User Guide for the

BOLTRIGHT Program

Software to assist in the torqueing/tensioning of bolted joints

BOLTRIGHT is from Hi-Force Hydraulics Limited

Hi-Force is the leading manufacturer of hydraulic tooling.

http://www.hi-force.com
COPYRIGHTS

Copyright © 2005 by Hi-Force Hydraulics Limited. All rights reserved. No part of this
publication may be transmitted, transcribed, reproduced, stored in any retrieval system or
translated into any language or computer language in any form or by any means, mechanical,
electronic, magnetic, optical, chemical, manual or otherwise, without prior written consent from
Hi-Force Hydraulics Limited.

The software described in this User Guide is provided under license and may be used or copied
only in accordance with the terms of such licence. The details of the license are shown when you
first install the software. Details of the license, if required, are available from Hi-Force.

Important Notice

Hi-Force provides this publication "as is" without any warranty of any kind, either express or
implied, including but not limited to the implied warranties of merchantability or fitness for a
particular purpose. Some jurisdictions do not allow a disclaimer of express or implied warranties
in certain transactions; therefore, this statement may not apply to you. Hi-Force reserves the right
to revise this publication and to make changes from time to time in the content hereof without
obligation of Hi-Force to notify any person of such revision or changes.

Trademark References

BOLTRIGHT is a trademark of Hi-Force Hydraulics Limited.

All other products mentioned herein may be trademarks of their respective holders and are
hereby recognised.

Hi-Force Hydraulics Limited

Bentley Way - Daventry - Northants - NN11 5QH - England - United Kingdom

Tel: (0044)1327 301000

Fax : (0044) 1327 706555

URL: http://www.hi-force.com/
Email: sales@hi-force.com
Contents
Introduction 1
Introduction .........................................................................................................................1
About the Program...............................................................................................................1
System Requirements ..........................................................................................................1
Installing BOLTRIGHT.......................................................................................................2

Flange/Gasket Bolting Analysis 3

Introduction .........................................................................................................................3
Flange Specification ............................................................................................................3
Bolt Details ..........................................................................................................................4
Gasket Details......................................................................................................................5

Flange Bolt Tightening by Torque Control 6

Background..........................................................................................................................6
Minimum Bolt Load Required for Torque Tightening ........................................................6
Lubrication Condition in the Threads and Under the Nut Face ...........................................7
Torque Tightening Requirements ........................................................................................8
Torque Tooling Requirements .............................................................................................8

Flange Bolt Tightening by Tension Control 9

Introduction and Background to Tensioning .......................................................................9
Minimum Bolt Load Required for Tension Control ..........................................................11
Type of Hydraulic Tensioner.............................................................................................12
Determination of Hydraulic Pressure Requirements..........................................................12
Pressure Load Loss Factor...................................................................................13
Tightening Procedure ..........................................................................................13
Tensioner Model Number....................................................................................13
Results for Tensioning Requirements................................................................................13

Torque-Preload Calculation on an Individual Bolt 14

Introduction .......................................................................................................................14
Thread Diameter and Pitch Details ....................................................................................14
Bolt Material......................................................................................................................14
Lubrication Condition in the Threads and Under the Nut Face .........................................15
Calculate Torque Value .....................................................................................................15

Tightening Procedures 17
Introduction .......................................................................................................................17
Data Entry Form ................................................................................................................17
Tightening Procedure Page................................................................................................18
Introduction .........................................................................................................18
Saving the Tightening Procedure ........................................................................18
Printing the Tightening Procedure.......................................................................18
Torque Tightening Procedure..............................................................................18
Tensioning Procedure..........................................................................................19

User Guide for the BOLTRIGHT Program Contents • i

 Glossary of Terms 20

ii • Contents User Guide for the BOLTRIGHT Program

Introduction

Introduction
This chapter provides information on installing and starting BOLTRIGHT. It
presents the following topics:
About the program
System Requirements
Installing BOLTRIGHT

About the Program

A study commissioned by the Pressure Vessel Research Council (PVRC) of the
USA indicated that most flange joint failures resulting in leaks are due to:
Improper installation (26%)
Flange damage (25%)
Gasket (22%)
Loose bolts (15%)
Flange misalignment (12%)

Ensuring that bolts are adequately and correctly tightened is of key importance in
ensuring that a leak free joint is achieved. The purpose of the BOLTRIGHT
program is to assist Hi-Force customers to achieve the optimum bolt tightness
and to act as an aid in selecting the appropriate tooling.
The program will allow you to use imperial or metric units. Selection of what
units you want to use is made by clicking on the appropriate selection at the top
of the form.
The program uses a database containing details of over 350 flanges covering the
main standards in present use.

System Requirements
To install and run BOLTRIGHT, your Windows compatible PC must be
equipped with the following:

User Guide for the BOLTRIGHT Program Introduction • 1

 Microsoft Windows 95, 98, Me, Windows NT 4.0, 2000, or Windows XP.
32 MB of RAM for Windows 95, 98 and Me, 64 MB recommended.
64 MB of RAM for Windows NT, 2000, and XP; 128 MB is recommended.
10 MB of free space on your hard drive.
SVGA monitor with at least 800 x 600 pixel resolution.

Installing BOLTRIGHT
The BOLTRIGHT installation program provides easy step by step instructions
on every screen.
Before you install BOLTRIGHT
1. Close all other programs.
2. If you are installing BOLTRIGHT on Windows NT, 2000 or XP, log onto
your computer with administrator privileges.
To install BOLTRIGHT from a CD
1. Insert the CD into your CD-ROM drive. The installation program should start
automatically. If it does not, follow the instructions located on the sleeve of the
CD.
2. Follow the instructions on each screen to install the software.

2 • Introduction User Guide for the BOLTRIGHT Program

Flange/Gasket Bolting Analysis

Introduction
This page allows the flange, bolt and gasket details to be selected. It is designed
to be as easy to use and navigate as possible. The user normally makes selections
starting at the top and moving down the page.
Once all the selections have been made you can select to use the bolt tensioning
or bolt torqueing methods of tightening.

Flange Specification
This section allows details of the flange to be selected, it is broken into a number
of sub-groups:

Standard
The user would first normally select the flange standard being used, the ASME /
ANSI standard is the default used by the program. Selection is made by clicking
on the appropriate entry, options include either API or ISO. For ASME / ANSI
and ISO flanges the bolt force required is determined from gasket calculations
when a suitable gasket is available. If details of a gasket is not available from the
program’s database, or when an API flange is selected, the clamp force
requirement is based upon utilising a percentage of the yield strength of the bolt
material.

Flange Rating
The flange rating is a designation to indicate the flange’s temperature/pressure
rating. By clicking on the pull down box the user can select the appropriate
rating. If the default ANSI / ASME flanges are being used, the flange ratings
shown are sometimes referred to as flange classes, with terms such as 300 or 600
lb flanges being used.

Nominal Size
The nominal diameter of the flange. Again the program allows the user to select
the appropriate size by clicking on the pull down box and selecting the
appropriate entry.

User Guide for the BOLTRIGHT Program Flange/Gasket Bolting Analysis • 3

 Design Pressure
The program inserts a value for the design pressure once the user has selected the
flange rating. This value is based upon the pressure / temperature rating for
Group 1.1 materials in the ASME code. The values entered by the program can
be over written by your own values. This may be required depending upon the
flange material that you are using and the temperature that the flange is operating
at. Reducing the pressure reduces the clamp force required for sealing purposes.

Test Pressure
This is the pressure that the system is to be tested at, the program by default
enters a value 1.5 times the design pressure. The user can change the test
pressure to meet individual circumstances. The program determines the clamp
force needed for sealing purposes based upon test pressure. Reducing the test
pressure will reduce the clamp force needed since this is a key parameter in the
gasket sealing calculations.

Design Operating Temperature

The user can select the temperature that the flange will be operating at; the
default value is 20 C. The program allows the temperature to be entered in either
degrees Celsius or Fahrenheit by clicking on the pull down box next to the
temperature data entry box. If the temperature is above 100 C then the program
determines the stress relaxation that will occur in the bolt and compensates for
this so that the clamp force will be sufficient to ensure the gasket seals. If a
temperature above 100 C were selected then usually the design and test pressure
values would be reduced. The program will give a warning message if
temperatures below –50 C is entered since the program presently does not allow
for the special conditions that can pertain when very low temperatures are being
used.

Bolt Details
This section allows you to specify the bolt that you intend to use with the flange.
Once the flange rating and nominal size have been selected the program will
automatically display the number of bolts in the flange and their size. You can
select whether you wish to use a metric equivalent bolt or not and the bolt
material that you are using. The term bolt refers to a standard bolt with a
hexagon head or a stud bolt.

Metric Equivalent Bolt

By default the program uses inch sized bolts when ANSI / ASME or API flanges
are being used. For bolts 1-inch diameter and above, bolts having 8 threads per
inch (tpi) are used. The program provides the option to allow you to use metric
bolting in lieu of the inch bolting. To use metric bolting click on the button
marked YES. The comparable metric bolt will be displayed. Up to and including
M45, coarse series bolts are used. In sizes M48 and larger, metric bolts using the
constant 4 mm pitch series are used. In general the metric bolt that is specified
by the program is slightly larger than the imperial size.

Bolt Material
You can select the bolt material by clicking on the pull down box and clicking
on a selection. The default material used by the program is ASTM A193 - B7.If
the API flange standard is being used then the program only allows use of this
material in line with API requirements. It should be realised that for bolt
materials having a low yield strength excessive stresses may be induced to

4 • Flange/Gasket Bolting Analysis User Guide for the BOLTRIGHT Program

 ensure that sufficient clamp force is generated to seal the gasket. The program
contains details on the yield strength of the materials and details on their stress
relaxation properties.

Gasket Details
The program determines the clamp force required to effect a seal from the gasket
based upon the details of the flange selected and the gasket.

Gasket Type
The program presently allows you to select either spiral wound gasket or a ring
joint gasket.

Gasket Material
By clicking on the pull down box, you can select the gasket material for your
application.

User Guide for the BOLTRIGHT Program Flange/Gasket Bolting Analysis • 5

Flange Bolt Tightening by
Torque Control

Background
The program allows the joint to be tightened using either one of two methods.
The first method is tension control in which hydraulic tensioners are used to
induce a clamp force into the joint by stretching the bolt. The second method is
torque control in which clamp force is induced into the joint by applying a
torque to the nut that stretches the bolt. This section covers torque control.
Once the torque value has been calculated, there are options available to allow
either the full results to be displayed or for a tightening procedure to be
generated.
The form is divided into a number of panels; each panel will be covered in turn.

Minimum Bolt Load Required for Torque Tightening

This section indicates the bolt load required based usually on gasket sealing
calculations, each item will be covered in turn:

Bolt Size
The program indicates the size of the bolt that is used in the flange that was
selected on the Flange/Gasket selection page. The bolt size can only be changed
via the Flange/Gasket selection page since it is linked to the flange size.

Min. Load Required for Gasket Sealing

Based upon the gasket and flange details that were selected on the Flange/Gasket
selection page, the program will calculate the minimum load required per bolt to
ensure that the gasket seal will be effective. The gasket calculations performed
by the program are based upon the ASME 8 code. The calculation is based upon
using two factors to describe the sealing characteristics of the gasket. Gasket
factor y is to ensure that there is sufficient clamp force to seat the gasket
adequately to prevent leakage. Gasket factor m is used to ensure adequate
sealing against the internal pressure. The pressure used to determine the
minimum load is the test pressure that was entered on the Flange/Gasket
selection page.
If a gasket is not available from the database, then the gasket calculations will
not be completed and a zero will appear in this location. The bolt load

6 • Flange Bolt Tightening by Torque Control User Guide for the BOLTRIGHT Program
 calculation in such situations will be completed on the basis of a percentage of
the minimum yield strength of the bolt being used.

Min. Bolt Load Required to allow for Preload Scatter

It is well known that applying the same torque value to a bolt results in some
scatter occurring in the preload (clamp force). This scatter is the result of friction
and small variations in the thread and the nut face. To allow for this scatter and
to ensure that sufficient clamp force is generated to ensure that the gasket seals,
the program increases the calculated minimum load to allow for gasket sealing
by a factored amount. The factor used to account for this scatter in the program
is 1.3.

Bolt Stress
Based upon the minimum load required to allow for preload scatter, the program
will calculate the tensile stress in the thread of the bolt.

% Minimum Yield Utilised

The program will calculate from the bolt stress the percentage of the yield
strength of the bolt that is being used.

User Selected Minimum Bolt Yield Utilisation

This box allows you to enter your own value for the yield utilisation. With some
flanges and operating pressures, the program can determine quite low percentage
yield values. Based upon experience, custom and practice, it is desirable that a
minimum yield utilisation is used to allow for the possibility of uneven loading
and other effects such as relaxation. Presently on ANSI / ASME and ISO flanges
the program will suggest a recommended minimum yield strength utilisation of
40%, you can accept or reject this value. For API flanges, this recommended
value is 50% of the bolt’s minimum yield strength. The program will raise an
error message if you enter a yield utilisation over 80% since values higher than
this can result in yield of the bolt occurring as a result of combined tension and
torsional stresses.

Lubrication Condition in the Threads and Under the

Nut Face
This panel consists of three sections: a pull down box allowing the type of
lubricant to be selected, a box describing the lubricant and thirdly, a box giving
the coefficient of friction selected. In general terms, the use of a lubricant is
important since it reduces friction and thread wear allowing the bolts to be re-
used. A lubricant can also prevent galling from occurring. The program assumes
that the same lubricant is used in the threads as well as under the nut face. The
type of lubricant selected depends upon the specific requirements in terms of the
operating temperature as well as custom and practice at the particular company
or plant. A common type of lubricant is molybdenum disulphide that is
sometimes referred to as ‘moly’. Various types of anti-seize compounds are also
in common use.
To select a lubricant, click on the pull down box and click on the desired
lubricant. A description of the lubricant, as well as the applicable friction
coefficient, is entered into the other two boxes.
If you are using a type of lubricant not listed in the program, this can be directly
entered into the program by entering the details into box marked ‘Lubrication
Condition’ and the value for the coefficient of friction in box marked ‘Value of
the Friction Coefficient’. This will then be used by the program.

User Guide for the BOLTRIGHT Program Flange Bolt Tightening by Torque Control • 7
Torque Tightening Requirements
In this panel there is a button labelled ‘Calculate Torque Value’. Clicking on this
button the calculated torque value will be displayed. When the button is clicked,
the program will perform some checks on the validity of the data prior to the
calculations; a warning or information box may be displayed depending upon the
values entered.

Torque Tooling Requirements

Based upon the bolt size and calculated torque value the program will provide a
recommendation on the tooling to be used. There are two options regarding the
type of torque tooling. The default is for the program to select the appropriate
lightweight aluminium hydraulic torque wrench. These wrenches have a square
drive and are used in conjunction with a socket. The alternative type that can be
selected are low profile hydraulic torque wrenches. These compact designs use a
hexagon bush that fits over the nut to allow it to be tightened.
An image is displayed on the form showing the overall size of the selected
wrench. If further details about the wrench are required, this can be gained by
clicking on the button marked ‘Click for Additional Information on Tooling’.

8 • Flange Bolt Tightening by Torque Control User Guide for the BOLTRIGHT Program
Flange Bolt Tightening by
Tension Control

Introduction and Background to Tensioning

Using hydraulic tensioners to tighten bolts is considered by many to be a
superior method of tightening compared to using torque tightening. An hydraulic
tensioner consists of a high pressure hydraulic cylinder, with accessories,
designed to seat against the joint, grip the fastener thread using a compatible
threaded puller, and via applied hydraulic pressure, extend the cylinder piston
against the puller, to stretch the bolt to a known tension. When the pull force
equals the designed bolt preload, plus an additional amount to compensate for
bolt relaxation, the nut is run down the thread using a short tommy bar until it is
tight against the joint face. The hydraulic pressure is then released and the bolt is
prevented from returning to its original length, by the tightened nut,
subsequently leaving the required tension retained in the fastener. A hydraulic
tensioner is illustrated in the graphic.

One of the advantages of using hydraulic tensioners is that it is possible to

tension all the bolts in a joint simultaneously allowing uniform gasket
compression improving a joint’s integrity relative to other tightening methods.

User Guide for the BOLTRIGHT Program Flange Bolt Tightening by Tension Control • 9
 Ideally all the bolts in the joint should be tightened in a single, simultaneous
operation, referred to as 100% tensioning. However because of cost constraints,
since a tensioner is required for each bolt, 50%, 33% or 25% tensioning can be
completed. These tensioning procedures require the operator to make a number
of tensioning operations moving around the joint until all the bolts are tightened.
Because of the effects of elastic interaction in the joint, the first bolts are
tightened to a higher load than is needed so that when the final bolts are
tightened, the load in all the bolts will be approximately the same. This occurs
because the final bolts that are tightened, compress the joint under previously
tightened bolts reducing their preload.

When using a tensioner, an extra length of threaded stud is required above the
nut so that the puller can be attached. The length of thread required above the nut
is at least one times the diameter. The sequence of assembly is that first a nut
rotating socket is placed on the nut. With the socket placed over the nut, a bolt
tensioner is placed over the socket and the stud. A threaded sleeve is then rotated
onto the end of the stud so that it rests on the top of the hydraulic tensioner. With
the unit assembled, hydraulic lines are attached. The hydraulic pressure can be
delivered by a hand pump or electrically driven. Once hydraulic pressure is
applied, the nut is rotated by using a tommy bar securing into the socket. The
pressure can then be released and the unit removed. The assembly sequence is
shown in the diagram on the following page.

10 • Flange Bolt Tightening by Tension Control User Guide for the BOLTRIGHT Program
 Details of the separate sections and panels used by the BOLTRIGHT program
when tensioners are to be used are presented in the following sections.

Minimum Bolt Load Required for Tension Control

This section indicates the bolt load required based usually on gasket sealing
calculations, each item will be covered in turn:

Bolt Size
The program indicates the size of the bolt that is used in the size of the flange
that was selected on the Flange/Gasket selection page. The bolt size can only be
changed via the Flange/Gasket selection page since it is linked to the flange size.

Min. Load Required for Gasket Sealing

Based upon the gasket and flange details that were selected on the Flange/Gasket
selection page, the program will calculate the minimum load required per bolt to
ensure that the gasket seal will be effective. The gasket calculations performed
by the program are based upon the ASME 8 code. The calculation is based upon
using two factors to describe the sealing characteristics of the gasket. Gasket
factor y is to ensure that there is sufficient clamp force to seat the gasket
adequately to prevent leakage. Gasket factor m is used to ensure adequate
sealing against the internal pressure. The pressure used to determine the
minimum load is the test pressure that was entered on the Flange/Gasket
selection page.

User Guide for the BOLTRIGHT Program Flange Bolt Tightening by Tension Control • 11
 If a gasket is not available from the database, then the gasket calculations will
not be completed and a zero will appear in this location. The bolt load
calculation in such situations will be completed on the basis of a percentage of
the minimum yield strength of the bolt being used.

Min. Bolt Load Required to allow for Preload Scatter

It is well known that all tightening methods result in some scatter occurring in
the preload (clamp force). This scatter is the result of pressure variations that can
occur and the slight differences that can be present in the bolt material and the
thread and the nut face. To allow for this scatter and to ensure that sufficient
clamp force is generated to make sure that the gasket seals, the program
increases the calculated minimum load to allow for gasket sealing by a factored
amount. The factor used to account for this scatter in the program is 1.1.

Bolt Stress
Based upon the minimum load required to allow for preload scatter, the program
will calculate the tensile stress in the thread of the bolt.

% Minimum Yield Utilised

The program will calculate from the bolt stress the percentage of the yield
strength of the bolt that is being used.

User Selected Minimum Bolt Yield Utilisation

This box allows you to enter your own value for the yield utilisation. With some
flanges and operating pressures, the program can determine quite low percentage
yield values. Based upon experience, custom and practice, it is desirable that a
minimum yield utilisation is used to allow for the possibility of uneven loading
and other effects such as relaxation. Presently on ANSI / ASME and ISO flanges
the program, when tensioning is being used, will suggest a recommended
minimum yield strength utilisation of 30%, you can accept or reject this value.
For API flanges, this recommended value is 50% of the bolt’s minimum yield
strength. The program will raise an error message if you enter a yield utilisation
over 80% since values higher than this can result in yield of the bolt occurring as
a result of combined tension and torsional stresses.

Type of Hydraulic Tensioner

Hi-Force offer two types of hydraulic tensioners, this panel allows you to select
the appropriate tensioner for your application.
The Hi-Force standard STS Series stud bolt tensioners are designed for top side
(above sea) operation in a wide variety of applications including pipeline
flanges, heat exchangers, pressure vessels, compressor covers etc. The range
comprises six different hydraulic tensioner cylinders suitable for tensioning bolts
from 16 mm to 100 mm (3/4” to 4”) diameter. Each hydraulic cylinder can be
used with a variety of interchangeable nut rotating sockets and threaded pullers
ensuring that the maximum number of bolt diameters can be accommodated
using the minimum number of cylinders.
The Hi-Force STU Series sub-sea bolt tensioners are designed and manufactured
to suit the demanding requirements of divers operating in the harsh sub-sea
environment. Normally, 100% tensioning is used with sub-sea tensioners.

Determination of Hydraulic Pressure Requirements

This panel consists of a number of entries that are detailed below:

12 • Flange Bolt Tightening by Tension Control User Guide for the BOLTRIGHT Program
 Pressure Load Loss Factor
This factor allows for the reduction in the load that occurs when the hydraulic
pressure from the tensioner is released and the strain is taken by the nut. Because
the nuts deform slightly as they take up this load, a reduction in the clamp force
occurs. The magnitude of the loss depends upon the length to diameter ratio of
the bolt. Longer bolts lose less load than short bolts because they extend more
for a given load and are less susceptible to strain changes when the nut sustains
the loading. For short bolts the magnitude of the load loss can be such as to make
the use of hydraulic tensioners inadvisable.
The default value of the pressure load loss factor is 1.25 which is typical for
many joints. However you can adjust this value to suit the particular
requirements of a specific joint. Increasing the factor will increase the preload
requirement.

Tightening Procedure
You can select the appropriate tightening procedure for your particular joint. The
default is 100% tensioning, this is when all the bolts are tightened in a single,
simultaneous operation. Alternatives include 50%, 33% or 25% tensioning
procedures.

Tensioner Model Number

The program will display an appropriate tensioner to use for the joint.

Results for Tensioning Requirements

Once the Calculate button has been pressed, the results will be displayed in a
window on the right hand side of the form. Additional results can also be viewed
by clicking either the ‘View Full Results Button’ or the ‘Generate Tightening
Procedure’ Button on the bottom of the form.
The results in the pane that are displayed include the tensioner pressures
required. For 50%, 33% or 25% tensioning procedures, two pressures are
presented referred to as pressure A and pressure B. Pressure B is the pressure
required to induce the load in the bolt allowing for the pressure load loss factor.
For 100% tightening procedures only pressure A is quoted. Pressure A is greater
than pressure B to allow for the elastic interaction that occurs when one bolt is
tightened in the vicinity of a previously tightened bolt. In order to achieve the
final required tension in all the bolts it is required to tighten the first set of bolts
(in a 50% tensioning procedure), or all the bolts (in a 33% or 25% tensioning
procedure) to a higher tension than that which is finally required. This is done so
that when all the bolts have been tightened and the effects of elastic interaction
accounted for, the required bolt tension is consistently achieved in all the bolts. It
is of crucial importance that pressure A is not applied to all the bolts
simultaneously as this may cause the flange to be over stressed.

User Guide for the BOLTRIGHT Program Flange Bolt Tightening by Tension Control • 13
Torque-Preload Calculation on
an Individual Bolt

Introduction
There may be instances when it is required to determine the tightening torque
required to be applied to a particular joint that is not a flange. For example the
torque required to the bolts on a clamp or similar part. This section of the
program will allow you to complete such calculations by selecting the thread
size, bolt material and lubricant applicable to the particular application. Details
of each panel on the form are given in the following sections.

Thread Diameter and Pitch Details

This section allows you to define the thread details that you are using. You can
select either a metric thread or a inch sized thread. By clicking on the box
marked ‘Select Thread Size’ a box will drop down giving standard thread sizes
available. If a size is clicked, the relevant details for this thread will be entered
into the boxes (bolt diameter, thread pitch etc.)
If any of the sizes entered into the boxes do not match your particular application
it is possible to edit the values that the program has provided and adjust to suit
your circumstances. For example, the nut face diameter that is shown is for a
standard hexagon nut, if you are using a flanged nut then this value should be
increased to match that of the nut that you are using. Similarly if the hole
diameter is different than in your application, this should also be changed.
If the particular thread that you are using is a special and not in the list provided
by the program, calculations can still be completed for this thread by entering all
the details (bolt diameter, thread pitch etc.) directly into the program.

Bolt Material
You can select the bolt material by clicking on the pull down box and clicking
on a selection. Once a selection has been clicked, the program will insert the
yield strength for the material into the edit box. If the material that you are using
is not in the list provided by the program, you can enter the yield strength
directly into the box.
To calculate the tightening torque, the percentage of the yield strength that the
bolt will be stressed has to be entered into the program. The default value is 60%
which is typical for the oil/chemical industries. In general mechanical

14 • Torque-Preload Calculation on an Individual Bolt User Guide for the BOLTRIGHT Program
 engineering, higher values up to 75% of the minimum yield strength of the bolt
are typically used. You can adjust this value to suit your particular application.

Lubrication Condition in the Threads and Under the

Nut Face
This panel consists of three sections: a pull down box allowing the type of
lubricant to be selected, a box describing the lubricant and thirdly, a box giving
the coefficient of friction selected. In general terms, the use of a lubricant is
important since it reduces friction and thread wear allowing the bolts to be re-
used. A lubricant can also prevent galling from occurring. The program assumes
that the same lubricant is used in the threads as well as under the nut face. The
type of lubricant selected depends upon the specific requirements in terms of the
operating temperature as well as custom and practice at the particular company
or plant. A common type of lubricant is molybdenum disulphide that is
sometimes referred to as ‘moly’. Various types of anti-seize compounds are also
in common use.
To select a lubricant, click on the pull down box and click on the desired
lubricant. A description of the lubricant as well as the applicable friction
coefficient is entered into the other two boxes.
If you are using a type of lubricant not listed in the program, this can be directly
entered into the program by entering the details into box marked ‘Lubrication
Condition’ and the value for the coefficient of friction in box marked ‘Value of
the Friction Coefficient’. This will then be used by the program.

Calculate Torque Value

Clicking on this button will display the calculated torque value. When the button
is clicked, the program will perform some checks on the validity of the data prior
to the calculations; a warning or information box may be displayed depending
upon the values entered. The torque value in metric (Nm) and inch units (Lbf-ft)
will be displayed.
If full details of the calculation are required, clicking on the button marked
‘View Full Details’ will allow a window to appear displaying the full results that
can be printed out.
The program will also display the applicable Hi-Force tool that could be used to
apply the torque to the bolts.

User Guide for the BOLTRIGHT Program Torque-Preload Calculation on an Individual Bolt • 15
Tightening Procedures

Introduction
The program can create a tightening procedure for the joint. A significant
problem that arises when tightening a joint consisting of several bolts, if all the
bolts are not tightened simultaneously, is elastic interaction (sometimes referred
to as bolt cross talk). This is due to the tightening of one bolt affecting the
tension in the bolts that aren’t being tightened because of compression of the
joint. This can lead to uneven clamping of the joint that can be a direct cause of
gasket leaks. There are ways in which elastic interaction can be reduced.
When tightening using an applied torque, a tightening sequence is usually
specified and applying a fraction of the total torque in a series of passes around
the bolts. A tightening sequence defines the order that the bolts are to be
tightened. For a circular pattern of bolts present on flanges the sequence is based
upon a criss-cross pattern, i.e. tightening bolts diagonally opposite to each other
working around the joint. It has been shown that the larger the number of passes
around the joint, the more even will be the clamp force in the bolts.
When tightening using tension control, elastic interaction can be eliminated by
using a 100% tensioning procedure. That is, a tensioner is used on each bolt with
equal and simultaneous pressure applied. However because of access or lack of
availability of tensioners, 50%, 33% or 25% tensioning procedures may be
applied. With a 50% tensioning procedure being applied only half of the bolts
are tensioned at any one time. With 33% tensioning only a third of the bolts are
tightened at any one time, with 25% tensioning only a quarter. In order to
compensate for elastic interaction, different pressures (pressure A and pressure
B) can be applied to the tensioners. Initially a higher pressure is applied
(pressure A) to induce a higher load in the bolts first tightened so that they will
have the appropriate load once all the bolts have been tightened.

Data Entry Form

When the button is clicked ‘Generate Tightening Procedure’, you are asked if
you need to include reference information on the joint such as a title. You can
decide to include the information or not, by clicking on the Yes or No button.
If Yes is clicked the Data Entry Form is displayed allowing you to enter values
for the title, organisation, name, joint tag and any comments about the joint you
wish to add. This information will be included in the tightening procedure if any
values are entered. On clicking the Ok button, the form closes and another
window opens showing your default Internet browser displaying the tightening
procedure generated by the program.

User Guide for the BOLTRIGHT Program Tightening Procedures • 17

Tightening Procedure Page

Introduction
The program will display a tightening procedure for the specific flange and bolt
conditions specified. The procedure will be displayed using your default Internet
browser (usually Internet Explorer). The tightening procedure generated is a
guide and may have to be adapted to your specific situation and circumstances.
The top section includes details such as the title, name joint tag etc. if this
information was entered.
Details of the flange and gasket are provided for reference purposes. One of the
prerequisites in the procedure is to ensure that all the personnel involved are
adequately trained in the use of the tightening equipment. Contact Hi-Force if
you require any assistance in regard to training provision. The tightening
procedure detailed by the BOLTRIGHT program is specific to Hi-Force tooling
and equipment. It can be unsafe to use the procedures produced by the program
using other manufacturer’s equipment.

Saving the Tightening Procedure

The tightening procedure can be saved for viewing at a later date by using the
File – Save As option on the browser that you use. When you click Save As a
window will appear asking you for a file name to save the file under. The default
name is ‘BOLTRIGHT Tightening Procedure’ however it is suggested that you
change the name to prevent the file being over written by the program. The
program writes a file with this name to disk every time the program generates a
tightening procedure, therefore you must use a different file name if you wish to
retain it. The file is saved in html format (the same format as used on the World
Wide Web).

Printing the Tightening Procedure

Printing of the procedure can be completed as per any other web page by using
the File – Print menu option.

Torque Tightening Procedure

Prior to commencing tightening of the joint it is crucial to ensure that the flanges
are parallel to each other. When tightening is by torque control, the procedure
generated by the program provides details of the tightening sequence. On flanged
joints a tightening sequence is required in order that an even bolt loading is
achieved i.e. the load is the same in all the bolts. Such an even loading is key to
ensuring that the joint does not leak. The cause of uneven loading in the bolts,
even when the same tightening torque is applied to all the bolts, is elastic
interaction. This is when the tightening of one bolt affects the tension in a bolt
next to it as a result of the joint compressing.
The basis for the sequence is a criss-cross tightening pattern. This is illustrated in
the image below.

18 • Tightening Procedures User Guide for the BOLTRIGHT Program

 In order to further to reduce the effects of elastic interaction, a multi-pass
tightening sequence is suggested by the program. This is when the bolts are
initially tightened to a torque value below what is finally required. The bolts are
re-tightened to a final torque on a subsequent tightening pass around the joint.
The program suggests a three pass tightening procedure where the bolts are
tightened to 25%, 50% and then finally 100% of the full torque. On critical joints
it can be advisable to introduce a fourth tightening pass introducing a 75%
torque pass between the 50% and 100% passes.
Following the final tightening pass, a checking pass is suggested in which all the
bolts are checked to the final torque value.
The program also suggests, as a final check, that each bolt should be ‘ringed’ by
tapping lightly with a lead, or similar, hammer ensuring that the threads are not
damaged. If any bolts are loose the tone of the sound given off will be different
to a tightened bolt. A loose bolt could be as a result of cross-threading or similar
problem in which the torque value may be achieved but no tension results in the
bolt.

Tensioning Procedure
If the tightening method is by hydraulic tensioning, the program will generate a
procedure applicable to the particular joint and tooling being used. As indicated
in the section on Flange Bolt Tightening by Tension Control, when a 100%
tensioning procedure is being used, a single pressure is applied to all the
tensioners, referred to as pressure B. The program determines this pressure by
using the information required for the bolt load and the particular tensioner
selected and calculating the pressure that would be needed to generate this force
in the bolt. The procedure is only applicable to the tensioner specified being
used. Changing the model of the tensioner will affect the pressures needed to
generate the bolt loads and hence make the procedure invalid.
When 50%, 33% or 25% tensioning procedures are being used it is necessary to
tighten the bolts to a higher pressure (referred to as pressure A) to allow for the
effects of elastic interaction. In order to achieve the final required tension in all
the bolts, the first set of bolts (in a 50% tensioning procedure), or all the bolts (in
a 33% or 25% tensioning procedure) to a higher tension than what is finally
required. This is done so that when all the bolts have been tightened and the
effects of elastic interaction accounted for, the required bolt tension is
consistently achieved in all the bolts. It is of crucial importance that pressure A
is not applied to all the bolts simultaneously as this may cause the flange to be
over stressed.

User Guide for the BOLTRIGHT Program Tightening Procedures • 19

Glossary of Terms

ANSI
American National Standards Institute. This organisation draws up standards,
including standards for flanges.

anti-seize compounds
An anti-seize compound is used on the threads of fasteners in some applications.
The purpose of the compound depends upon the application. It can prevent
galling of mating surfaces - such compounds are frequently used with stainless
steel fasteners to prevent this effect from occurring. In some applications it is
used to improve corrosion resistance to allow the parts to be subsequently dis-
assembled. Thirdly, it can provide a barrier to water penetration since the threads
are sealed by use of the compound.

API
The American Petroleum Institute based in Washington D.C. in the US sets
standards relating to the petroleum industry. API flanges are flanges that have
been made to specifications by this organisation. All API Specification 6A
flanges have "Ring Type Joint" sealing surfaces.

ASME
American Society of Mechanical Engineers. A US based organisation that is
responsible for a number of important standards that are used world-wide
including the ASME 8 standard on pressure vessels.

ASTM
American Society for Testing and Materials - a US based standards body.

bearing stress
The stress under the bolt head or nut face. It is the total force in the bolt divided
by the area between the inner diameter of bolt head or nut face and the outside
diameter.

blind flange
A flange that has no central opening usually used to close off and seal a pipe end
or outlet.

20 • Glossary of Terms User Guide for the BOLTRIGHT Program

 bolt cross talk
See elastic interaction.

chamfer
A tapered surface that is usually present at the starting end of an externally
threaded fastener to aid starting the thread.

countersunk
A tapered section at a start of a hole. Internal threads are often countersunk to aid
mating with the external thread.

design pressure
The maximum allowable pressure for the system. The default value for the
program for ASME/ANSI flanges is the maximum based upon the
pressure/temperature ratings for Group 1.1 material groups in the ASME code
and BS 1560-3.1. As the temperature increases the maximum permissible
working pressure decreases. The user can adjust this value as required.

elastic interaction
A term used to describe the phenomena in which the tightening of one bolt can
affect the tension in the surrounding bolts. It is due to the bolt being tightened
compressing the material under the neighbouring bolts. Ways in which elastic
interaction can be reduced are to tighten all the bolts simultaneously or to tighten
the bolts in several passes, increasing the torque value on each pass. Elastic
interaction is sometimes referred to as bolt cross talk.

external thread
A screw thread that is formed on an external cylinder, such as on bolts, screws,
studs etc.

fatigue
The tendency for materials to fail under repeated loading at a stress level
considerably less than the static strength of the material. This characteristic of
materials is known as fatigue and it is a common cause of failure in many
products, including bolts.

flange
A disk containing a large central hole with holes for bolts around its periphery.
Usually used in pairs with a gasket between, the bolts clamp the flanges together
and provide the pressure for the gasket to seal.

flange rating
A designation code to indicate the pressure/temperature rating of the flange. For
ANSI/ASME flanges the flange rating is commonly referred to as the class
rating, for example Class 900, the 900 used to represent the working pressure in
psi in high temperature service. For ISO flanges the rating system is a PN
followed by a number in bar to represent the nominal working pressure.

friction
Mechanical resistance to the relative movement of two surfaces.

User Guide for the BOLTRIGHT Program Glossary of Terms • 21

 friction coefficient
A dimensionless number representing the ratio of the friction force to normal
force. Typically for threaded connections it is about 0.12 but can vary
significantly depending upon the materials used and whether a lubricant has been
used.

galling
A severe form of adhesive wear which occurs during sliding contact of one
surface relative to another. Commonly occurs on stainless steel and other high
alloy fasteners when used without a lubricant when clumps of one part stick to
the mating part and break away from the surface.

Gasket factor m
Defined as the ratio of residual gasket contact pressure to internal pressure.

Gasket factor y
Defined as the applied stress required to seat the gasket on the flange faces.

hard joint
A 'hard' joint has a high stiffness (does not compress significantly under the
loading applied by the bolt). A hard joint is defined (according to ISO 5393) as
one whose torque value is achieved after the bolt has turned approximately 30
degrees of rotation from the snug level. The 'snug' state is when the plates
comprising the joint are in metal to metal contact - no gaps present.

ISO
The International Organisation for Standardisation. The world body for setting
standards including standards for flanges.

joint tag
A record attached to, or near, the flange that provides various details on the joint
assembly. The details can include a unique joint ID, the date of assembly and
who assembled and tested the joint. The details on the tag can vary from plant to
plant, however their purpose is to improve quality assurance and ensure that a
leak free joint is achieved.

ksi
An abbreviation for 1000 pounds per square inch. Used typically for imperial
bolt yield and tensile strengths.

Major Diameter
The major diameter of an external thread is the diameter of an imaginary
cylinder parallel to the crests of the thread.

Minor Diameter
The minor or root diameter is the diameter of a cylinder that just touches the
roots of the thread.

22 • Glossary of Terms User Guide for the BOLTRIGHT Program

 molybdenum disulphide
A solid lubricant that acts as a high pressure resistant film. Can be used by itself
as a dry lubricant as well as in with other solid lubricants and in oils and greases.
Used in threads, such lubricants act as a separating film to prevent corrosion
formation on the thread surface (even under adverse temperature and
environmental conditions), ensuring the release of the threaded connection. Such
films can also act as friction stabilisers.

MSS
Manufacturer’s Standardisation Society of the Valve and Fittings Industry is a
non-profit technical association organised for development and improvement of
industry, national and international codes and standards. They have standards
defining flange dimensions. ASME has incorporated most of the MSS-SP44
specification flanges into B16.47 Series of flanges. The BOLTRIGHT program
includes these flanges in the database that it uses.

multi-pass tightening sequence

Tightening the bolts in a joint to a percentage of the total torque prior to
tightening the bolts to a higher torque value on a second pass, then on a third
pass, if required, until the final torque value is achieved. The purpose of such a
procedure is to achieve the same loading in all the bolts in the joint, negating the
effects of elastic interaction in the joint.

Nominal Size
The nominal size of the pipe being used with the flange. For ANSI and API
flanges, the size refers to the inside pipe diameters when originally standardised.
As technology improved, thicker pipe walls were used to contain the pressure
and now the size does not correspond to the inside pipe diameter but only
approximate to it. For ISO flanges, the nominal size is given as DN followed by
a diameter in mm.

Nominal Thread Diameter

This is the diameter commonly used to describe the thread. For example, for a
M100x4 bolt, the nominal thread diameter is 100mm.

Pitch
This is the distance from the top of one thread crest to the next. With imperial
threads, the pitch of the thread is denoted by tpi – threads per inch.

Pitch Diameter
The pitch or effective thread diameter of the external thread is the diameter that
has equal metal and space widths. Put more simply, it is the mean diameter of
the thread. Is also a term used in RTJ gaskets – in this case it is the theoretical
diameter of the ideal mid point (imaginary circular centre line) of a ring groove.

preload
The clamp force generated by a bolt or other threaded fastener when initially
tightened. In metric units it is usually measured in newtons (N) or kilo-newtons
(kN). In imperial units, preload is usually measured in pounds force (lbf).

User Guide for the BOLTRIGHT Program Glossary of Terms • 23

 pressure A
Used when hydraulic tensioners are used and all the bolts in the joint are NOT
tightened simultaneously (100% tightening procedure). Pressure A is greater
than pressure B to allow for the elastic interaction that occurs when one bolt is
tightened in the vicinity of a previously tightened bolt. It is of crucial importance
that pressure A is not applied to all the bolts simultaneously as this may cause
the flange to be over stressed.

pressure B
Used with hydraulic tensioners; this is the pressure needed to induce the required
load in the bolt after allowing for the pressure load loss factor.

pressure load loss factor

A factor that allows for the reduction in the clamp load that occurs when the
hydraulic pressure from the tensioner is released and the strain is taken by the
nut. Because the nuts deform slightly as they take up this load, a reduction in the
clamp force occurs. The magnitude of the loss depends upon the length to
diameter ratio of the bolt.

prevailing torque
The prevailing torque is the torque required to run a nut (or bolt) down a thread
on certain types of fasteners that are designed to resist vibration loosening. This
prevailing torque can be provided by an insert in the nut/bolt thread, by using
nuts that have their threads locally distorted or by using micro-encapsulated
adhesive applied to the threads.

property class
A metric designation system which defines the strength of a bolt or nut. For
metric fasteners, property classes are designated by numbers where increasing
numbers generally represent increasing tensile strengths. The designation symbol
for bolts consists of two parts:
1. The first numeral of a two digit symbol or the first two numerals of a three
digit symbol approximates 1/100 of the minimum tensile strength in MPa. (A
MPa is a unit of stress equal to one million pascals. It is equivalent to one
N/mm²).
2. The last numeral approximates 1/10 of the ratio expressed as a percentage
between minimum yield stress and minimum tensile stress.
Hence a fastener with a property class of 8.8 has a minimum tensile strength of
800 MPa and a yield stress of 0.8x800=640 MPa.
The designation system for metric nuts is a single or double digit symbol. The
numerals approximate 1/100 of the minimum tensile strength in MPa. For
example a nut of property class 8 has a minimum tensile strength of 800 MPa. A
bolt or screw of a particular property class should be assembled with the
equivalent or higher property class of nut to ensure that thread stripping does not
occur.

psi
Pounds per square inch – an imperial unit to measure pressure.

raised face flange

A flange having the central section raised above the face of the flange to provide
a sealing surface for a flat gasket or containing a ring groove for a ring gasket.

24 • Glossary of Terms User Guide for the BOLTRIGHT Program

 relaxation
The loss of clamping force in a bolt which commonly occurs as a result of
embedment. Can also be caused by gasket creep, differential temperature
expansion or vibration loosening.

RTJ
Ring Type Joint – a type of metallic gasket manufactured from a range of
materials. The cross section is usually oval or octagonal and they are used in
conjunction with ring joint flanges. Very high pressures can be contained with
this type of gasket. The maximum temperature is usually limited by the type of
gasket metal used.

soft joint
A 'soft' joint has low stiffness and whose final torque is reached after
approximately 720 degrees of bolt rotation (according to ISO 5393).

spiral wound gasket

A semi-metallic gasket that consists of alternate layers, usually is the form of v-
section strips of metal and a filler, wound in a spiral form. This type of gasket is
versatile and can be used over a wide range of pressures and temperatures.

stress area
The effective cross sectional area of a thread when subjected to a tensile force. It
is based upon a diameter which is the mean of the pitch (or effective) and the
minor (or root) diameters of the thread.

stress relaxation
Stress relaxation refers to the decrease in stress at a constant deformation. When
stress relaxation occurs, the stress needed to maintain a constant total
deformation decreases as a function of time. In terms of bolting, the reduction in
stress over time results in a decrease in the clamp force provided by the bolt.
Stress relaxation is a major consideration in the selection of bolting materials
that are required for high temperature operations.

stud bolt
A rod that’s threaded at both ends used with two nuts, one at each end,
commonly to tighten flanges.

tensile strength
The maximum strength of a material measured in units of stress i.e. N/mm2 in
metric units. Used to be known as the Ultimate Tensile Strength (UTS).

tension
The force created in the bolt as a result of tensioning or torqueing a bolt. Tension
is measured in kilonewtons (kN) or newtons (N) in metric units and tons or lbf in
imperial units.

tensioner
A hydraulic tool used to tighten a fastener by stretching it rather than applying a
large torque to the nut. After the fastener has been stretched, the nut is run down

User Guide for the BOLTRIGHT Program Glossary of Terms • 25

 the thread to snug up with the joint, the hydraulically applied load is then
removed resulting in tension being induced into the fastener.

test pressure
The pressure the system is tested at. The default value used by the program is 1.5
times the design pressure. This can be adjusted as required by the user.

thread stripping
Thread stripping is a shear failure of an internal or external thread that results
when the shear strength of the threaded material is exceeded by the applied
forces acting on the thread.

tightening factor
The tightening factor is a measure of the scatter in a bolt's clamp force because
of the tightening method used to tighten the fastener. It is defined as the
maximum bolt preload divided by the minimum value anticipated for that
tightening method.

tightening procedure
A specification that defines the steps required to correctly tighten a particular
joint.

tightening sequence
A listing of the sequence in which the bolts in a joint are to be tightened.

tolerance class
A combination of tolerance grade and a fundamental deviation which is given to
an internal or external thread. A tolerance class for an internal thread when
combined with the tolerance class for an external thread gives the class of fit for
the mating threads.

torque
The amount of twisting moment applied to a bolt. Torque is a product of force
times the perpendicular distance from the point of application to the point of
rotation. In metric units torque is usually measured in newton-metres (Nm) and
in imperial units in lbf-ft (pounds force feet).

tpi
Threads per inch – a measure of the pitch of the thread. Above 1 inch nominal
diameter in the petroleum/chemical industry bolts have a standard pitch of 8 tpi.

working pressure
see design pressure

yield strength
The tensile stress in a material, which if increased would result in permanent
elongation of the part i.e. if the load is removed the part would not return to its
original length. Measured in units of stress i.e. N/mm2 in metric units.

26 • Glossary of Terms User Guide for the BOLTRIGHT Program