DuraSquirt® DTI

Flange Bolting System May 2020

Proudly Designed, Engineered & Made in America Since 1994

Torque a flange in 15 minutes or less!

The DuraSquirt® Flange System allows a flange to be torqued in a single pass, utilizing all of
the benefits Direct Tension Indicators (DTIs). This is based on an improved Flange Bolt-Up
study, sponcered by BP America and the Pressure Vessel Research Council (PVRC)

This is a DTI DTI on a stud (L) and a fully torqued DTI (R)

In the early 1990s, BP America and The Pressure Vessel Research Council (PVRC) sponsored
the University of Akron Ohio, to develop a way to improve flange bolt-up procedures, using
experimentally determined elastic interaction coefficients.¹ The study resulted in a way to fully
torque a flange, in a single tightening pass, while achieving uniform bolt stresses around the
flange. The groundbreaking procedure was made possible, by determining and compensating
for elastic interaction between all bolts, within a flange.

Elastic interaction is the phenomenon that occurs between a group of bolts as tightening
initializes and progresses throughout the group. As each bolt is tightened, other bolts in the
group may tighten or loosen, due to dynamically changing forces within the flange assembly.

¹ Bibel, G. D. and Ezell, R.M. “An Improved Flange Bolt-Up Procedure

Using Experimentally Determined Elastic Interaction Coefficients,”
 Independently Verified
In 2017, the University of Houston, in cooperation with Bechtel and Carber, spent a year
assessing the system. The study’s verbatim conclusions appear below.²

A study on ABT-DTI bolting technique was conducted to determine whether it represents a

cost-effective improvement to bolted flange connections using the traditional bolting method.
The ABT-DTI bolting system was tested and compared to ASME PCC-1 bolting method. The
experimental work consisted of bolting and hydro-testing two 12-inch 600 class flanges with
raised face sealing surfaces on a small tabletop. A total of 13 bolting tests (9 DTI and 4 ASME
legacy) were conducted. For verification purpose, a finite element model was developed and
analyzed using ANSYS software to compare between the experimental and computational
results.

The following conclusions can be drawn based on the computational and experimental
results obtained:

1. ABT-DTI system is significantly faster than the ASME PCC-1 Legacy method by 60 to
44170 percent.
2. ABT-DTI system reliably produces a leak free connection upon startup.
3. ABT-DTI system requires 75% fewer movements by the bolting operators.
4. ABT-DTI system does not require the use of precision torques as compared to ASME
111PCC-1 Legacy technique.
5. ABT-DTI system reliably yield these results with operators who have received minimal
111training and have limited experience with BFJA’s³.

² Braun, Moreno, Pascali, 2018,”Assessment Studty of Applied Bolting Technology’s Durasquirt® DTIs”, University of Houston
³ Using Experimentally Determined Elastic Interaction Coefficients,” Journal of Pressure Vessel Technology 114 (Nov. 1992):
439-443. Bolted Flange Joint Assembly
 Elastic Interactions Explained
Elastic interactions are determined by monitoring bolt stress continuously throughout the
tightening procedure. After several iterations of assembly, disassembly and reassembly,
updating elastic iteration data during each attempt, compensated individual bolt loads can be
applied to a final tightening effort.

For example, imagine there is a two-bolt flange Bolt 1 Bolt 2

and the target bolt stress for all bolts is 40ksi TARGET KSI
(see figure 1) 40 KSI 40 KSI

1. Tighten bolt #1 to 40ksi 30 KSI

2. Tighten bolt #2 to 40ksi.
3. Bolt #1 drops to 30ksi final due to
elastic interaction.

In equation form, bolt #2’s interaction is expressed 0 KSI 0 KSI

as:
Figure 1
40 = N -25% of N or 40 = N - .25xN

Where N represents how tight we need bolt #1, so Bolt 1 Bolt 2

53 KSI
when bolt #2’s interaction decreases it by
25%, bolt #1 will be at the desired target stress. TARGET KSI
40 KSI 40 KSI
Solving for N:

N = 53ksi

Repeat tightening, compensating for elastic

interaction between 1 & 2 (figure 2).
0 KSI 0 KSI
1. Tighten bolt #1 to 53ksi
2. Tighten bolt #2 to 40ksi. Figure 2
3. Bolt #1 drops 25% to 40ksi leaving both
bolts at 40ksi.

This concept can be extended to all flange sizes and bolt counts. So long as compensated
elastic interaction information is applied to subsequent torqueing iterations, eventually, a single
tightening pass is possible.

The procedure is remarkably accurate, but repetitive flange monitoring, disassembly and
reassembly is not practical for real world implementation. What is needed is a reasonably
priced, simple solution. Something that indicates compensated bolt stresses during a single
tightening pass, i.e. small, calibrated bolt load cells, established by repetitious testing.
Applied Bolting has been making Direct Tension Indicators, or DTIs, that visually illustrate
induced bolt stress for structural applications, since 1994. Since 2016, we have applied this
experience to the elastic interaction issue, to enable easy pipe flange bolting. DTIs have been
described by ASME’s Guidelines for Pressure Boundary Bolted Flange Joint Assembly, PCC-1,
as a core fundamental for bolted joint assembly personnel, since 2013.⁴

Flange Kits and DTIs

The DuraSquirt® Flange System consists of a kit of DTIs, individually calibrated to account for
elastic interactions between each bolt. Like our structural DTIs, each bolt is tightened until
DuraSquirt indication media appears. The DTIs are numbered and placed in consecutive order
around the flange, and then tightened in numerical order, after an effective snugging operation.⁵

Each DTI is laser marked, detailing the flange diameter, class, and its position number, within
the ring. There is a large number for installation crews to position all DTIs around the flange in
numerical order, and smaller text along the OD for inspectors, to confirm proper placement.

ABT 12-300 shown

Applied Bolting Logo

Circumferential info for

inspection:
bolt position

Diameter and class

Large text for installers

⁴ ASME PCC-1 Appendix A, sec A-2.3 subsection r: Ensuring Correct Use of Additional Joint Components
⁵ An effective snugging operation being defined as applying an accurate torque value determined by an accurate K value, or nut
factor, or by utilizing Applied Bolting’s Target Stress DTIs (TS).
 The text along the OD is visible even if a nut
is threaded on and lists flange diameter and
class, as well as the total number of DTIs
within the specific flange kit. This prevents
DTI kits of the same bolt diameter, and
designed for a specific flange, from being
used with a flange with a different stud
count.

Also, the flange diameter and class label

allows inspectors to confirm the proper kit
has been deployed in cases where the bolt
diameter and count is common across
flanges.

Instructions
Each DTI kit includes well-illustrated, easy to read instructions.
 DuraSquirt® Flange System Line Card
Part # 3-300PL = 3” Class 300 Plain DuraSquirt® DTI Flange Kit

ABT Kit # Wt/Kit Bolt # DTIs

NPS⁶
(lbs.) Diameter /Kit
(in)
(in)

3 3 - 300 .86 3/4 8

4 4 - 300 .86 3/4 8

6 6 - 300 1.30 3/4 12

Class 300

8 8 - 300 1.89 7/8 12

10 10 - 300 3.38 1 16

12 12 - 300 4.07 1-1/8 16

14 14 - 300 5.09 1-1/8 20

16 16 - 300 6.21 1-1/4 20

18 18 - 300 7.45 1-1/4 24

20 20 - 300 7.45 1-1/4 24

ABT Kit # Wt/Kit Bolt # DTIs

NPS⁶
(lbs.) Diameter /Kit
(in)
(in)

3 3 - 600 .86 3/4 8

4 4 - 600 1.26 7/8 8

Class 600

6 6 - 600 2.54 1 12

8 8 - 600 3.05 1-1/8 12

10 10 - 600 4.97 1-1/4 16

12 12 - 600 6.21 1-1/4 20

16 14 - 600 9.00 1-1/4 20

DuraSquirt® Flange Systems are only designed to be used with:

1. ASME B16.20 Dual ring spiral wound gaskets, Camprofile Gaskets with Outer Rings, or
00000Camprofile Gaskets with Inner and Outer Rings.
2. ASME B16.5 & ASTM A105 weld neck, raised faced flanges: WeldNeck, Socket Weld,
00000Threaded, and Blind
3. ASTM A193 B7, A320 L7 and B7M studs.

Each DTI kit is composed of the same number of DTIs as there are bolts in the flange. Kits
should be ordered in the same quantity and at the same time as gaskets.

⁶ Nominal Pipe Size

 DTI Testing and Compliance
Testing is performed at/in Applied Bolting Technology Products’ ISO 9001 accredited laboratory
complying with BS EN 10204 Metallic products - Types of inspection documents, Type 3.1.

Testing verified per ASTM E1685, Standard Practice for Measuring the Change in Length of
Fasteners Using the Ultrasonic Pulse-Echo Technique.

DTIs sampled per ASTM F1470, Standard Practice for Fastener Sampling for Specified
Mechanical Properties and Performance Inspection.

Tested in accordance with ASTM F606, Standard Test Methods for determining the Mechanical
Properties of Externally and Internally Threaded Fasteners, Washers, Direct Tension Indicators,
and Rivets.

Manufactured in the USA with American made Steel in mercury free environments. Products
comply with the requirements of, "Buy America" 49 U.S.C. 5323(j)(1), and the applicable
regulations in 49 CFR part 661. DTIs are coated with dry black phosphorous, dry to the touch

⁷ ASME PCC-2, Article 3.11 pg. 126, Hot and Half Bolting Removal Procedures
 ASME PCC-1 2019

10.1 Tightening Method/Load-Control Technique

(e) Proprietary force-sensing devices that can provide accurate and reliable real-time (increasing
and decreasing) bolt tension readings/printouts are available from several manufacturers.

APPENDIX A

TRAINING AND QUALIFICATION OF BOLTED JOINT ASSEMBLY PERSONNEL

A-2.3 Training of Fundamentals

(r) ensuring correct use of additional joint components

(4) use of prevailing torque nuts, instrumented studs, reaction washers, tensioning nuts,
1111111direct-tension-indicating washers, and other special-purpose accessories.

(5) use of proprietary nuts, washers, etc. There are innovative proprietary nuts, washers,
1111111and other mechanical and hydraulic devices that assist the assembly process and may
1111111have the capability to improve bolt-load accuracy and reduce scatter. Awareness of
1111111those devices should be included. Detailed training on the application of these devices is
1111111available from the supplier and/or manufacturer.
.