In the realm of equipment maintenance, the significance of proper bolt fastening cannot be overstated. Neglecting this crucial aspect often leads to equipment failures, such as broken flange bolts in wind power towers or leaks in petrochemical equipment. This article aims to shed light on the paramount importance of bolt tightening in equipment maintenance, exploring accidents resulting from bolt-fastening issues and offering practical solutions.
Critical importance of bolt tightening in equipment maintenance
Examining two notable cases reveals the severe consequences of overlooking bolt-fastening procedures. In a startling statistic, the UKOOA found that 81% of 100 flange leakage accidents were attributed to incorrect bolt load or pre-tightening force.
Wind turbine collapse due to broken bolts
Case overview: A wind turbine experienced multiple alarms and a sudden shutdown due to high vibration values. Post-maintenance, the turbine collapsed within 24 hours, leading to extensive damage.
Lesson learned: Frequent inspection and maintenance of fans during operation are imperative to prevent catastrophic failures.
CNC Machine breakdown due to bolt fastening problems
Case overview: A CNC high-speed end-face cylindrical grinder malfunctioned, resulting in processing errors. Disassembly revealed damaged fixing devices and guide rail balls, causing scratches and pits on the guide rails.
Lesson learned: Proper bolt fastening during the manufacturing process is critical to ensure precision and prevent unforeseen breakdowns.
Factory leakage and environmental consequences
Petrochemical plants and factories face environmental and safety risks when bolt fastening is not meticulously executed. Leaks not only cause material loss and environmental pollution but also pose a significant threat to human safety. As factories increasingly grapple with difficult-to-detect leaks, the probability of accidents rises, impacting industrial production, economic development, and personal safety.
Optimizing bolt fastening
Several success stories demonstrate the positive outcomes of optimized bolt-tightening practices:
Improved sealing in diesel hydrotreating unit:
Optimization: Petrochemical company optimized bolt tightening for feed and reaction product heat exchangers, achieving a “zero leakage” goal during operation.
Preventing coking tower flange leaks:
Optimization: Utilizing pre-tightening force control technology for flanges in a coking workshop prevented leaks despite significant daily temperature changes.
Addressing oil slurry steam generator issues:
Optimization: Transforming bolt fastening technology resolved leakage problems in the oil slurry steam generator, preventing accidents in the biennial operation cycle.
Essentials of bolt fastening: tensile yield and preload calculations
Understanding the bolt-tightening process is essential. The process involves determining the bolt tensile yield, calculating axial preload, and executing the tightening process. Modern tools such as pneumatic/electric torque wrenches, hydraulic wrenches, and bolt tensioners play a crucial role in achieving accurate values.
Challenges and continuous improvement in bolt fastening technology
Despite advancements, challenges persist in achieving uniform pre-tightening force across bolts. The article highlights the historical shift from manual fastening to pneumatic, electric, and hydraulic methods, emphasizing the need for precision and accuracy in bolt-tightening processes.
Navigating the road of bolt fastening
Bolt fastening remains a critical aspect of equipment maintenance, with ongoing efforts to improve accuracy, lifespan, and ease of use in fastening technologies. TRAXX actively contributes to the development of new products and technologies, fostering collaboration, and driving advancements that protect the environment and reduce factory losses.