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ASME PCC-1 : Flange Assembly Load And Bolt

Torque Values Computation
Prepared by:
SAEC- DELHI
Mechanical-Static
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a) Introduction

Failure may happen during flange tightening operation though design performed
according to international codes.
As a general practice, oil & gas industry are gradually adopting ASME PCC-1 for
reducing the same.
So far, in SAEC Delhi, all vendor calculations of ASME PCC-1 were checked manually
by engineers. The method was time consuming and had chances for errors going
unnoticed. No tool for checking was available to engineers, thus, the approach was
more dependent on individual capability and less on a systematic approach.

Benefit of the presentation :

Glimpses of ASME PCC-1 guidelines.
Features & Utility of the developed spreadsheet for ASME PCC-1 calculations.
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Contents
1. Objectives
2. Abbreviations terminology
3. Requirement of ASME PCC-1
4. ASME PCC-1 APPENDIX-K
5. ASME PCC-1 APPENDIX-J
6. ASME PCC-1 APPENDIX-O
7. Current Practice in SAEC Delhi
8. Recommendation for changes
9. Features of Developed Spreadsheet
10. Summary Of Training
11. Assessment and Evaluation
12. Source Of Reference
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1. Objectives

Prevalent Practice in Industry

Details of Important Appendices of ASME PCC-1
Target Torque Determination
Assembly Bolt Stress Determination
Process Change recommendations
Utility of Spreadsheet Developed
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2. List of Abbreviations
T : Target Torque t : Thread Friction Factor
K : Nut Factor n : Nut Friction Factor
D : Bolt Nominal Diameter SgT : Target Gasket Stress
F : Target Bolt Load Ag : Gasket Area
y : Minimum Yield Strength nb : number of bolts
P% : Utilization Factor Ab : bolt root area
p : pitch per thread
N : threads per inch
d2 : d-0.6495p for metric thread or d-0.6495/n for unified thread
: Half included angle for thread
De : Effective bearing diameter of nut face = (do + di) / 2
Do : outer bearing diameter
di : inner bearing diameter

3. Requirement of ASME PCC-1
Prevalent Practice in Industry
How a suitable torque value for flange joint
tightening value was conventionally
established?
Based on Bolt size and operators
experience tightening was performed
Visual examination of Stud elongation
and leakage was a confirmation of
adequacy of the torque
Torque Value considered may be not
suitable for the joint
Leaks
from bolted flange joints
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Trial & Error method (with less consideration for
Gasket or Nut failure scenarios)
No Set of Rules, Guidelines or Formulae to arrive
at the values
Time Consuming
High Torque
- Crushing of Gasket
- Damage to bolt / nut thread
Low Torque
- Inadequate joint closure
- Longer time for tightening
Unnecessary cost to any operating facility
Pose significant operational, environmental, and
safety risks

3. Requirement of ASME PCC-1
Solution to the Problem
How to compute the correct torque for
a configuration?
Features
ASME PCC-1
Compute Target torque required
during operation as per Appendix J,
K&O
Recommendation from other Codes /
Specifications
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PCC-1 is a post-construction guide which deals with proper
flange tightening
Provides installation or operating guidance once a vessel is
fabricated or when in service.
Computation of Target torque required during operation to
- minimize the time required to assemble a joint
- minimize human error during bolt tightening
API-660, 2015: (Cl. 7.8.1, bulleted point)
- Based on Purchaser recommendation, the flange joints of
a heat exchanger may be checked in accordance with
Appendix-O of ASME PCC-1.
Shell DEP 31.21.01.30- General Feb 2011(Cl. No. 7.8.12.6
and 9.11.4) :
- After flange design, bolt assembly and gasket seating
stresses to be checked in accordance with Appendix-O of
ASME PCC-1
- During maintenance / reinstallation of flange, Appendix
K of ASME PCC-1 can be used for determining the
torque values.
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4. ASME PCC-1 APPENDIX-K

What do we compute using Appendix-K ?

It is simplest approach but actual bolt load determination is difficult which may give erroneous result and does
not check gasket or flange damage.
Inputs:
Only need bolt diameter & bolt load.
Assumptions:
Generally, we assume design bolt load as per Appendix-2 of ASME Section VIII Div.1
Factor K (nut factor) which is generally 0.2 (but based on experience of flange, bolt and gasket properties and
size, the K factor can be altered or experimentally determined through lab testing)

Target Torque, T= KDF

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5. ASME PCC-1 APPENDIX-J

What do we compute using Appendix-J ?
It is a more detailed procedure than Appendix K and can provide more accurate result. However, this
approach also do not check gasket or flange damage conditions. It takes into consideration the type of bolt
tensioning tool.
Inputs:
Bolt properties e.g. inner bearing surface diameter, outer bearing surface diameter, pitch of thread, bolt tensile
area. These can be referenced from ASME PCC-1 appendix H based on standard bolt diameter and bolt
material yield strength.
Assumptions:
Friction factors of nut face & thread which is can be assumed in the range of 0.12 to 0.16 or experimentally
determined through lab testing.
Percent utilization factor of 0.5 on bolt yield strength is considered as minimum.

Bolt Preload: F = As y P%
Bolt Stretch Factor: f1= p/ for metric thread or 1/n for unified thread
Thread Friction Factor: f2=t d2 /Cos
Face Friction Factor: f3=De n/2

TARGET TORQUE, T = F(f1+f2+f3)

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6. ASME PCC-1 APPENDIX-O

What do we compute using Appendix-O ?

This procedure is the most detailed and provides satisfactory result in all respect. It considers the integrity of
all components (flange, bolt and gasket) including the joint integrity. However, many input data from
component manufacturer (gasket / flange / bolt) are required which usually are not available at initial stage or
till finalization of the manufacturer. These data are not generally provided in product catalogue.
Inputs:
From Gasket Manufacturer : Minimum gasket operating stress; minimum gasket seating stress; Gasket
minimum and maximum permissible stress
From Bolt Manufacturer : Minimum and maximum permissible bolt stress
From Flange Manufacturer : Maximum stress prior to flange damage; Maximum rotation prior to flange
damage

Ag
Bolt Stress, Sbsel = SgT
nb Ab
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7. Current Practice in SAEC Delhi

Available Pressure Vessel Design Need was identified

Software do not perform ASME PCC-1 for development
calculations. of a Unified checking
tool
Engineers perform manual checking of VP
calculations.
VP checking procedure is time consuming
and has chances of committing human
errors.
No tool , spread sheet was available in
SAEC Delhi / Gfiles
Spreadsheet was
developed to perform
ASME PCC-1
calculations
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8. Recommendation for Changes

Development of Spreadsheet for Global Use in all GS offices

EAEC SAEC SAEC

EAEC
Manila Delhi Mumbai
Seoul

Development of One single file

(by SAEC Delhi Mechanical - Static)

Developed based on Appendices J, K & O of

ASME PCC-1
Validated based on Vendor Data
Incorporated EAEC comments
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9. Features of Developed Spread Sheet

Separate worksheets for computation Ease of Input, Computing, Reporting and Result viewing

Bolt Data Data base : Unified and Metric threads are built-in. Bolt Root
Area, Bolt Tensile Area & No of thread per inch / pitch of
thread as per Appendix H & Dimension across flats as per
TEMA D-5 / D-5M
Bolt Data input : Automatic by size and type selection (i.e. no
manual input)

Data base: As per Appendix-2 of ASME Section VIII Div-1

Gasket Data
is built in
Gasket Data Input: Automatic by material and type selection
(i.e. no manual input)
Provision available for
- input of user defined m& Y values
- separate input for pass partition gasket

Flange Damage Stress Checking Using WRC 538 method

Flexibility of Input Single or Mixed units (i.e. US customary and/or SI )

Result Viewing Single tabular view of data for all flanges in same exchanger -
useful for checking and comparison
Both quick check and detailed (step-wise) calculations are
available for same input.
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9. Features of Developed Spread Sheet

Accuracy Check of the Spread Sheet

Sl. Test Cases Deviation

No (ARP / CFP Project data) Percentage
Appendix-K

1. 160E-302 Channel Flange 0.48 %

Appendix-J

1. E-107-101A/B Channel Flange 0.19 %

2. E-107-105 Return Head Flange 0.18 %
3. E-107-111A/B Return Head Flange 0.20 %
Appendix-O

1. E-144-101A/B Shell Flange 0.00 %

2. E-107-115 Return Head Flange 0.25 %
3. E-137-105A/B Floating head Flange 0.00 %

Spreadsheet results are showing reasonable level of accuracy

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10. Summary of Training

Requirement of ASME PCC-1
Capabilities of Spread sheet developed and its extend
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11. Assessment and Evaluation

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12. Sources of Reference

ASME PCC-1 for all computational logic and formulae.

ASME Section VIII Division 1 Appendix-2 & Appendix GG

TEMA Tables D-5 and D-5M

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Thank You