Flange Integrity Program
Maxpro provides controlled torquing, tensioning and dis-assembly services for day to day maintenance, major turnarounds and capital projects. Our trained technicians understand the importance of flange joint integrity and plant reliability so we ensure all flanges have the correct hardware, proper lubrication & surface finish and the desired bolt load calculations to minimize the chance for leaks during the critical start-up phase.
BOLTRIGHT PRO is a joint integrity software, designed to assist users across a wide variety of industries, where accurate bolt load calculations are a minimum requirement to maintaining leak free environments.
In simple terms, flanges and joints are simple methods of joining pieces of pipework together using gaskets, nuts and bolts.
However, a leaking joint or loss of joint integrity can lead to catastrophic consequences such as loss of asset due to fire, contamination of the environment and even loss of life.
BOLTRIGHT PRO considers the latest industry standards, ensuring that our SME and the customer has access to accurate calculations in accordance with PCC1, to use in conjunction with the quality of Maxpro’s bolting products.
BOLTRIGHT PRO is an innovative, bolted joint integrity software program utilized by our customers with the provision of accurate bolt load calculations, based on key input data, related to each specific bolted joint. BOLTRIGHT PRO has been primarily designed for use in the Oil & Gas industry, where the safe movement of hydrocarbons in a leak free environment is absolutely critical, however it can also assist in many other industries, where bolted joints are present.
All available data about the joint including flange size, material and rating, gasket type, bolt size and material grade, lubricant type and operating temperature. BOLTRIGHT PRO analyzes this data and produces a comprehensive calculation, of the required torque or tension to be applied to all of the flange joint bolts to achieve a leak free joint, first time every time! Additionally, BOLTRIGHT PRO will produce a clear and easy to follow bolt tightening procedure, which will include the correct tool selection, from within MAXPRO’S extensive range of bolting tools, along with the correct sequence of applying the loads, onto the respective flange joint bolts, including the applicable pump hydraulic pressure settings, for each stage of the bolt tightening process.
The methodology of the BOLTRIGHT PRO software calculations is fully traceable to PCC1 standards, ensuring that the latest best practice procedures are followed at all times. As part of the software joint integrity review process, BOLTRIGHT PRO will also display all of the relevant combined stresses within the joint, once the bolt tightening is completed. This includes not only bolt stress but also gasket and flange stress, to ensure all of the stresses within the joint are within acceptable levels. The flexibility of the BOLTRIGHT PRO software enables the user to change any of the input data in order that optimum integrity can be achieved within each and every joint. As an example a change of bolt material and lubricant type can and will affect the BOLTRIGHT PRO software calculations and bolt tightening procedures.
Each completed flange will come with a Joint Tightening Report (JTR) detailing all the information from flange size and rating, gasket type, bolt and nut material, lubrication used and target bolt stress etc.