Bolting Yellow Pages

Enerpac ‘Yellow Pages’ stand Section Page

for Technical Information! Bolting Theory 70

If selecting bolting tools is not your daily

routine, then you will appreciate these Torque Tightening 72
pages. The ‘Yellow Pages’ are designed
to help you work with hydraulics. They will
Tensioning 74
help you to better understand the basics
of bolting system set-ups and of the most
commonly used bolting techniques.
Bolt and Nut Sizes 76
The better your choice of equipment, the
better you will appreciate these tools. Key to measurement 77
Take the time to go through these ‘Yellow Pressure/Torque, S & W 78
Pages’ and you will benefit even more from Enerpac Bolting Service 80
Enerpac Bolting Solutions. Enerpac Academy

GLOBAL LIFETIME WARRANTY STATEMENT

www.enerpac.com Enerpac products are warranted to be free of defects in materials and

 isit our web site for the
V workmanship. Any product that does not conform to specification will
complete Global Lifetime be repaired or replaced at Enerpac’s expense, anywhere in the world;
Warranty or call your simple as that !! This warranty does not cover ordinary wear and tear,
Authorized Service Center. abuse, misuse, alterations, or the use of improper fluids. Determination
of the authenticity of a warranty claim will be made only by Enerpac or its
Authorized Service Centers.

Enerpac is certified for Where specified, CE Marking

several quality standards. Enerpac electric & Conformity
These standards require power units meet the Enerpac provides a
compliance with standards for ATEX 95 Certified design, assembly and test Declaration of Conformity and
management, administration, The ATP, ZA XA-Series air requirements of the Standards CE marking for products that
product development and pumps and S- and W-Series Council of Canada (CAN conform with the European
manufacturing. Enerpac work­ torque wrenches are tested C22.2 No. 68-92), and UL73 Community Directives.
ed hard to earn the quality and certified according to the for the United States. Units
rating ISO 9001, in its ongoing Equipment Directive 94/9/EC were tested and certified for ASME B30.1
pursuit of excellence. “ATEX Directive”. both USA and Canada by Our cylinders fully comply with
TÜV, a nationally recognized the criteria set forth by the
Product Design Criteria testing laboratory. American National Standards
All hydraulic components are Institute (except ‘BRD’, ‘CLL’
designed and tested to be safe EMC Directive 2004/108/EC and CLS series).
for use at maximum 700 bar Where specified, Enerpac
ENERPAC, 720 W. James St., Columbus, WI 53925 USA
(10.000 psi) pressure unless electric power pumps meet
otherwise specifically noted. the requirements for Electro­
magnetic Compatibility per
DIN 20024 EMC Directive 2004/108/EC.
Enerpac thermoplastic hoses
are related to the criteria set
forth in Deutsche Industrie
Norm 20024.

68 www.enerpac.com
 Bolting Solution and Application Worksheet
 Please complete the following information prior contacting Enerpac for your bolting proposal:

Requested By: ____________________________________________________________________________________________________

Requested Date: __________________________________________________________________________________________________
Company: ________________________________________________________________________________________________________
Industry:__________________________________________________________________________________________________________
Contact: __________________________________________________________________________________________________________
Title:______________________________________________________________________________________________________________
Phone: ___________________________________________________________________________________________________________
Fax:_______________________________________________________________________________________________________________
Email:_____________________________________________________________________________________________________________
Description of Application (provide drawings if possible):
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
Type of Application:
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________

APPLICATION TECHNICAL DATA

Bolt Quantity:_______________________ Application Position:

Bolt Diameter:______________________
 Top-side  Vertical  Inverted
Bolt Threads per Inch/Pitch:_________

Bolt Grade:_________________________

Bolt Coating:_______________________
Gasket Type:_______________________

App. Operating Temp., °C or °F:

___________________________________

Known Bolting Values:

 Load

(kN / lbs)_______ % of Yield (N/mm2 /psi)

 Stretch-Bolt Length
Specify Dimensions: INCH MM (Metric)
(mm / inch)__________________________

 Turn of Nut A __________ B ___________ C ____________ D___________ E______________

(Preload / Degrees)__________________
Distance to Closure:___________________________________________________
 Torque
Current Lubrication: Type________________ Brand__________________
(Nm / Kgm / Ft.lbs)___________________

69
 Bolting Theory
Function of Bolts and Nuts

Threaded fasteners are used across Correctly tightened bolts make use of
industry to assemble products ranging their elastic properties, to work well
from pipelines to heavy-duty earth they must behave like springs. When
movers and from cranes to bridges load is applied, the bolt stretches and
and many more. Their principle tries to return to its original length.
function is to create a clamping This creates compressive force across
force across the joint which is able the joint members.
to sustain the operating conditions
without loosening.

Hooke’s Law of Physics Behavior of Bolts and Nuts

Elastic Plastic Bolt

Elasticity is defined in Hooke’s Law of In the plastic deformation a part of
Range Range Failure physics: The stress in a bolt is directly the elongation will remain after the
proportional to its strain. The stress- load is removed. The point where
UltimateTensile strain of a bolt has an elastic range this permanent elongation occurs is
Point Tensile
Point and a plastic range. In the elastic called the yield strength. The further
Proof Load range Hooke’s Law is true. application of load takes the bolt to
a point where it begins to fail this is
Stress

All of the elongation applied within termed its ultimate tensile strength
the elastic range is relieved when (UTS). At this UTS-point, if additional
the load is removed. The amount of force is applied to the bolt it will
elongation increases when more load continue to elongate until it finally
is applied. When a bolt is stressed breaks. The point at which the bolt
beyond its proof load (maximum load breaks is called the tensile point.
under which a bolt will behave in an
Strain
elastic manner), the elastic elongation Careful attention must be paid to
changes to plastic deformation the grade of bolt being used as bolt
and the strain will no longer be grades differ in the elastic range.
proportional to the stress.

Uniform preload (residual load) Preload

Under tight Over tight
The main purpose of a bolt and nut Uneven bolt loads can result in:
is to clamp parts together with the • Some bolts being loose while
correct force to prevent loosening in others are overloaded.
operation. The term preload refers to • Crushing of the gasket on one side,
the loading in a bolt immediately after leakage on the other side.
it has been tightened.
Preload is normally dictated by
The amount of preload (residual load) the joint design, (see Enerpac Bolted
is critical as the joint can fail if the load Joint Integrity) for information on
in the bolt is too high, too low or not common joint types or contact your
uniform in every bolt. local representative.
1. Bolt loosens due to cycle loads of vibration.
2. Sealing face surface damage.
3. No compression.
4. Cracking.
5. Flange rotation.
6. Yielding of bolts.
7. Over compression of gasket.

70 www.enerpac.com
 Bolting Theory
Tightening Methods

Principally there are two modes of tightening: "Uncontrolled" and "Controlled".

Uncontrolled tightening Controlled tightening 1. Torque tightening

Uses equipment and/or procedures that Employs calibrated and measurable Achieves preload in a bolt and nut
cannot be measured. Preload is applied equipment, follows prescribed assembly via the nut in a controlled
to a bolt and nut assembly using a procedures and is carried out by trained manner using a tool.
hammer and spanner or other types of personnel. 2. Bolt tensioning
impact tools. There are two main techniques: Torque
Achieves preload in a bolt and nut
tightening and Bolt tensioning.
assembly by stretching the bolt axially
using a tool.

Advantages of Controlled Tightening

Known, controllable and accurate Safe operation following Reliable and repeatable results
bolt loads prescribed procedures Using calibrated, tested equipment,
Employs tooling with controllable Eliminates the dangerous activities of following procedures and employing
outputs and adopts calculation to manual uncontrolled tightening and skilled operators achieves known
determine the required tool settings. requires that the operators be skilled results consistently.
and follow procedures.
Uniformity of bolt loading
Especially important on gasketed joints The right results first time
as an even and consistent compression Reduces operational time resulting in Many of the uncertainties surrounding
is required for the gasket to be increased productivity in-service joint failures are removed
effective.
Reduces tightening time and operator by ensuring the correct assembly and
fatigue by replacing manual effort with tightening of the joint are carried out
the use of controlled tooling. the first time.

Bolting Integrity Software

A comprehensive on-line software
solution for Bolted Joint Integrity.

Integral databases hold data for:

• BS1560, MSS SP44, API 6A and 17D
flanged joints
• Common gasket materials and configurations
• Comprehensive range of bolt materials
• Comprehensive range of lubricants
• Enerpac's Controlled Bolting Equipment including:
Torque Multipliers, Hydraulic Wrenches and Bolt
Tensioning tools
Custom Joint information can also be entered.

The software offers Tool selection, Bolt Load

calculations and Tool pressure settings, as well
as, a combined Application data sheet and Joint
completion report.

Visit www.enerpac.com to access our free on-line bolting software

application and obtain information on tool selection, bolt load
calculations and tool pressure settings. A combined application data
sheet and joint completion report is also available.

71
 Torque Tightening
Torque Tightening What is Torque? Torque Tightening and
Preload
Turning movement It is a measure of how much force
acting on an object which causes that The amount of preload created when
object to rotate. torqueing is largely dependant on the
effects of friction.
What is Torque Tightening?
The application of preload to a Principally there are three different
Force
fastener by the turning of the “torque components”:
fastener’s nut. • torque to stretch the bolt
Stretch of Fastener (Pre-load) • torque to overcome the friction in
bolt and nut threads
• torque to overcome friction at the
nut spot face (bearing contact
surface).

Preload (residual load) = Applied Torque minus Frictional Losses

Friction points should always be Lubrication Reduces Friction Frictional Losses

lubricated when using the torque
tightening method. Lubrication reduces the friction during 10% converted to preload
tightening, decreases bolt failure
during installation and increases
Lubrication Reduces Friction bolt service life. Variation in friction
coefficients affect the amount of
preload achieved at a specified 50% at 40% in
Residual Bolt Load (kN) E

torque. Higher friction results in less nut face threads

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 Frictional Losses (dry steel bolt)

should be applied to both the nut
bearing surface and the male threads.

Torque (Nm) E
(Applied load)

Lubricated with Moly grease (µ = 0,10)

Light oil (µ = 0,15)

Dry unlubricated (µ = 0,20)

Example of how a lubricant can reduce

the effect of friction and convert more
torque to bolt preload.

72 www.enerpac.com
 Torque Tightening

Manufacturer’s rating of pressure and torque are maximum safe limits.

Good practice encourages using only 80% of these ratings!

Torque Procedure Select the Right Wrench

When torquing it is common to tighten only one bolt at a time, this can result Choose your Enerpac torque
in Point Loading and Load Scatter. To avoid this, torque is applied in stages wrench using the untightening
following a prescribed pattern: rule of thumb:
• When loosening a nut or bolt more
torque is usually required than when
tightening.
Torque Sequence • For general conditions it can take up
to 2½ times the input torque to
1 breakout.
• Do not apply more than 75% of the
maximum torque output of the tool
when loosening nuts or bolts.

Conditions of bolted joints

• Humidity corrosion (rust) requires up
to 2 times the torque required for
tightening.
• Sea water and chemical corrosion
Step 1 Spanner tight ensuring that 2 Step 4 Increase the torque to full requires up to 21⁄2 times the torque
- 3 threads extend above nut torque following the pattern required for tightening.
Step 2 Tighten each bolt to one-third shown above. • Heat corrosion requires up to 3 times
of the final required torque Step 5 Perform one final pass on the torque required for tightening.
following the pattern as each bolt working clockwise
shown above. from bolt 1, at the full final
Step 3 Increase the torque to two- torque.
thirds following the pattern
shown above.

Breakout Torque Read Instruction Manuals

When loosening bolts a torque value The use of penetrating oils or Please refer to the product
higher than the tightening torque is anti-seize products is always Instruction Sheets for safe use
normally required. This is mainly due recommended when performing guidelines and detail on the
to corrosion and deformations in the breakout operations. correct set up and operation of
bolt and nut threads. the equipment.

Breakout torque cannot be accurately

calculated, however, depending on
conditions it can take up to 2½ times
the input torque to breakout.

73
 Tensioning
Tensioning requires longer bolts What is Bolt Tensioning

Tensioning is the direct axial Tensioning requires longer bolts, and

INCORRECT stretching of the bolt to achieve a seating area on the assembly around
preload. Inaccuracies created through the nut. Tensioning can be done
friction are eliminated. Massive using detachable Bolt Tensioners or
mechanical effort to create torque Hydraulic Nuts.
is replaced with simple hydraulic
pressure. A uniform load can be
applied by tensioning multiple studs
simultaneously.

CORRECT
Preload (residual load) = Applied Load minus Load Losses

What is Load Loss?

L Minimum = Load loss is a loss of bolt elongation The preload depends on Applied Load
1xD depending on factors such as thread and Load Loss (load loss factor).
deflections, radial expansion of the
nut, and embedding of the nut into
the contact area of the joint. Load
loss is accounted for in calculation
and is added to the preload value to
determine the initial Applied Load.

Glossary of Terms
Applied Load: Load Loss: Proof Load:
The load applied to a bolt The losses in a bolt which occur on Proof load is often used interchange-
during tensioning which transfer of load from a tensioning ably with Yield Strength but is usually
includes an allowance for Load Loss. device to the bolt assembly (these may measured at 0,2% plastic strain.
arise from phenomena such as thread
Bolt Tensioning: deflection and embedding of the nut Tensile Point:
A method of controlled tightening to the contact area of the joint, and is The point at which the tensile loading
which applies preload to a bolt by calculated as a factor of the length to on a bolt causes the bolt to rupture.
stretching it axially. diameter ratio of the bolt).
Torque Tightening:
Breakout Torque: Load Scatter: The application of Preload to a bolt by
The amount of torque required to The spread of differing loads in a turning of the bolt's nut.
loosen a tightened bolt. (Usually more sequence of bolts after they have been
torque is required to loosen a bolt than loaded. It is mostly due to the elastic Ultimate Strength:
was used to tighten it.) interaction of the bolts and the joint The maximum tension which can be
member; as subsequently tightened created by tensile load on a bolt.
Elastic Range: bolts further compress the joint,
The range on a bolt's stress / strain previously tightened bolts are subject Yield Strength:
curve where stress is directionally to some relaxation. The point at which a bolt begins to
proportional to strain. plastically deform under tensile loading.
Preload:
Plastic Range: The load in a bolt immediately after it NOTE: Bolt is used as a generic term
The range on a stress / strain curve has been tightened. for a threaded fastener.
where the tensile load applied to a bolt
results in permanent deformation.

74 www.enerpac.com
 Tensioning

Manufacturer’s rating of pressure and torque are maximum safe limits.

Good practice encourages using only 80% of these ratings!

Tensioning Operation
Tensioning permits the simultaneous provides a uniform clamping force
tightening of multiple bolts; the tools across the joint. This is especially
are connected in sequence via a high- important for pressure containing
pressure hose assembly to a single vessels requiring even gasket
pump unit. This ensures each tool compression to affect a seal.
develops the exact same load and

General Procedure

Set-up using a 100%

tensioning procedure
All bolts are tensioned simultaneously.

Step 1 Step 2 Step 3 Step 4

Step 1: The bolt Tensioner is fitted The bolt behaves like a spring,
over the stud when the pressure is released the
Step 2: Hydraulic pressure is applied bolt is under tension and attempts
to the tensioner which then to contract, creating the required
stretches the stud. clamping force across the joint.
Step 3: The Stud’s nut is wound down
against the joint face
Step 4: Pressure is released and the
tool removed.

Less than 100% Tensioning Set-up using a 50%

tensioning procedure
Not all applications allow for the The load losses are accounted for in
simultaneous fit of a tensioning device calculation and a higher load is applied Half the bolts are tensioned
on each bolt, in these cases at least to allow the first sets to relax back to simultaneously, the tools are relocated
two tensioning pressures are applied. the target preload. on the remaining bolts and they are
This is to account for a load loss in subsequently tensioned.
those bolts already tensioned as the
next sets are tightened.
Read Instruction Manuals
Please refer to the product
Instruction Sheets for safe use
guidelines and detail on the
correct set up and operation of
the equipment.

75