Armed and Ready to Blow!

Ian MacMoy

February 6, 2015

The Tensile time bomb!

Tensile vs. Shear

Pressure loss has been

the detonator of recent
catastrophes all over the
world.

Page 3

Page 7

Two wrongs dont make

it right
It just make it normal
practice
Page 9

In the race to bring equity out of a commodity we have

over looked a few rules.
Is it by mistake, or is it by design?
For the past ten years I have been applying the coatings that have been used on
topsides, coastal regions and pipelines. For the past three years I have been a
Technical Speaker, Expert Witness, and Writer for NACE, ASTM and more
recently API.
Currently, I am working on the science behind ASTM, NACE and API in subcommittees and how they affect our industry when referred to as normal
practice and normative reference.
This is important, because normative references and Standards are by which Oil
Companies, OEM, and Engineering Firms use to
justify their Coating Specifications.
Getting back to the importance of fastener coatings.
We have been in a RACE with corrosion, ever since
we learned how to stave it off with cathodic
prevention and oxygen depletion.
A couple of decades ago, cadmium was king, but received very unpopular
publicity, due to it being toxic in nature. So we started looking for other
solutions to extend the life of our fasteners. Our first choice was Hot Dip
Galvanizing (ASTM A 325 & ASTM A 563) as it was already being used in the
utilities and was easily accessible.
This was when we realized one important issue in pressure bolting. The
application of the LOAD applied in the form of torque made Hot Dip Galvanized
fasteners a terrible application. We tried lubricants, but none worked. PTFE
was looking for new applications other than frying pans at the time, so we used
it as a dry lubricant and it worked. We also noticed that the combination of
systems gave a higher resistance to corrosion, which meant we could extend the
lifecycle and recoup a better return on investment to projects.

Author:
Ian MacMoy
Product Design
Specialist/ NACE
ASTM
API

Ian@doxsteel.com

1
2

4.3 Materials and Dimensions 4.3.1 The following bolting material grades
are covered by this standard: ASTM A193 Grades B7 and B7M; ASTM A194
Grades 2H, 4, 7, 2HM and 7M; ASTM A320 Grades L7, L7M, and L43; ASTM
A540 Grades B22 and B23.
4.3.2 All requirements of the referenced ASTM specifications shall be met except
as modified by this standard. In the case of conflict between the requirements of
referenced specifications and this standard, the requirements of this standard shall
apply.
4.3.3 Oversizing of nut threads or under sizing of bolt threads is not permissible.

API 20E Section 4.3.3 (Alloy and Carbon Steel Bolting for Use in the
Petroleum and Natural Gas Industries)
The Hot Dip process is difficult to control and
the thickness varied quite a bit. We began
using zinc plating and kept the PTFE topcoat.
This gave us a 2-year lifecycle we could work
with. The industry immediately saw the
benefits of extending the maintenance
intervals and eliminating the down time. But
could we go to five years? That way we could
combine maintenance checks on fasteners with
pumps and valves. A new player was in the
works from the automotive industry, and
aluminum-ceramics (ASTM F1428) could provide
the 5 years, as long as we kept the topcoat of
PTFE for lubricity to apply the needed torque
to achieve the load. So we kept oversizing the
nut threads to accommodate this new system.
Life was great!
I have been applying ceramics for the last 6
years and writing and co-writing coating
specifications for the past three years.
I always have had a license to apply PTFEs, and
aluminum ceramics and having that, made it
easy to be approved as a vendor.
It was not until API released 20E Alloy and
Carbon Steel Bolting for Use in the Petroleum
and Natural Gas Industries1 which
standardized bolt manufacturing that I realized
that there was something I missed.
It states in 4.3.3 and in section 5.10.1 that
over sized nuts would not be permitted, in
accordance with ANSI/ASME B1.1.

Now why is this a problem if NACE International

clearly states in TG 148 the following:

Over tapping of the nut threads is a viable

option to prevent make-up problems such as
galling, seizing, fretting, and other thread
damage. When the total dry film thickness
(DFT) of the coating system is >0.75 mils
(18 m), over tapping of the nuts is a normal
practice to prevent make-up problems.2 As
defined by TG 148/NACE.
If we go back to Hot Dipped Galvanizing on
bolting (ASTM A 325 & ASTM A 563) and look at
the scope, to understand its purpose: The
Bolts are intended for use in structural
connections 3 and nuts for general
structural4.
For pressure bolting, the industry also came up
with ASTM A193 and A194. The scope of the
standard helps us understand its purpose:
Steel bolting for pressure vessels, valves,
flanges, and fittings for high temperature and
high pressure service5, These nuts are
intended for high-pressure or high
temperature service, or both6. For this type
of service, platings (zinc and cadmium) where
considered designs in the tolerances of the
threads for corrosion protection. This is the
bolting the petrochemical industry refers to in
standards like API 6A7 and API 20E8 from the
American Petroleum Institute.

We need to understand there is a major difference between structural bolting that works with
the shearing of the shaft and pressure bolting that works with tension on the treads; I am
quoting a book to better illustrate the difference.
The distinction between tensile and shear joints is important, because the two types
differ in the way they respond to load, the ways in which they fail, the ways in which
they are assembled, etc. In general, the tensile joint is the more complex of the two. 9

Bolted joints are classified by the service loads placed on them. If those loads-forces-are
applied in a direction more or less parallel to the axis of the bolts, as in the upper sketch,
here, the joint is called a tensile or tension joint. If the line of action of the forces is
essentially perpendicular to the axes of the bolts, as in the lower sketch, the joint is
called a shear joint. 9

over sizing was never allowed,

ANSI/ASME B1.1 clearly states the
measurements of allowances
Tom Goin

After learning all this I went to see the sub-committee chair of API 20E, Mr. Tom Goin. My question
to him was, why are you not allowing oversizing any more? He stated, over sizing was never
allowed, ANSI/ASME B1.1 clearly states the measurements of allowances between the internal and
external thread pitch. By the way API 6A does not allow it either; it has to do with tensile strength
and equipment under pressure.10
My response was, ASTM A325 and ASTM A563 allow it!
ASTM A563 allows, Nuts shall be tapped oversize after coating, to the minimum and maximum
thread dimensions in table 5.
The fact is that these two standards are for structural bolting and do NOT apply to pressure bolting
ASTM A193 and A194, remember: The distinction between tensile and shear joints is important,
because the two types differ in the way they respond to load, and the ways in which they fail11

I have to tell you that this was something I did not want to hear. As much as I understood the
importance of actual science over normative reference, it was still something I had come to know
as a normal practice.

President Ronald Regan said, Trust but verify was something he learned from doing
business with the Russians. Now Tom Goin is not the Russians, but I did want to get
another opinion before everything I had once known was turned upside down.
So I went to see Jerry Longmire who is the Head Chair of API Supply Chain 20. He had
helped author the standard and he stated, Not only was oversizing never allowed, but
that oversizing nuts was the cause of 70% of the failures in ASTM A194 Proof Load Tests.
I also learned, that is when it has been carried out correctly, most if not all of the Proof
Load Tests are being done by the manufacturer, not the distributor, who oversized the
nut by 10 mils (250 microns) to accommodate the coating thickness.

I called 26 fastener distributors and this is what they told me;

that either they have never heard of this test, their POs do
not call for this test, or they have it done by the
manufacturer before the modifications are done. Meaning
the modified nuts which do not comply with ASTM A194 and
ASME B1.1 are being installed in the field without ever being
subjected to the pressure qualifying tests.

A series of newsworthy
events, many of them
tragic, have made us
realize that the
threaded fastener still
plays a major role in
our lives.
Oil drilling platforms
have tipped over,
airplane engines have
failed, roofs have
collapsed, and
astronauts have died
because of bolted joint
failures.
The Nuclear Regulatory
Commission has
declared bolting to
be unresolved generic
safety issue with
number one priority.

- John H. Brickford

I was scared to hear this as ASTM A194 clearly states, All

nuts shall be capable of withstanding the proof loads
specified12 it also states Modification of thread
dimensions may result in loss of load carrying ability13
Even ASTM A563 (HDG), clearly states that Nuts hot dip or
mechanically zinc coated in accordance to 4.7.2 or 4.7.3
shall be proof load tested after zinc coating and over
tapping.
So what happens if you have a non-standard fastener?
Here the path becomes a little murky, but I will still give
you a useful answer unless your need for accuracy and
safety is critical John H. Bickford 14
The nut depends on the first two threads of the engagement
to hold 57% of the load. If the first thread shears the rest
follow in a domino effect.
The stress picture is not an attractive one since most of the
load is on the first thread. If you look at the chart below the
fall of the stress is not linear, its curved.

When you oversize you lose thread

engagement.
Looking at the drawings below, the one on the left has full
engagement of the threads and the force is transmitted through the nut to the
bolt. The picture on the right shows an oversized nut, the force is concentrated on
the peaks of the threads. When the whole thread pitch is not used the force is
concentrated an plastic deformation occurs in the valley. This will start a chain
reaction of failures. The joint will lose load through relaxation of the threads and
begin to creep and therefore leak both pressure and containment.
One of the offsets that occurs in the field is creep, which is the outcome of tensile
strength loss from a consistent load, or multiple high low loads over time.
A broken bolt is easier to detect than a strip thread, so we never want the
threads to strip.17

My question remained: we have never seen a failure; bolts dont break from over
sizing of the nut!
So I did some research and found the amount of tension we can create in a bolt not only
depends on the strength of its body but on the shear strength of its threads. We will
want to be sure that the thread engagement is great enough to allow us to develop the
full ultimate strength of the bolt.
What we do see is Poor Thread Engagement. If the bolt is undersized, or the nut
oversized, thread contact areas will be less than those planned by the designer, and
substantial plastic deformation may occur. Especially in gasketed joints where relaxation
is substantial and can be as high as 80-100% lose of initial tension. 18
Fasteners that do not meet ANSI (ASME B1.1) specification are generally avoided.19

This figure is a simplified view of the stress in a loaded joint.

The Ticking Bomb:

Creep Relaxation

The gasket joint is sealed by

applying load to the
fasteners.
Not having a full thread
engagement is failure in the
making.
The threads have
concentrated stress and
plastic deformation will
occur. The resulting
deformation will release the
load needed to maintain the
seal of the joint.
This is common occurrence
in the field associated with
oversized nuts.
Pressure loss has been the
detonator of recent
catastrophes all over the
world.

There are two danger points where stress concentrates.

1. Where the head joins the body
2. The first thread to engage the nut
I have been doing this for years and we have never had a
failure.
My next question was, How much can oversizing of 10 mils
affect the strength of the nut?
I was impressed with what I found:
If the pitch diameter of that bolt is 10 mils less than
nominal, it will have less than half the rated strength; at
20 mils, it will have only a quarter of its rated strength15
In my experience it may be necessary to over-tap more
than 10 mils to allow for a ceramic coating thickness
-William Eccles CEng FIMechE BSc PhD
Bolt Science Limited
But we never undersize the bolt, we only oversize the nut;
this is what I found:
A similar loss of strength occurs if the pitch diameter of
the nut is greater than nominal, Anything that reduces
the amount of contact between male and female threads
will affect the strength.15
By the way ANSI B1.1 also states, Standard internal threads
provide no allowance for coating thickness. 16

It was Winston Churchill that said, It may not be the best system, but its the best one we
have so far.
That is how we see coatings and oversizing. We know there has to be something better, but this
is the best solution we have come up with and the aluminum ceramic coating gives us our 5,000
salt spray hours.
Any coating that requires over tapping in order to apply a coatings optimal thickness should
be avoided when tensile strength is accounted for as in ASTM A193 and A194 and ASME B1.1.
Removing the substrate of a thread in a nut is changing the thread engagement needed to
maintain the tension strength of the nut.
Having written and helped write four aluminum filled ceramic coating specifications for major
OEMs and in those specifications it states: oversizing as a viable means to accommodate coating
thickness, has made me very aware of the definition of normal practice, which I now know
is wrong.
I am not a mechanical engineer; it was wrong of me to state oversizing even when it was known
to be normal practice by the coating specifications and ASTM F1428 Section 5.4.1.-Sizing

5.4.1 Sizing--- The thickness of the coating is limited by the basic thread size. Where greater
thickness is necessary, threads may be produced undersize or oversize (before coating) to
accommodate the coating thickness, providing that the finished fastener (after coating) meets
all specified mechanical properties, as agreed upon by the supplier and the purchaser.

ASTM F1428 statement to oversize in its application should not be treated as a normative
reference and standardized. When working with pressure bolting ASTM A193 and A194, as
well as ASME B1.1 shall be followed.

We have been doing it this

way for years
dont rock the boat.
-(You dont want to know who said this)

Conclusion:

When one ignores the mechanical engineering and science, as over sizing does, one does not
comply with the standards; it puts the safety, health and environment around a system at risk.
Once one introduces uncalculated risk into the system, one becomes negligent for terms that
one defines as a normal practice.
In Conclusion, NACE TG 148 should redefine its terminology for normal practice and clearly
Specify oversizing as a de-rating of the fastener, and not to be used in pressure bolting.
Then, outline the pressure bolting to follow the ASTM A193, ASTM A194 and ASME B1.1 as well
as API 6A and 20E.
It should also outline the importance of the Proof Load Test and its correct application and
procedures.
NACE International is here to provide guidance to the industry with actual science and lab
testing, and provide technical task groups in order to further our knowledge and use of new
technologies. I hope we are doing so today.

Footnotes and Biography:

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20.

Alloy and Carbon Steel Bolting for Use in the Petroleum and Natural Gas Industries API
20E American Petroleum Institute
NACE International Task Group 148 on Coatings and Methods of Protection for Threaded
Fasteners Used with Structural Steel, Piping, and Equipment
ASTM A 325 Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi
Minimum Tensile Strength. Scope 1.2
ASTM A 563 Standard Specification for Carbon and Alloy Steel Nuts. Scope 1.1
ASTM A 193 Standard Specification for Alloy-Steel and Stainless Steel Bolting for High
Temperature or High Presssure Service and Other Special Purpose Applications. Scope 1.1
ASTM A 194 Standard Specification for Carbon and Alloy Nuts for Bolts for High Pressure
or High Temperature Service, or Both. Scope 1.1
Specification for Wellhead and Christmas Tree Equipment, American Petroleum Institute
6A
Alloy and Carbon Steel Bolting for Use in the Petroleum and Natural Gas Industries API
20E American Petroleum Institute
An introduction to the design and behavior of bolted joints, third edition, John H.
Bickford. Pg 4 Basic Concepts
Tom Goin, 20E Supply Chain Sub Committee Chairman at the American Petroleum
Institute.
An introduction to the design and behavior of bolted joints, third edition, John H.
Bickford. Pg 4 Basic Concepts
ASTM A 194-03b Standard Specification for Carbon and Alloy Nuts for Bolts for High
Pressure or High Temperature Service, or Both. Section 7.2.1
ASTM A 194-03b Standard Specification for Carbon and Alloy Nuts for Bolts for High
Pressure or High Temperature Service, or Both. Section S7.1
An introduction to the design and behavior of bolted joints, third edition, John H.
Bickford. Pg 28 Threads and Their Strength
An introduction to the design and behavior of bolted joints, third edition, John H.
Bickford. Pg 75 Threads and Their Strength
ASME B1.1 2003, Unified Screw Threads (UN and UNR Thread Forms) Sec. 7.6
An introduction to the design and behavior of bolted joints, third edition, John H.
Bickford. Pg 16 Stress and Strength Considerations
An introduction to the design and behavior of bolted joints, third edition, John H.
Bickford. Pg 197 Stress and Strength Considerations
NACE International Task Group 148 on Coatings and Methods of Protection for Threaded
Fasteners Used with Structural Steel, Piping, and Equipment pg 5
ASTM F 1428 Standard Specification for Aluminum Particle-Filled Basecoat/Organic or
Inorganic Topcoat, Corrosion Protective Coatings for Fasteners