TORQUING & TENSIONING OF

FASTENERS
 WHY TORQUEING AND TENSIOINING ?

 TORQUEING

 TENSIONING

 HOW TO CHOOSE BETWEEN TORQUEING & TENSIONING ?

 DO’S & DO NOT’S

 RIL- PROCEDURE- STEPWISE GUIDANCE .

 WHY Torqueing / Tensioning ?
← To Ensure equal tightening of all the Fasteners of a joint- Manual
tightening varies from person to person, Position to position.

← To Provide the Pre-defined torque / load to the fasteners -Measurement

of torque is not possible , when done manually .

← To Save time & labor.- Same job requires less no. of persons , and less
time .

← To avoid hot tightening.- It is very difficult to check for looseness at odd

locations , VIZ. HOT- Expander Flange joints in PTA, Preheater’s joints
in PE, Etc.

← High reliability.- Rarely heard about failure, leak from any m/c fastened
joint.
What is torque ?
Torque is the turning moment applied to a fastener when it is turned by a wrench or spanner, as
shown in the diagram below.

This turning moment or torque is simply calculated by the formula:

torque = force x radius

• Why is it necessary to apply a specified torque to a fastener ?

Applying torque to a threaded fastener turns the nut down the screw thread. If the fastener is
clamping two pieces of material together e.g. a flanged joint, then applying torque will exert a
stress in the bolt, which will apply a clamping force to the joint.

In order to correctly load the fastener and prevent premature failure of the fastener or the joint it is
necessary to provide a safe and correct load and therefore the correct torque.
 TORQUEING ::

“ We use a torque wrench to turn a nut ; the action of

turning the nut tightens it against the joint face.”
 Sequence to be pre-decided on basis of no. of bolts
( One-Top, Two-Bottom, Three-Right, Four- Left........ and so on )

 The machine to be SET for torque to be applied.

( Torque Value from RIL-procedure, and / or OEM data sheet, also
cross Check the MOC of bolt / studs., Type of equivalent lubrication used. )

 Apply the torque in three steps.

( 50 %, 80%, Full )

 Check - again by tightening, all the nuts.

( No nut is missed , no damage to the nut has occurred )
 Hydraulically operated torque
Manually operated torque wrenches wrench
 Connection for
Hydraulic Oil to
wrench

Reaction point cum

Holder
Square drive to suit
to socket
 TENSIONING ::
“ When stretched within elastic limits , the bolt will try to return to
its original size and exert a reaction on the joint face, thereby
clamping the joint together.”

• Refer the load table – available with the tensioners,

• Install the tensioners on alternate bolts.
• Apply the 70 % load. remain at an oblique angle , neither in front of the
.
tensioners, nor at 90 .
• Tighten the nuts.
• Change the tensioners on remaining half of the bolts.
• Repeat the operation “C” & “D”.
• Again change the tensioners on first half of the bolts, and repeat the operation.
• Change the Pre- SET Load to 100 %.
• Again repeat the same for remaining half of the bolts, with load 100 %.
 HOW TO CHOOSE BETWEEN TORQUEING &
TENSIONING ?

• Protrusion length of studs: Tensioning is not possible in studs , whose protrusion length from nut face is
< “d”.

• No. of bolts / studs : Tensioning is used to save time , if the no. of bolts are too !! Many !! ( > 100 nos. in
some Exchangers , vessels ) tensioning shall not help , as the preparation time is too high , also it is not
practical to deploy half no. of tensioners ( = 50 ) to complete the tightening in 4 cycles.

• Long threaded studs / bolts : The longer bolts does requires the special type of torque wrenches .
( General purpose torque wrench comes with set of sockets ).

• Availability of a reaction point : This is a must if using torque wrench .

• Cost effectiveness: Cost wise there is nothing to choose between a TORQUE WRENCH and a SET OF
TENSIONER , yet the overall hiring rates of tensioners remain high, due to the accessories ( high pressure
hoses, Air / Electrically operated hydraulic pumps ) which are generally charged separately, if you have same
sizes of studs in different equipments , GO FOR Tensioners , and complete the job as quickly as possible .

• Skill requirements: Generally torqueing is very easy to understand , however the selection of lubricant is
critical.
 Puller bar /
Reaction nut

Bridge ,
Interface
Hyd. Oil inlet / between NUT &
outlet points TENSIONER

Slot for Tommy ,

TENSIONER
tightening the
NUT
 DO’S & DONT’S
Do’s
• Use the correct tool.
• By a competent operator.
• With the correct procedure.
• To the correct standard.

DON’TS
• STAND , OR ALLOW ANY ONE TO STAND IN FRONT AND AT 900, WHEN
TENSIONING IS UNDER PROGRESS,
• MIX UP THE MAKE OF MACHINE AND DATA CHART/TABLES.
• HASITATE TO ASK FOR THE CONVERSION OF UNITS.
 RIL- PROCEDURE- STEPWISE
GUIDANCE .
• RAISE A SERVICE PR .

• CALL THE A.R.C. CONTRACTOR , AND SHOW THE EQPT.

• PROVIDE THE NECESSARY DATA SHEETS – LOAD CHARTS AND TABLES.

• GET THE TORQUING TOOLS ISSUED FROM CES.

• KEEP AT LEAST 15 – 20 % NEW FASTENERS READY FOR REPLACEMENT .

• CHECK FOR NEED OF SCAFFOLD, PLATFORM , UN SKILLED WOKERS FOR SUPPORT,

• KEEP A UNIT CONVERTOR CHART , RIL PROCEDURE, CATALOGUE OF TORQUE

WRENCH, / TENSIONER available at job site,

• GET THE TORQUE VALUE REVIEWED BY A SENIOR. ( IF YOU ARE DOING IT FOR THE
FIRST TIME )

• GOOD LUCK …