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PVP2004-2365 Brown Efficient Assembly
PVP2004-2365 Brown Efficient Assembly
Warren Brown
Syncrude Canada, Alberta, Canada
brown.warren@syncrude.com
ABSTRACT
This paper details the results of recent testing and experience The other research project, which commenced in 2001, was
into the assembly of bolted joints. Pressure boundary bolted joint undertaken at Ecole Polytechnique, Montreal, Canada and was
assembly procedures are examined and details are presented that funded by industry and the PVRC. The project examined heat
result in a reduction in the required effort to assemble any given joint exchanger joint integrity issues, including bolting patterns and bolt
by more than 50%. The selection of correct assembly load levels is torque. This paper presents some of the information and conclusions
addressed and suggestions for joint integrity improvement are made. from that research project. The results of the PVRC project support
Experimental results are also presented on the use of bolt lubricants both industry and the Japanese research conclusions; that it is
and the effect of temperature on the lubricant properties. possible to further streamline pressure vessel and piping bolted joint
assembly. In so doing, industry is served by both reduced costs and
improved joint integrity.
INTRODUCTION
In past years the correct procedure for assembling bolted
joints on exchangers, piping and pressure vessels was not a well- BOLTED JOINT ASSEMBLY PROCEDURES
documented subject. There were general guidelines in books on The objective of a bolting procedure is to tighten the bolted
bolted joints, such as Bickford [1], however these were often not joint to the desired gasket stress level, whilst doing this in such a way
specific enough. Frequently, an external bolting contractor or so as to not damage the sealing capabilities of the joint during the
consultant was employed to provide suitable answers. The situation, tightening process. This is commonly achieved by specifying a
at the plant level, was improved with the release of the Fluid Sealing gradual increase in bolt stress for each bolting pass and also by using
Association bolting pamphlet [2]. In recent years, ASME recognised a bolting pattern during the first few bolting passes. A typical
the deficit and released PCC-1 [3]. This document provides a formal, example of this approach (for a 24 bolt joint) is outlined in Fig. 1.
well-written guideline that instructs end users on the assembly of This bolting procedure is perhaps the most commonly used procedure
bolted joints. and is taken from the ASME PCC-1 [3] bolted joint assembly
guidelines.
Recently, however, there has been industry experience and
several research projects that have pointed to the fact that it was The effectiveness of this bolting pattern in achieving the
possible to assemble a joint with less effort than the methods outlined desired objective is historically well proven. However, the use of this
in PCC-1. The industry and research efforts were aimed at decreasing pattern is somewhat complex, in that the bolt numbers must be
the required effort by reducing the complexity of the bolting pattern marked on the flange prior to tightening and the pattern followed
and by increasing the bolt load at a faster rate. The research work closely to ensure bolts are not missed. Additionally, for the first three
commenced independently in both Japan and Canada. The Japanese passes, the pattern requires that the fitter must go from one side of the
work was funded by the JPVRC and Japanese industry. It has been joint to the other between tightening actions. This is particularly
presented on several occasions at the ASME PVP (Tsuji[4], arduous for larger diameter flanges, in awkward locations, where
Takaki[5] and Kumakura[6]). The Japanese research work is being heavy bolt assembly equipment must be used. This often creates
formulated into a standard industry procedure, for certain gasket resistance in the field to the implementation of this bolting procedure.
types, which utilises primarily circular bolting passes.
type joint. The bolt stress levels were controlled and measured using
specially constructed bolt load gauges. A variety of different gasket
24 1 types were tested, including Corrugated Metal (CG), Kammprofile
2 2 1st Pass = 20% (PG), PTFE and Spiral Wound (SW) gaskets.
22 3 2nd Pass = 60%
21 4 3rd Pass = 100%
4th , 5th ,.. = 100%
20 5 All passes in star
19 6 pattern except the
4th and subsequent
18 7 which are circular
pattern (i.e.:
17 8
1,2,3,4,…) and are
16 9 repeated until the
15 10 nuts do not turn.
1 11
13 12
24 1
2 2 1st 4 bolts = 20% Figure 3 – RA.S.T. Test Rig
22 3 2nd 4 bolts = 60%
21 4 All other = 100% 1
0.7
subsequent which
0.6
18 7 are circular pattern
0.5
(i.e.: 1,2,3,4,…) Pass #1
17 8
and are repeated 0.4 Pass #2
Pass #3
16 9 until the nuts do 0.3
Pass #4
15 10 not turn. 0.2 Pass #5
14 11 Pass #6
0.1
13 12
0
CG1 CG2 CG3 CG4 PG1 SW1 SW2 SW3 PTFE1 PTFE2 PTFE3
Figure 2 – BP4 [Quadrant Procedure] Gaske t De scription
0.8 0
Assembly Efficiency
BP1
BP2
BP3
BP4
0.7
0.6 Pass1 Pass2 Pass3 Pass4 Pass5 Pass6
0.5
Figure 6 - Pattern Effort Comparison
0.4
0.3 Whilst it is encouraging to see such high levels of saving in
0.2 effort associated with the modified passes, one must always keep in
0.1
mind that the required effort will multiply exponentially if the utilised
procedure damages the gasket during assembly and causes
0.0
operational leakage necessitating re-assembly of the joint. Gasket
BP1
BP2
BP3
BP4
failure due to poor assembly is often seen in the field (for example,
Pass 1 Pass 2 Pass 3 Pass 4 Pass 5 Pass 6 buckling of a spiral wound gasket). To examine the effect of the
various procedures on gasket performance, testing of a variety of
Figure 5 - Procedure Efficiency Comparison gasket types for each of the procedures was conducted. The tests
performed on PTFE gaskets were the most revealing of these tests.
It is apparent from this graph that BP1 required 6 passes to
achieve a gasket load close to the desired value. This compares with
0.014
only 4-5 passes for the other bolting procedures. There is therefore a
direct saving associated (in this case) of a 17% reduction in the 0.012
Flange Gap (inches)
number of passes. Other gaskets, which compress less, will give an 0.010
even larger reduction in effort. However, the indicated reduction in
0.008
effort does not fully demonstrate the achieved saving in assembly
effort. A circular pass requires much less effort than a pattern pass, 0.006
due to the fact that the tightening head is moved directly from one 0.004
bolt to another, rather than to the other side of the joint. A more
accurate measure of the level of effort for each of the procedures is 0.002
shown in Fig. 6. This graph outlines the distance that the tightening 0.000
head must be moved, from nut to nut, to complete each pass of the Quad 1 Quad 2 Quad 3 Quad 4
different procedures for the 24" flange. This measure is more closely Assem. BP1 Assem. BP2 Assem. BP3 Assem. BP4
indicative of the level of effort associated with each of the bolting
Post T est BP1 Post T est BP2 Post T est BP3 Post T est BP4
patterns.
Figure 7 - Procedure Comparison, Flange Gap
The percentage values that appear above each column give
the percentage of total movement for that bolting procedure, by Figure 7 shows gap measurements between the RA.S.T. rig
comparison to BP1. As can be seen, there is a dramatic reduction in flanges, at the middle point of the four quadrants (i.e: at 45°, 135°,
the required work from BP1 to BP2 (33% reduction) and an even 225° and 315° angular positions) for the four bolting procedures. The
more dramatic reduction for BP3 and BP4 (77% and 70%). It is deflection results are presented for identical 3.2mm (1/8inch) PTFE
therefore evident that there are major labour savings to be obtained gaskets, both immediately after assembly and then after heating for
from the optimisation of bolting procedures. 10 hours at 175°C (350°F). Since even compression of the gasket is
an important measure of the effectiveness of a bolting procedure, the
above graph clearly demonstrates which of the bolting procedures are
superior. Perhaps surprisingly, it is not BP1 that achieved the most
even compression of the gasket. It was, in fact, BP2 that achieved,
essentially, a uniform compression of the gasket. The reason for this
400
can be easily seen in Fig. 5. For BP1 the circular passes (pass 4
350
onward) commenced when the average gasket stress was only 50% of
the final value, whereas for BP2 the average gasket stress was 70% of 300
the final value when the circular passes commenced. Commencing
0.16 be no more than 50% of bolt yield. On the other hand, new, properly
0.14
lubricated bolts can be loaded much higher (to at least 70% of bolt
yield) as one can be much more confident of the accuracy of the load.
0.12
In addition, the new, properly lubricated bolts will further improve
0.10
joint integrity as the loading will be more even and the bolts will be
0.08 loaded nearer to the desired level. One can, therefore, easily increase
0.06 joint integrity by using new bolts, hardened (ASTM F436) washers
-5 (23) 25 (77) 40 (104) 100 (212) 200 (392) and excessive amounts of lubricant.
Assembly Temperature °C (°F)
Copper #1 (K=0.16) Copper #2 (K=0.12)
Moly #1 (K=0.1) Moly #2 (K=0.08)
Nickel #1 (K unavail.) Nickel #2 (K=0.15) SUMMARY - MAXIMISING JOINT INTEGRITY
Note: The Nut Factor listed above is from manuf. literature for the lubricant. One of the reasons that pressure vessel and piping joint
Figure 9 - Example Lubricant Nut Factors assembly remains a mystery for many is that there are a multitude of
factors at play that all interact to determine if a given joint will seal or
In addition, another factor that is evident from the graph is that not. What may work for a refinery, may not work at all for a chemical
the actual temperature during joint assembly affects the nut factor. plant and vice-versa. However, joint integrity can be maximised in
For some lubricants the difference in achieved load for a given torque
any plant when the following, equally important, factors are this is where the majority of saving in joint assembly effort can be
considered: made without any reduction in joint integrity.
1) Personnel - without people who are willing to push the limits
and experiment with joint assembly and, equally, others that It is also possible to simplify the bolting pattern and still
are willing to accept change, it is very difficult for any plant maintain the desired level of integrity. It should be noted, however,
to improve joint integrity that the bolting pattern has less effect on expended effort than does
2) Gasket Selection & Configuration - the selected gasket must increasing the bolt load more rapidly. The possible level of
be appropriate for the service. The joint should be configured simplification is also highly dependent on gasket type and it is
to restrain the gasket and keep it intact during assembly and recommended that, for softer gasket types (PTFE, Soft Sheet and
operation. The moment arm between the bolts and gasket Spiral Wound) at least one or two pattern passes are used.
should be minimised. Thermal loading that can cause flange
radial movement and fail gaskets (ref. Brown [7]) must also It has also been detailed that joint integrity may be greatly
be accounted for in gasket selection. Gaskets claiming to be improved by following a plan that includes testing of the lubricant
the panacea for all joint leakage should be used with caution, being employed, the use of new bolts, hardened washers and
as they rarely improve the situation. The gasket should be of excessive lubricant levels. In addition, the specified bolt load should
as simple construction as possible, as complexity leads only be selected to be as high as possible.
to more ways it can (and will) fail.
Further details of these tests will be published as a Welding
3) Load selection - the selected load should be maximised for Research Council Bulletin by the Pressure Vessel Research Council.
the given application. Where this proves not to be sufficient
then joint modification (different bolts, gasket or gasket
configuration) or "hot-torquing" (re-torquing of the bolts at ACKNOWLEDGMENTS
around 200°C (400°F), with modified nut factor - ref. Fig. 9) The author would like to thank the companies and individuals
should be employed. who supported the original Pressure Vessel Research Council project
4) Utilise proper load control and an appropriate bolting from which the results presented in this paper were taken;
procedure. Both of these factors depend on the individual
M. Derenne & L. Marchand - Ecole Polytechnique / TTRL
plant and it takes a relatively simple program to establish the
R. Brodzinski - BP Refining Technology, USA
appropriate limitations within any plant. A suitable starting
S. Yuen - Shell Canada
point is to study the achieved load for a specified torque
A. Bausman - Eastman Chemicals
using a simple load cell, ultrasonics, bolt length measurement
or even a hydraulic tensioning head connected to a pressure The Pressure Vessel Research Council is also thanked for
gauge. providing funding and, perhaps more importantly, the platform from
5) Personnel and Procedures (again) - without proper training of which research projects such as this one can be launched.
personnel, appropriate quality control and good record
keeping of bolting procedures it is not feasible to improve
joint integrity, as it will never be possible to properly REFERENCES
determine exactly why a joint has leaked. If you can not [1] Bickford, J.H., 1998, "Gaskets and Gasketed Joints", Marcel
determine why a joint has leaked then it is not feasible to Dekker, New York, USA
determine the most appropriate solution to the problem. [2] Fluid Sealing Association, 2001, “Gasket Installation
6) Accept Failures as Learning - We learn the most from joint Procedures; Assuring Joint Integrity and Maximum Safety”, Fluid
failures and are able to greatly improve any integrity program Sealing Association, Wayne, PA, USA (www.fluidsealing.com)
from the learning gained. One of the most important, and [3] ASME PCC-1. 2000, “Guidelines for Pressure Boundary Bolted
often overlooked, ways to determine why a joint has leaked is Flange Joint Assembly”, American Society of Mechanical Engineers,
to examine the gasket. Often the reason for the failure is in NY, USA
plain sight (over-compression or buckling, under- [4] Tsuji, H. 2001, "Tightening Sequence of Bolted Flange Joint",
compression, physical destruction, chemical degradation or special presentation at the ASME PVP 2001 Conference, Atlanta,
oxidation, excessive flange rotation, etc…). Georgia, U.S.A.
[5] Takaki, T., Fukuoka, T. 2003, "Methodical Guideline for Bolt-Up
Employing these simple guidelines will enable most plants to
Operation of Pipe Flange Connections", ASME PVP 2003
immediately achieve a very high level of joint integrity. In addition,
proceedings, 457, Cleveland, Ohio, USA, 23-30.
the learning along the way will subsequently enable the ultimate goal
(100% leak-free operation) to be achieved shortly thereafter. [6] Kumakura, S., Saito, S. 2003, "Tightening Sequence for Bolted
Flange Joint Assembly", ASME PVP 2003 proceedings, 457,
Cleveland, Ohio, USA, 9-16.
CONCLUSIONS [7] Brown, W. 2002, “The Suitability of Various Gasket Types for
It has been demonstrated that the integrity of pressure vessel Heat Exchanger Service”, Proceedings of the ASME PVP 2002,
and piping bolted joint assembly can be increased, whilst decreasing ASME, Vancouver, Canada, 433, pp. 45-51
the effort expended, by increasing the bolt load more rapidly. In fact,