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Proceedings of the ASME 2016 35 International Conference on Ocean, Offshore and Arctic Engineering
OMAE2016
June 19-24, 2016, Busan, Korea

OMAE2016-54652

INTEGRITY ASSESSMENT OF HOT BOLTING TOOL

Guomin Ji Madjid Karimirad


MARINTEK MARINTEK
NO-7450, Trondheim, Norway NO-7450, Trondheim, Norway

Frank Klbo Per-Christian Irgens


MARINTEK Irgens Engineering AS
NO-7450, Trondheim, Norway NO-1397, Nesya, Norway

ABSTRACT
INTRODUCTION
Hot Bolting is the practice of removing and replacing or
freeing and re-tightening bolts on live operating piping and Hot Bolting is the sequential removal and replacement of bolts
equipment while the system is pressurized. It is potentially in a flanged joint, while the system is pressurized under
hazardous and the utmost caution needs to be exercised when operation. It is not recommended as best practice although it is
planning and carrying it out. The hot bolting tools designed by widely carried out. The hot bolting operation could be
Irgens Engineering AS aim to establish a safe barrier for flange performed without or with the help of additional tools.
connections during the hot bolting operation. Their application
would extend the hot bolting operation, increase the safety and The hot bolting has the potential to save time and costs by
simplify the working process. Qualification of new hot bolting allowing a continuous operation in the plants and platforms.
tools was carried out by the joint efforts of producer, operator However, any potential benefits arising from hot bolting should
and classification society. The paper addresses a part of the be carefully weighed against the risks encountered. The
integrity assessment of the new hot bolting tools. The non- Engineering Equipment Materials and Users Association
linear finite element analyses were performed by ABAQUS for (EEMUA) have published an information sheet in 1999 called
sequential loading during hot bolting operation under the Guidance Procedures for the Removal and Replacement of
temperature specified by operator and the non-linear contact Flanged Joint Bolting on Live Piping and Equipment [23]. The
interactions between different components were taken into guidance from EEMUA is applicable for hot bolting operation
account in the analysis. In the present study, the structural without any tool/clamp and it was essential document before
integrity was investigated for 4" class 1500 flange with ring carrying out any bolt work on live plant.
gasket and class 150 flanges with IFG gasket of four different
dimensions (1/2", 1.5", 3", and 8"). The gasket stress and strain In the EEMUA information sheet the application of the hot
as well as contact pressure of the gasket were studied to bolting without any tool/clamp is restricted by [23]:
investigate the possible leakage. The test was performed for 4" 1) Flange joints considered for hot bolting should have a
class 1500 flange with ring gasket by Irgens Engineering AS, minimum of eight bolts and the bolt material should have a
and the comparison between analysis and test results showed minimum strength equal to or greater than grades B7/2H.
good agreement both for the gap between flange just outside 2) Hot bolting should not be carried out on joints which show
ring gasket and the flange bolt force. significant signs of corrosion or necking, or which have
worn or cracked threads on the fasteners.
Keywords: Hot bolting, structural integrity, sequential loading,
finite element analysis, gasket.

1 Copyright 2016 by ASME


In order to extend the hot bolting operation to flange joints with The integrity of the hot bolting clampTM designed by Irgens
less than eight bolts, increase the safety in replacing corroded Engineering AS needs to be investigated before it can be widely
or damaged bolts and simplify the working process, Irgens applied in the industry. The qualification work about the new
Engineering developed the Hot Bolting Clamp system to hot bolting tools was carried out by the joint efforts of
establish a safe barrier for all flange connections during hot producer, operator and classification society. In literature 3D
bolting operation. The Hot Bolting Clamp system was non-linear finite element method was generally used to
patented in 2009 and first used in a live system in 2011. This investigate the behavior of flange joints with GFRP gasket and
system consists of a mechanical clamp that is installed around metal ring gasket. The strength of the flange and the leak
the flange connection to take over the flange bolt forces when a tightness of the GFRP gasket were investigated by finite
flange bolt is removed. The Hot Bolting Clamp has a robust element analysis in [9, 14], and analysis showed that the
design that makes it also safe to use heavy equipment for distribution of contact stress has a dominant effect on sealing
removing rusty flange bolting. Change-out of the flange bolts performance. The gasket characteristics and no-leak conditions
are performed by the new technology without any damage, of the metal-to-metal contact flanges were investigated in [3, 4,
leakages or interruptions in daily production on pipelines or 20], and the best flange dimensions are recommended for no
process plants. This system is offered to the international leak conditions. The safe operating conditions for gasketed
marked by Hydratight, marketed under the name MorSafe flange joint under combined internal pressure and temperature
[10, 12]. were investigated in [2] and the sealing capability of joints was
concluded to be related to the gasket seating or contact
pressure, which varied with bolt load variation during bolt up
and operating conditions providing possible leakage and
ultimately joint's failure.

Although there are no literature related to the study of Hot


Bolting Clamp it could be regarded as bolted flanges with
special designed backstops. In current study the 3D non-linear
finite element method is also applied to assess the structural
integrity of both flange joints and hot bolting clamp and to
investigate whether or not leakage will occur during hot bolting
operation. In the modeling of hot bolting operation the
following aspects are different from the modelling of traditional
flange joints:
1) Complex loading procedure
2) Increased non-linear contact pairs
3) Modelling of backstops
a) Clamp assembly 4) Changeling to achieve convergence with increased model
size
The numerical analyses are performed for Class 1500 flange
with ring gasket and Class 150 flange with IFG gasket.

FINITE ELEMENT MODELLING OF HOT BOLTING


OPEARATION

Abaqus/Standard [1] is used to perform the Finite Element


analysis of flanges and the Hot Bolting ClampTM.
Abaqus/Standard has numerous material models available to
simulate the behavior of most typical engineering materials,
b) Assembled clamp
including metal and non-metal gasket.
Figure 1: Hot bolting clamp from Irgens Engineering AS.
The general sequential loading procedure used to simulate the
The design basis of the hot bolting clamp is to control the
hot bolting operation and the applied loads for Class 1500
gasket stress to maintain a leak free gasket at maximum
flange with ring gasket and Class 150 flange with IFG gasket
loading, and it is equipped with Backstops to counteract the
are shown in Table 1. In each step the loads are ramped up to
pretension of the hot bolting clamp and prevent gasket
the target value.
crushing. The illustration of the hot bolting clamp is shown
in Figure 1.

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Table 1 Sequential loading procedure and applied loads would normally have during lifetime. The following condition
Step 4" Class Class 150 flange with which is most critical to the safety of hot bolting operation is
1500 flange IFG gasket investigated in simulation.
with ring 1/2" 1.5" 3" 8" minimum gasket contact pressure is assumed to occur at
gasket
10% relaxation of bolt pre-tension with test internal
0 Initialize the surface-surface contact interactions between various
pressure (1.5 times of the design pressure)
parts
1 Apply pretension loads The pre-tension load is applied according to operator's
163 15 26 70 103 specification [22].
at flange bolts (kN/bolt)
2 Apply the hydrostatic
pressure inside the 380 20 20 20 20
flange (Barg)
3 Apply partial clamp
[13]
loading (kN/bolt)
4 Apply backstop loading
[13]
(kN/bolt)
5 Apply full clamp
[13]
loading (kN/bolt)
6 Remove flange bolt F1
7 Rebolt flange bolt F1
*
7 All four or eight flange

bolts removed
*
8 Re-bolting all the bolts
*
9 Removing clamps
1) The step marked with * are applied for class 150 flanges with IFG
gasket. Figure 2: Illustration of model assembly of Hot bolting
2) The loads for step 3, 4 and 5 are presented in [13] clamp from Irgens Engineering AS (8" class 150 flange
with IFG gasket).
Surface to surface contact with finite sliding is used to model
the nonlinear contact interaction between the components. The
contact between following components are taken into account Class 1500 flange with ring gasket [11, 13, 15]
in the FE-model:
Gasket and flange hub The dimensions of 4" class 1500 flange with ring gasket are
Flange bolts and flange hub shown in Table 2 and Figure 3. The material properties of the
Clamp and flange flange with ring gasket are presented in Table 3 and the plastic
Clamp and clamp bolts material properties shown in Figure 4 are used in the numerical
Clamp and backstops simulation.
Penalty friction formulation with friction coefficient of 0.15 is
used in analysis for tangential behavior. The "hard" contact is The finite element model of 4" class 1500 flange with ring
used to simulate pressure-overclosure in normal direction, and gasket is shown in Figure 5. The pipe connected to the lower
the separation of surfaces is allowed after contact. flange is fixed in x, y and z directions. The clamp and clamp
bolts are fixed in x and y direction in first two steps, and then
For each clamp bolt there are two backstops located on its the boundary condition for clamp and clamp bolts are removed
sides. The precompression load of the backstops can be from step 3. This procedure is used to achieve numerical
adjusted through the holes in the bottom flange of hot bolting stability of the clamp on which there is no loads applied before
clamp and it counteracts part of the pretension loading of the step 3.
clamp and prevents gasket crushing. The low part of backstop
is tie-constrained with bottom flange of clamp and the length of
The eight-node linear brick element with reduced integration
backstops is fixed in first three steps. In step 4 the
C3D8R is used for all the components including flange, ring
precompression load is applied on the backstop and this load
gasket, flange bolts, clamp, backstops and clamp bolts. The fine
will keep constant to step 8.
mesh (<1mm) is used in the contact areas and coarse mesh is
used in other parts.
Gaskets play an important role in the sealing performance of
bolted flange joints, and their behavior is complex due to
nonlinear material properties combined with permanent
deformation. FEM analysis focuses on the flange sealing
contact pressure (gasket stress). The gasket stress through the
hot bolting operation should be within the stress range which it

3 Copyright 2016 by ASME


Table 2 Dimension of 4" class 1500 flange with ring gasket
[5, 6]
Part Dimension
Width of ring A 11.13 mm
Type R ring Height of ring H 16 mm
gasket Width of flat on octagonal ring C 7.75 mm
Average pitch diameter of ring p 161.93 mm
Bolt circle 11/8 inches
Flange bolt Bolt diameter 5/4 inches
Number of bolts 8
Bolt circle diameter 241.3 mm
Hex nuts of Height 39/32 inches
flange bolts Width 2 inches
Outside diameter 310 mm
Inner diameter 80.1 mm
Flange flange thickness 54.0 mm
Length (welding neck) 124 mm
Hub diameter 162 mm Figure 5 Finite element model of 4" class 1500 flange with
Pipe diameter 114.3 mm ring gasket

Class 150 Flange with IFG gasket [11, 13, 16, 17, 18,
19]

The class 150 flanges with IFG gasket with four different
dimensions are shown in Table 4 and they have same material
properties as presented in Table 3. The elastic material
properties of flange are used in the numerical simulation. The
Figure 3 Type R ring gasket gasket data (IFG 5500, 2mm Gasket) given in [8] is used in the
simulation and the relation of the Secant unloading modulus EG
Table 3 Material properties of 4" class 1500 flange with ring and gasket thickness eG is shown in Table 5.
gasket
Part Young's modulus E Poisson Yield Stress Table 4 Dimension of class 150 flange with IFG gasket [5, 6]
(GPa) (MPa) Part Dimension " 1.5" 3" 8"
Flange/pipe 210 0.3 250 Inner diameter (mm) 21 49 89 219
Flange bolts 210 0.3 724 IFG gasket Outer diameter (mm) 48 86 137 279
Ring gasket 210 0.3 200 Thickness (mm) 1 1 1 1
Blot circle (inches) 5/8 5/8 3/4 7/8
Bolt diameter (inches) 1/2 1/2 5/8 3/4
Flange bolt
Number of bolts 4 4 4 8
Bolt circle diameter 60.3 98.4 152.4 298.5
(mm)
Hex nuts of Height (inches) 31/64 31/64 39/64 47/64
flange bolts Width (inches) 7/8 7/8 17/16 1.25
Outside diameter 90 125 190 345
(mm)
Inner diameter (mm) 15.8 40.9 77.9 202.7
Flange thickness 9.6 15.9 22.3 27
Flange
(mm)
Length (welding 46 60 68 100
neck) (mm)
Hub diameter (mm) 30 65 108 246
Pipe diameter (mm) 21.3 48.3 88.9 219.1

Figure 4 Plastic material properties

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Table 5 Secant unloading modulus of the gasket EG (MPa)
and gasket thickness eG (mm)
Ambient temperature
Gasket stress (MPa)
EG (MPa) eG (mm)
0 2
1 1.919
20 726 1.753
30 966 1.684
40 1488 1.636
50 1631 1.599
60 2048 1.573
80 3117 1.541
100 3224 1.514
120 3833 1.497
140 3975 1.479
160 4094 1.464
180 4382 1.451
200 4750 1.439
Figure 7 Finite element model (8" class 150 flange with IFG
gasket)
220 4445 1.424
230 4517 1.413
ANALYSIS RESULTS
The finite element model of class 150 flange with IFG gasket is
shown in Figure 7. The boundary conditions applied for class
150 flanges with IFG gasket are similar as that applied for class The non-linear static analysis was performed to simulate the hot
1500 flange with ring gasket. The eight-node linear brick bolting operation.
element with reduced integration C3D8R is used to model the
flange, flange bolts, hot bolting clamp and bolts. The IFG
gasket is modelled by 8-node, three-dimensional gasket Class 1500 flange with ring gasket [11, 13, 15]
element GK3D8N with thickness-direction behavior only.
Typical use of GK3D8N gasket elements involves a tabular Maximum Von-Mises stress of different components during the
representation of the pressure versus closure relationship in the analyses for seven load steps are listed in Table 6. The stress of
thickness direction of the gasket. The pressure versus closure the lower clamp and backstop at step 6 is shown in Figure 8 and
models available in ABAQUS allow the modeling of very the stress of gasket ring at step 5 is shown in Figure 9. The
complex gasket behaviors, including nonlinear elasticity, stresses at the location of contact area between the flange and
permanent plastic deformation, and loading/unloading along ring gasket are exceeding the yield stress as shown in Figure 9
different paths. In addition to the single loading curve, whose and Figure 11, and part of flange and ring gasket enters plastic
closure increases monotonically, the user can define any regime. The structural integrity of flange and hot bolting clamp
number of unloading curves at different levels of plastic is maintained as long as the material failure does not occur.
closure. The verified material model for the IFG gasket with
loading and unloading curves was shown in. Table 6 Maximum Von-Mises stress (MPa)
Part Maximum Von- Load step in which max
Mises stress (MPa) stress occurs
Ring gasket 384 Step 5
Flange 565 Step 5
Flange bolts 662 Step 2
Clamp 390 Step 6
Backstops 555 Step 6
Clamp bolts 569 Step 6

The contact pressure pattern over the surface of the ring gasket
is shown in Figure 10 for load steps 6. The minimum contact
pressure over the surface of the ring gasket drops from 418
Figure 6 Verification of the input of gasket material model MPa (at load step 5) to 368 MPa (at load step 6) which is about
in ABAQUS [21] 10 times of the applied pressure during pressure testing (38

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MPa, 380bar) and about 15 times of the applied pressure at
maximum design pressure (25.5MPa, 255bar). The gasket
provider considers 5-6 times of the working pressure as
sufficient contact pressure to ensure that no leakage occur.

Upper flange

Figure 8 Lower clamp and backstop stress at step 6

Lower flange
Figure 11 Flange stress at step 5

Comparison with the test


Figure 9 Ring gasket stress at step 5
Test was performed by Irgens Engineering for 4" class 1500
flange with same sequential loading as applied in numerical
simulation. The comparison of the analysis results with the test
results for gap between flanges just outside RTJ gasket is
shown in Figure 12. The comparison of the flange bolt force is
shown in Figure 13. Comparison between analysis and test
results shows good agreement both for the gap between flange
just outside RTJ gasket and flange bolt force.

Figure 10 Contact pressure at surface of ring gasket at step


6

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the flange towards the pipe segment it connects and the gap
between two flanges at inner circle increases. The gasket stress
drops more significantly at outer circle when bolt F1 is
removed in the step 6 which is the most critical load step.

The stress plot of the gasket at step 6 is shown in Figure 14 for


1/2" class 150 flanges with IFG gasket. The stress at inner and
outer circle is similar. The flange behaves relative rigid during
the hot bolting operation.

The stress plot of the gasket at step 6 are shown in Figure 15 to


Figure 17 for 1.5", 3" and 8" class 150 flanges with IFG gasket.
With the increase of size the flange behaves more flexible, and
the gasket stress at outer circle is larger than that at inner circle
at step 6 for 3" and 8" class 150 flanges.

Table 7 Stress of gasket along the radial path towards bolt


Figure 12 Gap between flanges just outside RTJ gasket F1 (MPa) (1/2" class 150 flange)
Radial path Step
(mm) 1 2 3 4 5 6 7
0.00 82.3 80.1 71.7 72.9 69.8 39.0 31.9
0.96 83.3 81.3 74.1 75.1 72.7 39.0 32.8
1.93 83.8 82.1 75.9 77.0 75.2 39.1 33.7
2.89 88.8 87.2 81.7 82.8 81.6 38.5 34.3
3.86 96.6 95.1 90.0 91.3 90.6 37.8 34.7
4.82 104.3 102.9 98.4 99.9 99.8 38.1 35.9
5.79 102.4 101.2 97.0 98.5 98.5 37.1 35.8
6.75 97.7 96.8 93.8 94.9 95.0 37.1 36.7

Figure 13 Flange bolt force

Class 150 Flange with IFG gasket [11, 13, 16, 17, 18,
19]

The Von Mises stress of gasket along the radial path towards
bolt F1 which is removed in step 6 is shown in Table 7 for 1/2"
class 150 flanges with IFG gasket. The gasket stress reaches
maximum after step 1, and its variation is small during step 2 to
5. The stress drops more significantly at outer circle of gasket Figure 14 Gasket stress at step 6 of removing one flange
than at inner circle when bolt F1 is removed in step 6 and the bolt-F1 (1/2" class 150 flange)
most critical load step is step 7 with removing of all four bolts.

The Von Mises stress of gasket along the radial path towards
bolt F1 are shown in Table 8 to Table 9 for 1.5", 3" and 8" class
150 flanges with IFG gasket. The maximum gasket stress
occurs at outer circle of IFG gasket when full clamp load is
applied at step 5. With the increase of flange size the gasket
stress decreases significantly at inner circle of IFG gasket at
step 5. This is due to that the full clamp load induces rotation of

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Table 8 Stress of gasket along the radial path towards bolt
F1 (MPa) (1.5" class 150 flange)
Radial path Step
(mm) 1 2 3 4 5 6 7
0.0 36.4 34.2 35.1 36.4 37.2 22.6 22.3
1.0 37.2 35.1 37.0 37.4 38.2 21.2 21.2
1.9 38.0 36.1 38.1 38.4 39.3 19.8 20.1
3.8 38.9 37.3 39.3 39.5 40.6 18.7 19.5
5.8 41.5 39.9 42.4 42.6 44.1 17.2 18.4
7.7 43.1 41.7 44.3 44.5 46.0 16.6 18.1
9.6 46.6 45.3 48.2 48.4 50.1 15.3 16.9
10.6 48.3 47.0 50.0 50.3 52.8 14.0 15.7
11.5 48.7 47.5 50.7 50.9 53.3 13.5 15.4
12.5 47.0 46.3 48.8 49.0 50.9 15.1 17.2

Figure 16 Gasket stress at step 6 of removing one flange


bolt-F1 (3" class 150 flange)

Table 10 Stress of gasket along the radial path towards bolt


F1 (MPa) (8" class 150 flange)
Radial path Step
(mm) 1 2 3 4 5 6 7
0.0 17.3 12.6 5.6 7.3 5.9 4.6 6.5
3.0 20.6 16.4 9.2 11.4 9.8 6.0 7.9
6.0 24.5 20.1 14.1 16.5 14.9 7.7 9.4
9.0 29.3 24.3 19.4 21.8 20.5 8.9 10.4
12.0 36.0 29.9 26.4 29.1 27.9 9.6 10.7
15.0 43.4 34.7 38.5 42.0 41.8 10.6 11.5
18.0 52.4 47.2 53.4 53.9 54.2 10.9 11.4
21.0 71.9 68.2 76.7 76.7 78.0 12.2 12.5
24.0 94.4 92.7 105.4 103.8 108.2 16.6 16.7

Figure 15 Gasket stress at step 6 of removing one flange


bolt-F1 (1.5" class 150 flange)

Table 9 Stress of gasket along the radial path towards bolt


F1 (MPa) (3" class 150 flange)
Radial path Step
(mm) 1 2 3 4 5 6 7
0.0 72.7 66.5 56.5 57.7 55.9 22.8 25.7
1.4 78.9 73.5 66.0 67.4 66.6 22.7 26.0
3.0 85.9 81.3 78.3 79.3 80.3 23.5 27.1
4.4 97.2 92.9 95.2 96.4 97.8 23.4 27.0
5.8 114.0 110.1 115.1 115.4 117.5 24.8 28.8
7.3 127.8 124.2 130.1 130.4 132.8 25.9 30.2
8.8 138.9 135.6 142.7 142.9 146.3 27.3 32.0

Figure 17 Gasket stress at step 6 of removing one flange


bolt-F1 (8" class 150 flange)

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The maximum and minimum contact pressures over the surface When the bolt F1 is removed the minimum contact pressure
of gasket are shown in Table 11. The minimum contact over the gasket surface for 1/2", 1.5" and 3" class 150 flanges
pressure at step 6 for 1/2", 1.5" and 3" class 150 flanges are are more than 8 times of the operation pressure which is
more than 8 times of the operation pressure. Although the adequate for avoiding leakage during hot bolting and removal
minimum contact pressure for 8" class 150 flanges is about 2.5 of flange bolts and replacement of them.
times of the operation pressure in step 6, the contact pressure
along the radial path towards bolt F1 increases to about 10 MPa For 8" class 150 flange the contact pressure along the radial
at half of the radial path as presented in Table 10. For path towards bolt F1 is larger than 10 MPa from half of the
compressible gaskets the minimum stress to seal for leakage radial path to the outer edge, and it meets the requirement of the
during installation is considerable higher than the minimum minimum stress to seal after off-loading provided by IFG
stress to seal in service [7]. When a compressible gasket is first gasket producer. The tests carried out by Statoil also show no
stressed, the leakage rate is minor increased by decreased leakage occurs during the hot bolting operation.
gasket stress [8], If this gasket type is average stressed to
40MPa under installation it is consider as tight at off-loading to
10MPa under 40 bar operation. Statoil has performed further ACKNOWLEDGMENT
analyses and extensive leakage tests for 8 CL150 size, and no
leakage has occurred during tests and it concluded that Hot This work has been carried out as part of a project funded by
Statoil, and Statoil is gratefully acknowledged for the
Bolting of this size is acceptable.
permission to publish the paper.
Table 11 Maximum and minimum contact pressure over
the surface of gasket (MPa) REFERENCES
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Class 150 flange with IFG gasket Clamps, Document number: 201012-05

9 Copyright 2016 by ASME


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18. MARINTEK, Finite element analysis of hotbolting tool -
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Replacement of Flanged Joint Bolting on Live Piping and
Equipment, May 1999

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