During plant turnarounds, every flange is inspected—and many stud bolts end up replaced. But doing this wrong—such as mixing old and new stud bolts—can create uneven preload and compromise seal integrity. I always recommend replacing the entire flange set at once and verifying torque values afterward. Consistency is key.
In a recent hydrocracker revamp, we replaced 200+ stud bolts and installed torque-bolted washers for even preload retention. The result? Flanges held tight for the next 18 months with zero leaks and no retorquing required. Replacing stud bolts properly is an investment that pays off well before the next turnaround.
