Description : Calculation for bolting-up protocol

As per G9D-7540-02

References
GEMTS Equip. ID Test
TAG number TAG number
Flange description Channel flange
Plant Example
Supplier drawing number B9-7501-sketch
Project PCE/M-3
Calculated by tester
Protocol date last week

Process Data
Design Temperature T deg.c 260.00
Design Pressure Pd bar 24.00
Test Pressure Pt bar 33.20

Gasket Data
Inside diameter; actual mm 1588.00
Inside diameter; effective Dgi mm 1588.00
Outside diameter; actual mm 1630.00
Outside diameter; effective Dgo mm 1628.00
Gasket pass partition rib area Ar mm2 0.00
Type Camprofile
Material Soft iron+graphite
Gasket factor cg --- 1.10
Min. seating stress @ ambient Sg;min MPa 15.00
Max. seating stress @ ambient Sg;max MPa 350.00
Max. seating stress @ temp Sg;max@T MPa 275.00

Bolt / Stud data

Total flange bolt force F tot N 12202734
Number of bolts n --- 72
Bolt reference number 6
Bolt size 8UN 1 1/8"
Bolt hole diameter Dh mm 32
Bolt length between nuts L mm 515
Bolt material A193 Gr.B7
Yield stress Sy MPa 723.90
Yield @ design temperature Sy @T MPa 610.00
Young's modulus E MPa 204775.00
Young's modulus @ design temp. E @T MPa 189600.00
Grease to be used Molykote P37
Friction coeff. Thread f --- 0.16
Friction coeff. Base/nut fs --- 0.16
Calculation summery
Margin to min. seating stress margin 1 --- 8.1
Margin to max. seating stress @T margin 2 --- 2.5
Margin to required force margin 3 --- 1.6
Margin to hot yield stress bolts margin 4 --- 2.0
Margin to specified tool margin 5 --- 1.0
Margin bolts for hydraulic tensioning margin 6 --- 1.7

Applied seating stress Sg MPa 121

Optimum seating tress Sg; optim MPa 64
Residual bolt stress (tensile str.area) Sb str.A MPa 333

Bolting-up torque T Nm 1030

Hydratight HL series: tool no. 01 fit / applicable? yes/no yes

Hydraulic pressure P hydr. bar 812
Effective OD mm 86
Min. Pitch mm 60
Clearance at base mm 32
Installing Height mm 185

Calculation gasket
Effective sealing diameter Dg mm 1608
Actual gasket contact width bg mm 20
Req'd force for design pressure F Pd N 6232724
Req'd force for test pressure F Pt N 7822265
Applied seating stress Sg Mpa 120.78
Optimum seating stress Sg; optim. Mpa 64.23
Margin to min. seating stress margin 1 --- 8.05
Margin to max. seating stress @T margin 2 --- 2.46
Margin to required force margin 3 --- 1.56

Calculation bolts
Bolt size 8 UN 1 1/8"
Bolt diameter d mm 28.58
Pitch diameter d2 mm 26.51
Angle of thread 2 alfa deg. 60
Pitch of thread p mm 3.18
Tensile stress area Abs mm2 509.68
Width across flats do mm 46.04
Residual bolt stress (tensile str.area) Sb str.A Mpa 332.53
Margin to hot yield stress bolts margin 4 --- 1.98

Calculation bolt torque

Auxiliary value x thread 0.51
Auxiliary value x bolt 2.45
Auxiliary value x nut 3.12
Bolting-up torque T 1029.88

Calculation hydraulic tensioners

Tool type Hydratight HL series: tool no. 01
Color code dark green
Max. Load F tool max. N 228000
Margin to specified tool margin 5 --- 1.03
Hydraulic Area A hydr. mm2 2277
Allowance for thread deflection a mm 0.076
Auxiliary value x defl. --- 0.09
Hydraulic pressure P hydr. bar 811.97
Applied bolt stress 'B' bolts Sb Mpa 362.75
Applied bolt stress 'A' bolts Sb' Mpa 435.30
Margin bolts for hydraulic tensioning margin 6 --- 1.66
External forces and moments to be included
in the pressure see G9D-7540-01

Shown on protocol for verification by maint.

In contact with flange face; for calc
Shown on protocol for verification by maint.
In contact with flange face; for calc
Contact area partition ribs with gasket

See sheet with gasket data

See sheet with gasket data
See sheet with gasket data
See sheet with gasket data

Design Pressure, P 2.40 MPa

Increase load to maximize safety margins 1 to 6. Width of Gasket, N 21 mm
Effective Gasket Width, b 20 mm
Point with mouse to input cell to see table Dia. At gasket load reaction, G 1608 mm
gasket design seating stress, y 275.00 MPa
Gasket Factor, m 1.10
For tensioners only Allowable stress at ambient temp., Sa 723.90 MPa
Allowable stress at design temp., Sb 610.00 MPa

Standard is Molykote P37 for CS and SS and

minus 30 degr.C < temp < 1400 degr.C
Average = 0.16 see also comment field
Average = 0.16 see also comment field
shall be > 1.3
shall be > 1.3
shall be > 1.3
shall be > 1.3
shall be > 1.0
shall be > 1.1

Shall be > 100 Mpa

Check if the required clearances and tool

dimensions as listed in this table fit with
the actual flange dimensions. If tool does
not fit or is not used, then specify no at
input location: "fit ? Yes/no". Input will effect
the output on the protocol. For picture see
G9G-7500-01

Dg = 0.5*(Dgo+Dgi)
bg = 0.5*(Dgo-Dgi)
F Pd = 0.12*Pi*Dg*Pd*(0.25*Dg+1.2*cg*bg)+cg*Ar*(Pd/10)
F Pt = 0.11*Pi*Dg*Pt*(0.25*Dg+1.0*cg*bg)+cg*Ar*(Pt/10)
Sg = F tot / (Pi*Dg*bg+Ar)
Sg; optim. = sqrt(Sg;min*Sg;max@T)
margin 1 = Sg / Sg;min
margin 2 = Sg;max@T / Sg *(E / E @T)
margin 3 = F tot / max.value(F Pd and F Pt)

Sb str.A = F tot / (n * Abs)

margin 4 = Sy @T / Sb str.A * (E / E @T)

x thread = p / (2*Pi)
x bolt = f * d2/ (2*cos(0.5*2 alfa))
x nut = fs * (do+Dh) / 4
T = F tot/(1000*n) * (x thread+ x bolt+ x nut)

Specified by hydratight
margin 5 = F tool max./(A hydr.*P hydr.*0.12)

x defl. = a*Abs*E*n/(F tot * L)

P hydr. = 10*F tot*(1+x defl.) / (n*A hydr.)
Sb = Sb str.A*(1+x defl.)
Sb' = 1.2 * Sb
margin 6 = Sy / Sb'
Wm2 = bπGy 27784245
Hp = 2bπGmP 533457.51
H = G²πP/4 4873861.8
Wm1 = Hp + H 5407319.3
Am = max(Wm1/Sb or Wm2/Sa) 38381.331
Ab 33816.96
W = 0.5(Am + Ab)Sa 26132171
169482.42
277.84003
239386.5
20004.482
277.84003
 Bolting-up protocol for : TAG number Channel flange

GEMTS Equip. ID Test Project PCE/M-3

Plant Example Protocol date last week

Materials, dimensions and strength data

Supplier drawing number: B9-7501-sketch
Gasket type and material: Camprofile Soft iron+graphite 1588 mm x
Bolt / stud material: A193 Gr.B7 72 x
Req'd bolt stress based on stress area 333
Safety margin as available according to the calc

Torque wrench
The nuts of all bolts shall be installed finger tight, followed by gradually increasing the bolt force to
the required value in minimum 4 passes. The bolt sequence shall be in accordance with ETS document
G9D-7540-01/03. The first pass may be done with a handspanner, without torque control.
pass 1 pass 2 pass 3
Bolting-up torque in Nm
Pass 4 shall be in circumferential pattern and be repeated until the nuts do not move.

Hydraulic tensioning
The nuts of all bolts shall be installed finger tight, followed by tightening with a hand spanner.
50% of the bolts shall be provided with hydraulic tensioners and fasten at pressure P 'A'.
The remaining 50% of the bolts shall be fastened at pressure P 'B'.
Tool No. NA means no toll (which fit) available
Color code
Hydraulic pressure P 'A' P hydr. bar
Hydraulic pressure P 'B' P hydr. bar
25% of the bolts out of the first set shall be re-tightened at pressure specified P 'B'. If the nuts
can be turned, all bolts shall be re-tightened. This step shall be repeated until the nuts do not move.

Inspection points
Gasket : material dimensions damange
Gasket surface : clean finish parallel to counter flange
Grease : Molykote P37 on bolt + nut on surface between nut and flange
Bolts and nuts : material dimensions tolerances
Alignment : angular rotational Center line offset without external force
ange

1630 mm
1 1/8" 8UN
MPa
1.6

(f= 0.16 fs= 0.16 )

t force to
TS document
.
pass 4

nner.

811.97
nuts
not move.

without external force

Description : Flange bolt-up calculation
As per G9D-7540-01

Process Data
Design Temperature T deg.c 260.00
Design Pressure Pd bar 24.00
Test Pressure Pt bar 33.20

Gasket Data
Inside diameter; actual mm 1588.00
Inside diameter; effective Dgi mm 1588.00
Outside diameter; actual mm 1630.00
Outside diameter; effective Dgo mm 1628.00
Gasket pass partition rib area Ar mm2 19296.00
Type Camprofile
Material Soft iron+graphite
Gasket factor cg --- 1.10
Min. seating stress @ ambient Sg;min MPa 15.00
Max. seating stress @ ambient Sg;max MPa 350.00
Max. seating stress @ temp Sg;max@T MPa 275.00

Bolt / Stud data

Total flange bolt force F tot N 12202734
Number of bolts n --- 72
Bolt reference number 6
Bolt size 8UN 1 1/8"
Bolt hole diameter Dh mm 32
Bolt length between nuts L mm 515
Bolt material A193 Gr.B7
Yield stress Sy MPa 723.90
Yield @ design temperature Sy @T MPa 610.00
Young's modulus E MPa 204775.00
Young's modulus @ design temp. E @T MPa 189600.00
Grease to be used Molykote P37
Friction coeff. Thread f --- 0.16
Friction coeff. Base/nut fs --- 0.16

The following data are automatically generated when using the excel
Program G9D-7540-02
Gasket sealing diameter Dg mm 1608
Actual gasket width in contact bg mm 20
Bolt size 1 1/8"
Basic pitch diameter d2 mm 26.51
Pitch of threads 8 UN p mm 3.18
one-half of thread angle Alpha degree 30
Tensile stress area Abs mm^2 509.68
Width across flats of nuts do mm 46.04
Hydraulic area of tensioner Ahydr. mm^2 2277
Relaxation factor hydr. Tensioning a mm 0.076

MINIMUM REQUIRED BOLT LOAD FOR PRESSURE

For test pressure

F;Pt = 1.1x{pi/4*Dg^2*Pt + pi*Dg*bg*cg*Pt} + cg*Ar*Pt

F;Pt = 7892734 N

For design pressure

F;Pd = 1.2x{pi/4*Dg^2*Pd + 1.2*pi*Dg*bg*cg*Pd} + cg*Ar*Pd

F;Pd = 6283665 N

Conclusion:
The minimum required bolt load shall be the maximum of two forces
as calculated above.
The bolt load is governed by the hydrostatic test pressure.
To anticipate for uncertainties a margin of 1.3 is applied.

F total = 1.3 * 7892734 = 10260554 N

OPTIMIZING

F total [KN] -> 10261 11287 12313 13339 14365

margin 1 > 1.3 5.68 6.25 6.82 7.39 7.96

margin 2 > 1.3 3.48 3.17 2.90 2.68 2.49
margin 3 > 1.3 1.30 1.43 1.56 1.69 1.82
margin 4 > 1.3 2.36 2.14 1.96 1.81 1.68
margin 5 > 1.0 1.20 1.10 1.02 0.95 0.88
margin 6 > 1.1 1.95 1.79 1.65 1.53 1.43

Conclusion:
The optimal bolt load for bolting-up is about
12313000 N

TORQUE TIGHTENING

T = Ftot/(1000*n) * {p/(2*pi) + f*d2/(2*cos(alpha)) + fs*(do + dh)/4}

T = 1039 NM

HYDRAULIC TENSIONING
Phyd = 10 * Ftot/n * {1 + a * (Ab * E)/(Ftot/n * L)}
Ahyd
Phyd = 819 Bar

50% of the bolts are tensioned in one step:

P'A' = 1.2*Phyd = 982 Bar
P'B' = Phyd = 819 Bar