Impact of BFJA Training on Bolted Flange Joint Assembly Reliability

2019 ◽  
Author(s):  
Ross Dupre
Keyword(s):  
Best Practices ◽  
Material Selection ◽  
Flange Joint ◽  
Mechanical Device ◽  
Gasket Material ◽  
Bolted Flange ◽  
Important Activity ◽  
Joint Assembly

Abstract A bolted flange joint assembly is a complex mechanical device, according to ASME PCC-1. A complex mechanical device’s reliability depends on many activities being performed prior and during the assembly of the bolted flange joint assembly (BFJA) being assembled. Some of these activities being; required torque calculations; gasket material selection, fastener selection, type of flange, fastener condition, lubrication, and maybe the most important activity being the assembly of the bolted flange joint. How does one ensure the correct methods and best practices being used during the assembly of the bolted flange joint? Education. Educating not only the assemblers but also the engineers, supervisors, foreman, etc. By educating more than just the assemblers we can create a proper culture to ensure BFJA reliability. We can quantify increased BFJA reliability spurred from education by using surveys completed by the assemblers who have gone through the training.

scholarly journals Solving the Puzzle of Bolted Joints

2011 ◽  
Vol 133 (06) ◽  
pp. 48-52
Author(s):  
Edward Hayman ◽  
Clyde Neely
Keyword(s):  
Best Practices ◽  
Bolted Joints ◽  
Bolted Joint ◽  
Flange Joint ◽  
Unit Load ◽  
Bolt Stress ◽  
Torque Values ◽  
Bolted Flange ◽  
Joint Integrity ◽  
Joint Assembly

This article discusses the various ways of solving the puzzle of bolted joint assembly. In 2001, The PCC-1-2000 Guidelines for Pressure Boundary Bolted Flange Joint Assembly presented with knowledge and practices specific to the assembly of bolted flange joints. The puzzle solution that came from this box was the most definitive to date and allowed those dealing with bolted joints to assemble the variables by methods that had been used successfully for many years by many people. This document is helping people across industry not only to assemble bolted flange joints, but also to establish joint integrity programs, procedures, and best practices. PCC-1-2010 shifts the emphasis to gasket stress and gasket type and provides instruction and information pertinent to bolt torque values. The 2010 document contains, for instance, a whole section on bolt stress—the unit load that should be put on the bolts—and includes tables as well.

Application of Bolted Flange Joint Assembly Guidelines HPIS Z103 TR to ePTFE Sheet Gasket

2008 ◽  
Author(s):  
Hirokazu Tsuji ◽  
Yuuki Terui
Keyword(s):  
Relaxation Rate ◽  
Modulus Of Elasticity ◽  
Elastic Interaction ◽  
Flange Joint ◽  
Fiber Sheet ◽  
Force Reduction ◽  
Assembly Procedure ◽  
Bolted Flange ◽  
Application Scope ◽  
Joint Assembly

Bolt tightening guidelines HPIS Z 103 TR for flange joint assemblies have been developed to provide a simple and effective procedure to tighten flange joint bolts. This assembly procedure is applicable to compressed fiber sheet gaskets and spiral wound gaskets, but is not applicable to expanded PTFE (ePTFE) sheet gaskets for the reason that the ePTFE material has lower modulus of elasticity and higher creep/relaxation rate. In this study, expansion of the application scope of HPIS Z103 TR to ePTFE sheet gaskets is investigated. Tightening tests are conducted using flange joint specimens of JPI 4 inch and 6 inch, and all bolt forces and flange gaps are measured at each tightening step to check for uneven tightening. Uniformity of the bolt forces and flange gaps are comparable to those obtained by other types of gaskets or by tightening procedure ASME PCC-1. The influences of gasket relaxation and elastic interaction on the bolt forces are also demonstrated. As a result, flange joint assembly guidelines HPIS Z 103 TR can be considered applicable to the high-density ePTFE sheet gasket, although a post-tightening step of 1 or 2 passes is necessary to compensate for the bolt force reduction induced by gasket relaxation.

Bolted Flange Joint Made of Glass Fibre Reinforced Polymer (GFRP) for Oil and Gas Pipelines

2018 ◽  
Author(s):  
Muhsin Aljuboury ◽  
Md Jahir Rizvi ◽  
Stephen Grove ◽  
Richard Cullen
Keyword(s):  
Glass Fibre ◽  
Oil And Gas ◽  
High Strength ◽  
Flange Joint ◽  
Element Analysis ◽  
Glass Fibre Reinforced Polymer ◽  
Linear Behaviour ◽  
Glass Fibre Reinforced ◽  
Gasket Material ◽  
Bolted Flange

The objective of this work is an experimental and numerical investigation for a bol Richard Cullen ted composite flange connection for composite pipes, which are used in the oil and gas applications, and obtain a joint with high strength and high corrosion resistance. For the experimental part, we have designed and manufactured the required mould, which ensures the quality of the composite materials and controls its surface grade. Based on the ASME Boiler and Pressure Vessel Code, Section X, this GFRP flange has been fabricated using biaxial glass fibre braid and polyester resin in a vacuum infusion process. Numerically, an investigation is carried out using 3D finite element analysis (FEA) of a bolted GFRP flange joint including flange, pipe, gasket and bolts. This model has taken into account the orthotropy of the GFRP material and the non-linear behaviour of the rubber gasket material for both the loading and non-loading conditions. Furthermore, the leakage propagation between the flange and the gasket has also been simulated in this investigation by using the pressure-penetration criteria PPNC in ANSYS. Finally, the flange has been tested under the internal pressure and the agreement between the experimental and numerical results is excellent.

Bolted Flange Joint Assembly Service Provider Assessments

2018 ◽  
Author(s):  
Brett Thibodeaux ◽  
Scott Hamilton
Keyword(s):  
Service Provider ◽  
Chemical Process ◽  
Technical Information ◽  
Bolted Joint ◽  
Flange Joint ◽  
Process Industries ◽  
The Past ◽  
Bolted Flange ◽  
Joint Assembly ◽  
Chemical Process Industries

There have been two major updates to ASME PCC-1 “Guidelines for Pressure Boundary Bolted Flange Joint Assembly” within the past 7 years. In 2010, substantial technical information was added, and in 2013 Appendix A “Training and Qualification of Bolted Joint Assembly Personnel” was added to the document. This paper provides an overview of a program to review and evaluate bolting contractors that serve the refining and chemical process industries, based on their level of alignment with the requirements of ASME PCC-1 Appendix A, and describes a method of applying the results using a risk-based approach.

ASME PCC-1:2018: What Is New and Different?

2018 ◽  
Author(s):  
Clay D. Rodery ◽  
Warren Brown
Keyword(s):  
Flange Joint ◽  
Bolted Flange ◽  
Joint Assembly

The next edition of ASME PCC-1, “Guidelines for Pressure Boundary Bolted Flange Joint Assembly” [1] will be published in 2018. This paper highlights the key revision items, the background behind them, and provides future insights toward what topics might be targeted for subsequent editions.

Determining Accuracy and Repeatability of Torque Through Powered Equipment

2017 ◽  
Author(s):  
Scott Hamilton ◽  
Benjamin F. Hantz ◽  
Jason Wright
Keyword(s):  
Axial Load ◽  
Calibration Method ◽  
Flange Joint ◽  
Physical Strength ◽  
Industry Standards ◽  
Torque Wrench ◽  
Industrial Assembly ◽  
Bolted Flange ◽  
Accuracy And Repeatability ◽  
Joint Assembly

This paper explores torque wrench accuracy, one source of the overall inaccuracy associated with bolted flange joint assembly. The accuracy and repeatability of various pneumatic torque wrenches were tested and analyzed. Pneumatic torque wrenches were benchmarked against a hydraulic wrench which has a lower perceived bolt load scatter. The testing was performed on two mock-up flanges, NPS 8 Class 150 and NPS 16 Class 300 raised-face flanges with spiral-wound gaskets. The analysis compares the accuracy and repeatability of the following: each tool versus its manufacturer’s claims; duplicate models of the same tool; and overall tool type (pneumatic or hydraulic) versus another tool type. Because accuracy is closely related to tool calibration, torque wrench calibration method and frequency are also discussed. There are several methods of applying axial load through torque that have been used within the industrial assembly of Bolted Flanged Joint Assemblies (BFJA’s). The most common tool used within the industry is the manual torque “clicker” wrench which traditionally allows an assembler to reach 600ft/lbs. While companies make wrenches that achieve higher amounts of torque, they are harder on the assembler to use so other tools, such as hydraulic and pneumatic torque wrenches (Powered Equipment), that require less physical strength are used instead. This paper will discuss the accuracy and repeatability of pneumatic and hydraulic wrenches and compare them to the manufacturer’s/industry standards.

Propagating ASME PCC-1 Appendix A Compliance

2016 ◽  
Author(s):  
Jason M. Barnard
Keyword(s):  
Construction Industry ◽  
Step Change ◽  
Bolted Joint ◽  
Flange Joint ◽  
Engineering Construction ◽  
Mechanical Joint ◽  
Bolted Flange ◽  
Joint Integrity ◽  
Industry Training ◽  
Joint Assembly

In November 2013 the revised ASME PCC-1 “Guidelines for Pressure Boundary Bolted Joint Assembly” were published including Appendix A, “Training and Qualification of Bolted Joint Assembly Personnel.” This Appendix outlines a training, examination and qualification system for ensuring a consistent level of knowledge and experience for bolting assemblers and specialists working on bolted flange joint assemblies. The ultimate objective is a mobile workforce capable of bolting ASME plant with a minimum performance standard safely and with no subsequent leaks. Major operators and contractors involved in oil and gas, petrochemical and power generation, or any industry that uses bolted flange joint assemblies, can benefit from PCC-1. Benefit recognition has begun with operators now specifying PCC-1 compliance in their procedures and bid packages. However, nearly three years after the introduction of Appendix A the number of Qualifying Organizations approved to deliver the program and individuals qualified via these programs remains stubbornly small in comparison with other programs and insufficient to meet the future safety demands of the industry or the objective of PCC-1 and Appendix A. This technical paper reviews key elements of Appendix A, compares Appendix A with other international qualifications and suggests recommendations intended to increase recognition and compliance with these guidelines. The recommendations and expected benefits follow from an extensive review of work by other organizations and published data concerned to reduce recorded leaks from bolted joints, including: a) Implementation lessons learned from a Qualifying Organization and Review Organization. b) Current international qualifications and the differing routes to achieve each qualification including: 1) ASME PCC-1 Appendix A Training and Qualification of Bolted Joint Assembly Personnel. 2) European standard EN1591-4 Qualification of personnel competency in the assembly of the bolted connections of critical service pressurized systems. 3) Engineering Construction Industry Training Board (ECITB) Mechanical Joint Integrity (MJI) technical training standards and Step Change in Safety Mechanical Joint Integrity Route to Competence Guidance 4) Additional country specific qualifications c) Program effectiveness study of the Engineering Construction Industry Training Board (ECITB) Mechanical Joint Integrity (MJI) program and the Step Change in Safety Hydrocarbon Release (HCR) model set up to achieve leak reduction in the UK North Sea sector. Finally, the paper will conclude with outlining the benefits to be gained globally through standardization of international qualification programs to enable true portability including: a) The need to increase the number of auditable Qualifying Organizations able to deliver the program, qualify individuals and engage operator/contractors in the process. b) Importance of effective communication and summary of the guidelines.

Effects of Stud Galling on Bolted Flange Joint Assembly Performance

2020 ◽  
Author(s):  
Ross Dupre
Keyword(s):  
Standard Test ◽  
Cold Welding ◽  
Flange Joint ◽  
Load Cells ◽  
Overall Performance ◽  
Bolted Flange ◽  
Assembly Performance ◽  
Contact Metal ◽  
Over Time ◽  
Joint Assembly

Abstract This study will focus on the galling of studs and what impact that has on the overall performance of a Bolted Flange Joint Assembly. Galling or “cold welding” occurs more so with softer metals. While tightening the nut on to the stud the contact metal will “pull” away from itself and the two surfaces will essentially become one. Once this happens the nut cannot be tightened or loosened and often cutting the stud is the only form of removal. We’ll be studying how this affects the performance (tightness) of a bolted flange joint assembly. Does the assembly loosen over time or does it remain at the proper tightness? Data will be captured using load cells to accurately represent the amount of force being generated by test studs. There will be a standard test ran with no galling. All other tests with galled studs will be measured and compared against the standard test. One test with only one stud galled, the next with two studs galled, the next with three studs galled, and so on. It may be expected to see some load loss on the load cells with the galled studs. The integrity of the studs, once galled, becomes less than ideal.

Sign in / Sign up

Export Citation Format

Share Document