The Significance Of Thorough Bolt Tightening In Equipment Maintenance

The impact caused by Bolt Tightening issues

With the expansion of petrochemical plants and the rapid growth of factory production, there is an increasing 

concern about the issues arising from improper bolt tightening in pipeline components and pressure vessels. 

Leakage not only results in material loss and environmental pollution but also poses a significant risk to human safety.

Furthermore, the presence of numerous hidden leaks in factories, which are often difficult to detect with the naked eye,

has amplified the likelihood of accidents during the production process. 

In recent years, there have been frequent incidents such as explosions, fires, equipment damage, product wastage,

casualties, and environmental pollution caused by equipment leaks. These incidents have inflicted significant

harm on industrial production, economic development, environmental sanitation, and personal safety.

It is evident that many of these problems stem from flange sealing issues. For instance, volatile organic 

compound (VOC) leaks in the petrochemical industry are challenging to identify visually. Unfortunately,

many factories neglect the use of professional tools for bolt fastening in an attempt to cut costs,

which ultimately proves to be futile and counterproductive.

Bolt fastening is a critical aspect of ensuring equipment safety and integrity. The process typically involves four steps:

1. Determining the Bolt Tensile Yield: This step involves finding the tensile yield of the bolt,

which is determined by the bolt material and can be obtained from mechanical manuals or relevant data sources.

2. Calculating Axial Preload: The axial preload is calculated as 0.7 to 0.9 times the tensile yield. 

There are two types of calculations for the preload: one for steel structures, which follows the international

standard VDI2230, and another for pressure vessels and pressure pipeline flanges with sealing gaskets.

The accuracy of the calculations in the first two steps is generally reliable and 

can be obtained through look-up tables or established standards.

3. Determining Torque Value: The third step involves determining the torque value 

that corresponds to the optimal preload load. This is based on available data and experience. 

However, there are potential errors in this step due to variations in the selection of 

fastening tools and methods, which can introduce hidden risks to equipment safety.

4. Tightening: The final step is to carry out the tightening process using suitable tools and techniques. 

Traditional methods like manual tightening with hammers or levers rely heavily on

operator experience and lack precision. In recent decades, significant advancements

have been made with the introduction of pneumatic, electric, and hydraulic tools such as torque wrenches and Bolt Tensioners. 

These tools allow for accurate torque values to be set and applied during the fastening process.

Bolt tightening is of most importance in equipment maintenance for several reasons:

1. Structural Integrity: Properly tightened bolts ensure the structural integrity of equipment.

Bolts play a critical role in holding components together, maintaining stability, 

and preventing any unintended movement or failure. Insufficiently tightened bolts can lead to

loosening over time, compromising the equipment's stability and potentially resulting in accidents or damage.

2. Leak Prevention: Bolts are often used to secure joints, such as flanges in pipelines or pressure vessels. 

If bolts are not adequately tightened, it can result in gaps or uneven pressure distribution, leading to leaks.

Leaks can cause material loss, environmental pollution, and even pose safety risks. 

Proper bolt tightening helps maintain a reliable and leak-free system.

3. Performance and Efficiency: Equipment relies on proper alignment and tension to function optimally. 

Inadequate bolt tightening can result in misalignment or excessive vibration,

affecting the equipment's performance and efficiency. By ensuring proper bolt tightening, 

equipment operates as intended, maximizing productivity and reducing energy wastage.

4. Safety: Bolt failure due to improper tightening can have severe consequences, including accidents,

injuries, and even fatalities. Loose or missing bolts can cause equipment components to detach, 

leading to sudden equipment breakdowns or falling objects. Proper bolt tightening is 

crucial to prevent such safety hazards and create a secure working environment.

Bolt fastening issues have been identified as a significant cause of leakage and other accidents.

In recent decades, there has been a concerted effort to address the shortcomings of existing fastening technologies,

including their accuracy, lifespan, and ease of use.SAIVS, like other renowned companies,

is actively engaged in the development of new products and technologies in this field.

Through collaboration and partnerships with various factories, SAIVS continuously enhances its products and technologies,

aiming to safeguard the environment and minimize losses for industrial facilities.