Leacking-free Flanges and Shorter Shutdowns, because of New and Innovative Hydraulic Bolting-technologies
Proceedings Publication Date
Patrick Junkers
Patrick Junkers, Alfred Jung
Part of the proceedings of
25% of all flanges maintained in refineries and chemical plants during a shutdown leak on startup; that conducted an official research in the UK. That is Millions of Euros lost in Productivity with every shutdown. Leaks and joint failures produces high economical wastages and damages caused to the environment and are so unnecessary, even when the user is under time-pressure. The blueprint of the VDI 2200 says, that flange-connections are a system, which is based on three elements: the flange, the bolted connections and the gaskets. The gasket must seal the flangeconnection. But therefore it must be protected twice: once for loss of graphite the other protection against the influence of gas and liquids which are transported in the flange. Failure-free joints require: Calibrated Torque / Tension tools with calibrated bolt load. Joint Parallelism necessitates Multiple-Tool-Use that takes click-on, hands- and backup-Free tool. It requires the application of at least one Torque-Tension-Tool on every 5 to 8 bolt section on a flange and the simultaneous tightening of all engaged fasteners. Even – circumferential bolt load within 10% necessitates controlling the nut turning friction. It requires a Torque-Tension-Tool that is bolt load calibrated, traceable to the Bureau of Standards. That takes a hardened washer underneath the Standard-nut to control the facial friction of the nut. A low friction nutthread lubricant to reduce the usual nut-turning friction and scatter. A washer engineered to regenerate the reduced nut turning friction to avoid inadvertent nutloosening. A tool to turn the Standard-Nut and simultaneously hold the washer stationary. A washer that stops the bolt from turning with the nut. A tool with no external reaction arms, backup wrenches and tensioning bridges. A tool to avoid the usual side load or over-pull.

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