Torque Tool with Integrated Sensors for Riser Bolt Pre-Tension Control
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Solution Overview
Problem
Bolted connections in riser systems face challenges with unpredictable friction coefficients and pre-tension loss due to vibrations and dynamic loads, leading to safety and operational issues.
Innovation Solution
A torque tool with integrated sensors to measure and control torque and pre-tension during bolt tightening and loosening, along with a method to calculate a performance indicator parameter for friction coefficient analysis and bolt management, ensuring bolts are within predetermined ranges to prevent failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional torque tools are used for bolt tightening, then the operation is simple, but the pre-tension measurement accuracy is insufficient
Solution Approach 1:
The patent combines a torque tool with integrated sensors (torque sensor and pre-tension sensor) into a single unified device. The torque sensor measures applied torque while the pre-tension sensor measures the resulting pre-tension in the bolt, allowing both measurements to be obtained simultaneously during the tightening operation without requiring separate measurement devices.
Solution Approach 2:
The patent introduces sensors as intermediary measurement devices that detect physical quantities (torque and pre-tension) during the bolt tightening process. These sensors act as mediators between the mechanical action of tightening and the measurement system, enabling accurate real-time measurement of both torque applied and pre-tension resulting from the tightening operation.
2Reliability
If bolts are tightened to ensure connection safety, then the connection reliability improves, but the risk of bolt failure due to vibrations and dynamic loads increases
Solution Approach 1:
The patent implements a feedback mechanism where the measured pre-tension values are compared against predetermined acceptable ranges. If the pre-tension falls outside the acceptable range, the system provides feedback to identify and replace the bolt. This closed-loop control ensures that only bolts meeting the safety criteria are used in the connection, maintaining reliability while accounting for vibration and dynamic load effects.
Solution Approach 2:
The patent applies preliminary action by measuring and verifying pre-tension values during the initial tightening process before the bolt is put into service. By ensuring the bolt achieves the correct pre-tension within acceptable ranges during installation, the system proactively prevents potential failure modes related to vibrations and dynamic loads that would occur during operation.
3Strength
If multiple bolts are used to ensure connection integrity, then the structural strength improves, but the time for inspection and replacement increases
Solution Approach 1:
The patent implements self-service by enabling the torque tool to automatically measure and evaluate the pre-tension of each bolt during the tightening operation. The system automatically compares measured values against acceptable ranges and identifies bolts that require replacement, eliminating the need for manual inspection and reducing the time required to ensure connection integrity across multiple bolts.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides accurate pre-tensioning, reduces material usage, and extends bolt service life by identifying and replacing bolts outside acceptable ranges, enhancing safety and operational efficiency.
Implementation Method 1
a torque sensor operable to measure the torque applied on the bolt
Implementation Method 2
a pre-tension sensor operable to measure a pre-tension in the longitudinal extension of the bolt
Data Source
AI summary
Torque tool (200) configured for making up and breaking out joints (1a, 1b) in a riser (100), the tool (200) comprising: a tool body (3) and a tool head (4), the tool head (4) having a socket (4′) configured to receive a head (14) of a bolt (2) and apply a torque on the bolt (2), a torque sensor (20) operable to measure the torque applied on the bolt (2), and a pre-tension sensor (21) operable to measure a pre-tension in the longitudinal extension of the bolt (2) when the bolt (2) is received in the tool head (4). There is also provided a method for pre-tensioning bolted riser joints (1a, 1b) comprising a plurality of bolts (2), a method of managing a plurality of bolts (2) for riser joints (1a, 1b), a method of managing a plurality of bolts (2) for riser joints (1a, 1b), and a riser connector (101).