Technical information
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1 Technical information Control of bolted connections The assembled screws are to be checked for the desired screwing results in order to ensure the function of the connection for the long term. Depending on the hazard potential of the connection, the assembly result must be secured. VDI 2862, with its parts 1 and 2, differentiates screw connections into three categories (Tab.1) according to the potential risks. Tab. 1: Hazard classes according to VDI Hazard class Risk assessment Description Category A High risk assessment Danger to life, limb and the environment Category B Medium risk assessment Malfunction / system downtime Category C Low risk assessment Noncritical At least category B applies to pressure-retaining systems; category A to critical media. The problem with sealing connections often results from gaskets with flowing or setting potential that are tensioned force-fitted thus causing a release of the connection (Fig.1). Montagevorspannung, z. B. 70% Rp0,2 - Mounting pre-stressing, e.g. 70% Rp0.2 Setzung durch Fließen in der Dichtung Setting through flowing in the gasket Drohende Leckage Imminent leaking Betriebsspannungen Operating voltages Fig.1: Illustration of the consequences of setting processes DIN EN was the first standard to cover relaxation and introduced the value P QR. The testing time is four hours. The left diagram illustrates the detrimental effect of gaskets seals with a strong setting potential (low P QR value) on the long-term stability of a flange system. There is a risk of leakage if the operating power is higher than the screw tension. If the screws are and VAT ID no. DE Page 1 of 6
2 remain highly tensioned, then the flange system can compensate for changing operating power without leaks, see the Figure on the right. Torsion introduced through torques during assembly also leads to a release and thus a loss of pre-stressing force in the screw connection. This must be observed especially for screw connections with a short clamping length. The problem can be prevented with torsion-free tightening processes, such as e.g. tightening through elongation with the help of clamping cylinders (bolt tensioning). With rotary procedures, it is especially important to secure the assembly result because of the uncertainty caused by hard to assess friction. This requires the application of an independent control variable (e.g. angle of rotation), in addition to the control variable (here torque), for testing. The approach with simultaneous measurement of torque and angle of rotation is not feasible for regular flange connections (Fig.2) because of the softness of the flange blades. Fig.2: Customary sealing connection with flat gasket (soft material or metal / soft material gasket) Sealing connections are increasingly tightened with torque wrenches. Unfortunately, the required torques are very frequently determined based on the requirements for the gasket instead of loading the screws highly with approx. 70%. It is not unusual to have tables specifying assembly torques that would utilize the same screws with soft gaskets (rubber) at only between 7 and 15% and hard gaskets (elastomer bound fibers / FA material) at up to 90% of their yield strength. Lightly pre-stressed screws are always subject to the danger of automatic loosening. A check of the assembly result is frequently provided for in the form of a prevail torque. For this, it must be noted that a validatable result cannot be generated because of the required overcoming of the breakaway torque from the static friction and the fact that control quantity and control variable are identical. Therefore: Checking the torque with prevail torque is not permissible! If torque is used for tightening, a check can be performed only by measuring length changes or the force. The possible testing methods are to be discussed in the following: Visual inspection and prevail torque Screw connections are usually subjected to regular visual inspections and in part tested with a prevail torque, which often complies with the nominal torque x 1.1. This approach does not produce verified reports on the current quality of the connection. It is doubtful that the static friction can be safely overcome with this procedure. It is therefore technically not meaningful. VAT ID no. DE Page 2 of 6
3 Test hammer A hammer is used to hit the bolt. The sound allows you to determine whether the screw is loose (dull sound) or tensioned (lighter, bell-like sound). This procedure allows you to detect screws that were forgotten during assembly. A validatable specification is not possible. Ultrasound measurements They are used with increasing frequency but their results are relatively doubtful because of coupling errors and disruptive influences (e.g. from mechanical vibration) and structural changes during the expansion of the screw material. Optimized procedures are offered successfully e.g. by Intellifast ( Strain gauges Measurements with strain gauges are too costly and therefore hardly practicable. Screws with integrated measuring pins The screws are provided with an axial bore for test benches. A measuring pin is inserted into these bores. During the tensioning process, the screw is expanded and the difference in length between screw and measuring pin is used to determine the tensioning status. For practical application, the Rotabolt-type micrometers from James Walker ( have also gained acceptance, for example. Mechanical measurements with micrometers These measurements with the very precise micrometers require screws that are manufactured to have exactly the same baseline measurement or labeling with exact manufactured length. As a system, the appropriate calibrated screws of the type CONBOLT are available from Heinr. Jungeblodt GmbH & Co. KG, Warstein ( (Fig.3). CONBOLT with short measuring pins CONBOLT with long measuring pins Fig.3: Measurable screws of the type CONBOLT The disadvantage is that only screws with both thread ends accessible can be measured. However, this is the case with most sealing connections on pipes and instruments. These screws allow measurable assessment of their status and thus an affirmation of their reusability only after dismantling. VAT ID no. DE Page 3 of 6
4 Load cells Generally, this measuring procedure is probably only rarely used because of the high costs. The cells are temperature-sensitive and can be used only on plane parallel surfaces. Force-measuring washers Procedures like the boltvalid measuring washers (Fig.4) seem to be more promising. Fig.4: boltvalid measuring washer The boltvalid measuring washers take measurements without being influenced by friction and torsion. The special measuring method also makes them capable of handling slanted surfaces. They take stable measurements in the temperature range from -20 to 80 C and can be used for through bolts as well as screws in blind hole connections. The boltvalid measuring washers also enable controlled retightening. They can be used in the ranges of low pre-stressing forces (starting at M6) and without limitation for very high pre-stressing forces. Fig.5: Illustration of the signal functions Relaxed, Check of the joint, Tensioning, Fully assembled, Pre-stressing force loss The change in the pre-stressing force of the screw connection (Fig.5) is measured. In the simple version, LEDs show, similar to a traffic light, the condition from red light for not tensioned, to yellow light all the way to green light for tensioned. In addition, a once again illuminated yellow light indicates a loss in pre-stressing force. Other colors, for instance a blue light, can VAT ID no. DE Page 4 of 6
5 be added in order to e.g. signal the pre-stressing to check the joint. This procedure allows permanent or time-controlled readout. It is resilient, provides high reliability and is integrated in a washer for measuring. The system can transmit measured values to a computer via radio or direct cabling and thus allows permanent monitoring. It is also possible to furnish the screw connection with an alarm that is triggered if the tension is fallen short of or exceeded and thus avoid the scheduled maintenance intervals. The signal values can be set individually. The manufacturer is Möller Metalldichtungen GmbH, Hecklingen ( Comparison of the procedures for screw monitoring The possible control methods differ very highly in suitability, price/performance ratio, ruggedness and the checking period. The following table (Tab.2) provides an overview for this. The established regulations stipulate application of the state of the art for the use of duct, tank and pressure devices. Technical information on this subject, the Technical legal terms, are provided on our website. Procedure Tab.2: Comparison of the procedures for screw monitoring Suitability Price/performance * Ruggedness Measuring period Visual inspection none high/none ½ to 1 year Prevail torque none high/none ½ to 1 year Strain gauges yes high/high low as needed Ultrasound yes high/high medium regularly Intellifast yes high/high high regularly Conventional load cell yes high/high high permanent ** boltvalid measuring washer yes low / very high very high as needed permanent ** Rotabolt *** yes high/high very high as needed CONBOLT *** yes very low / high very high as needed * No consideration of costs but of the cost-benefit ratio ** Procedure can constantly deliver measurement, at any required time and can trigger a safety alarm *** Direct recognition of hyperextension The correct assembly of screws has, in our experience, always lead to consideration cost reduction through the prevision of subsequent repairs, production loss and a lowering of environmental damage. Dangerous processes, like the retightening of screws or the coffering of leaking sealing connections during operation could always be prevented. Comment: The selection of applicable procedures depends on the risk analysis. Everybody acts on one s own authority. At least the recognized rules of engineering must be observed. Non-observance can result in legal consequences; with a threat to life and limb even to fines or prison terms of up to five years. Deliberate non-compliance in the event of a hazard or dame to persons or the environment constitutes malice or condoning acceptance. You can find more information on screws, flanges, gaskets, and sealing systems and their assembly in our sealing vade mecum (ISBN-13: , PP Publico Publications, in the licensed translation of the ASME PCC on the assembly of standardized steel flange connections (ISBN-13: , PP Publico Publications, VAT ID no. DE Page 5 of 6
6 and in our manual Technical information on sealing connections ( Our latest book Ten steps toward an optimal, permanently technically tight sealing connection (ISBN-13: ) was published by PP Publico Publications. Please visit our website for more interesting information on different subjects. I will be happy to provide personal technical consulting, even on short notice. Best regards from Bremen Peter Thomsen Legal disclaimer: The contents of the technical standards are in part quoted, in part reproduced in the words used in the standards; the comments and interpretations are based on longstanding experience, serve as a decision aid and do not substantiate any claim for warranty. Peter Thomsen / flangevalid Version: VAT ID no. DE Page 6 of 6
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