ASME PCC-1 Level 3 Bolting Assembler Fundamentals (Self Study)
Course Type:
Self Study
Course Number:
EL580Language:
Learn concepts related to manual tightening for bolted flange joints and pre, in-process, and post assembly quality assurance per ASME PCC-1 Appendix A.
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Course Access
This Self Study course is designed to be taken at your convenience and on your own schedule. You have 365 days from the time of purchase to finish the course.
Learn more about earning a microcredential through ASME's Bolted Flange Joint Assembly Program!
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This course is designed to train and evaluate a bolter's ability to apply in-depth concepts related to manual tightening equipment methods, pre, in-process, post assembly inspection/quality assurance, and troubleshooting bolted flange joints. Participants will also learn the reasons why requirements for bolted flange joints exist. This course covers training concepts identified for Level 3 Bolting Assembler Fundamentals.
This course is part of ASME’s Bolted Flange Joint Assembly Program, which provides formal on demand training, by fostering a deeper understanding of topics and concepts defined in ASME PCC-1 Appendix A.
This course is a prerequisite for the Level 4 Bolting Assembler Qualification Program.
Student will earn a microcredential for each level by completing courses covering the 4 skills levels:
- Level 1: Individual should be able to identify the main components of a bolted flange joint including the bolts, nuts, flanges, gaskets, and lubrication. This individual should also have a basic awareness of bolted flange joints and general terminology of bolting tools and equipment.
- Level 2: Individual should be able to perform general pre-assembly activities of bolted flange joints such as cleaning, inspection, assembly activities such as gasket and bolt installation, alignment, and manual torque tightening.
- Level 3: Individual should be knowledgeable with in-depth concepts of assembly requirements such as proper use of manual tightening equipment methods and pre, in-process, and post assembly quality assurance. This individual should also be familiar with the reasons why the majority of requirements for bolted flange joint assembly exist.
- Level 4: Individual should have advanced knowledge of all aspects of bolted flange joint assembly and should be able to develop and maintain bolted flange joint assembly procedures, training processes, and provide detailed oversight and guidance to bolted flange joint program.
By participating in this course, you will learn how to successfully:
- Apply in-depth concepts of assembly requirements such as proper use of manual tightening equipment methods and pre, in-process, and post assembly quality assurance.
- Perform inspection and assembly activities such as those outlines in Appendix A of ASME PCC-1: Pressure Boundary Bolted Flange Joint Assembly.
- Articulate the reasons why the majority of requirements for bolted flange joint assembly exist.
- Perform inspection, assembly, and troubleshooting activities such as those outlined in Appendix A of ASME PCC-1: Pressure Boundary Bolted Flange Joint Assembly.
Who should attend?
Anyone involved in the assembly, disassembly or quality assurance of bolted joints; Major operators and contractors involved in oil and gas, petrochemical and power generation, or any industry that uses bolted flange joint assemblies.
Course participants are expected to have:
- Access to a computer and reliable internet connection
- A calculator
- Software to display PDF files (such as Adobe Reader)
A Digital Badge will be issued to registrants who successfully complete the course and achieve a passing score of 75% or higher on the final exam.
Module 1: Overview of ASME PCC-1
Module 2: Level 3 Bolting Assembler Roles and Responsibilities
Module 3: Flanged Joints
- Failure of potential of brittle cast flanges on vales, pumps, and similar equipment
- Relationship between bolt stress and bolt elongation
- Relationship between bolt stress and gasket stress during assembly and operation (pressure and temperature effects)
- Sources of information on ASME PCC-1
Module 4: Bolts
- Relationship between applied torque and achieved bolt stress/load
- Brief detail of common bolting specifications including yield strength
- Nut strength versus bolt strength
- Generic bolt and nut material temperature limits
- Bolt and nut materials for stress-corrosion-cracking environments
- The need for bolt and nut corrosion resistance
- Influence of bolt length on bolt-load loss due to gasket creep relaxation and surface embedment loss
Module 5: Gaskets
- Gasket types and manufacturing methods
- Reasons why used or damaged gasket should not be used
- The need for gasket chemical compatibility
- Gasket temperature limits
- The effect of gasket stress on leak rate
- The effect of bolt-load loss (creep/relaxation and operating conditions) on joint leakage and overall joint reliability
- Gasket parameters, target gasket assembly stress, maximum permissible gasket stress, minimum gasket seating stress, minimum gasket operating stress
Module 6: Lubrication
- Limitations of lubricants, including oxygen ignition, oxidation, temperature, shelf life, catalyst poisoning, stress corrosion cracking, etc. (compatibility with process fluid and materials of construction)
Module 7: Bolting Tools and Equipment
- Importance of calibration and verification
- Acceptable tightening methods in relation to bolt size or bolt load
- Naturally occurring clearance problems related to general styles of tooling such as hand torque wrenches, torque multipliers, and impact wrenches
- Techniques used for load control by hydraulic tension
- Accuracy of each method and relationship to service or joint criticality
- Familiarization with methods for calibrating and verification of common field equipment
- Where to find guidance (user specifications, company guidelines, tool manufacturer web sites)
Module 8: Assembly of Flanges
- Identification of correct assembly target bolt load
- Reasons for requiring a disassembly procedure
- Acceptable levels of flatness corresponding to different gasket types
- Measurement of joint gaps during assembly
- Use of turn-of-nut method of tightening
- Use of startup re-torque and limitations
- Usage of F-6 tightening patterns with limitations based on bolt quantity and gasket types
- Disassembly procedures and critical issues
- Reason for needing pattern passes and chase passes in procedure
- Equipment-allowable nozzle loads and moments
- Parameters that determine appropriate bolt load (flange size, gasket type, flange class, flange type, flange material, bolt material, piping service)
- Troubleshooting flange joint leakage
Brett Thibodeaux
Fixed Equipment Reliability Area Group Leader, CITGO Petroleum Corporation
Brett Thibodeaux Has nearly 20 years of experience in the design, specification, maintenance, and troubleshooting of process equipment in both the refining and petrochemical industries.
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Self Study
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