Hi-Force Model Number
STS2-12 5) to 4 bolts eqi-spaced around the flange.
B2.3 Pressure A Tensioning. Apply Pressure A (i.e. 1005 bar (14570 psi)) and tighten the nuts using a
tommy bar. Release the pressure.
B2.4 Pressure B Tensioning. Transfer the hydraulic tools to the 4 bolts that are yet to be
tightened. Apply pressure B (i.e. 804 bar (11656 psi)) and tighten. Release the pressure and then re-apply
the pressure and ensure that the 4 nuts are tight.
B2. 5 Break Loose Tensioning Check. Transfer the hydraulic tools back to the 4 bolts that
had been previously 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. 804 bar (11656 psi)) then the tensioning is complete. If this "break loose" pressure is less
than pressure B then repeat steps B2.3 to B2.5.
Final Check. As a final check, use a hammer to "ring" each bolt to ensure that none are slack.

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