HYDRAULIC NUT OPERATING MANUAL

Bolttech Inc. 200 Riverside Drive West Newton, PA 15089 USA Phone: 724-872-4873 Fax: 724-872-8827 www.bolttech.com

INDEX
Hydraulic Nut Operating Manual Safety Precautions Tensioning Procedure Detensioning Procedure Maintenance Hydraulic Seal Installation Drawing Load Calculations Figure B Figure C Tensioner Hose Parts Ordering Information Exploded View of Stud Tensioner

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HYDRAULIC NUT OPERATING MANUAL

Hydraulic nuts are a special tool which seats against a joint, grips the bolt end and through applied hydraulic uid pressure the bolt or stud is pulled in tension. When the pull force equals the desired bolt preload plus an additional amount to compensate for relaxation, the nut is run down against the joined material. The locking ring on the hydraulic nut is tightened and when the hydraulic pressure is relieved, tension is retained.

HYDRAULIC NUT ADVANTAGES

Hydraulic nuts offer a method of tensioning multi-bolt assemblies (such as a ange) which greatly improves the integrity of the joint. The speed in which joints can be tensioned and de-tensioned shows an extraordinary time savings over conventional detachable bolt tensioning systems. The most important benet of using the Delta Series Hydraulic Nut Solution is that the design/maintenance engineer has a system available that can give the accurate bolt loads required to ensure joint integrity. An even bolt load distribution can be achieved through any number of bolts by linking tools through a common hydraulic harness. The fundamental advantage of this product is that direct axial load is applied to the bolt and inaccuracies created through friction are alleviated. Massive mechanical efforts to create torque are replaced with simple hydraulic pressure. The larger the stud, the larger the benet to using Delta Series Hydraulic Nuts.

SAFETY PRECAUTIONS
WARNING: High pressure hydraulics requires that the following basic rules are followed. ALWAYS WEAR SAFETY GLASSES when working with or near the pressurized hydraulic system. Always check the following points before pressurizing the hydraulic system: a) Check that the hydraulic harness is fully connected. There should be no loose ends and every male nipple should be connected to its corresponding female connector. Check that each female connector is securely locked in position on the corresponding nipple by physically pulling the connection. Check that the threaded portion of the hydraulic nut is screwed on the stud and that the thread engagement is sufcient. NOTE: The thread projection of the stud above the top of the ange should be sufcient to allow the tensioning tool to engage the stud a minimum of one (1) stud diameter.

b)

c)

Never exceed the maximum working pressure for each stud size or hydraulic nut. Maximum working pressure for standard hydraulic nuts is 21,750 psi. Never exceed the maximum extension for the equipment. NOTE: A line should appear when the tool is close to maximum extension. When pressurizing the system, observe the gauge, and be ready to stop, at the required pressure. Never leave the pressurized system unattended. If you must leave the area release the pressure and ensure that the return to tank valve on the pump unit is fully open. Read both Tooling and Hydraulic Hand Pump and Control Console Operation and Maintenance Manuals prior to operation. Never pressurize the Control Console or Hand pump unless the outlet is either connected to the tensioning system or is safely blanked with a blanking plug. REMEMBER: HIGH PRESSURE HYDRAULICS ARE SAFER IF THE BASIC SAFETY RULES ARE FOLLOWED. Bolttech, Inc. will not be held liable for any personal injury, property damage caused, interruption of business, loss of prots, losses of any kind, etc., resulting from any failure that occurs from the use of this Bolttech product. Additionally, Bolttech, Inc. will not be liable to repair or replace any product, which has been damaged, used improperly, or has been subject to an unauthorized repair by the purchaser or a third party.

TENSIONING PROCEDURE
1. Determine the proper pump pressure as shown in the Load Calculations section. Lubricate the threads on the stud and the mating surfaces of the hydraulic nut with moly lubricant (under 700 degrees F) or other proper lubricant for the application. 2. Select the Control Console or Hand Pump depending on which is best for the application. 3. Check that the studs have been assembled correctly. NOTE: The thread projection of the stud above the top of the ange should be a minimum of one (1) stud diameter. Also ensure that the nut on the opposite side has full thread engagement. 4. Select the correct hydraulic nut for the stud being tensioned and tommy bar(s) for the hydraulic nut and locking ring. 5. Read and follow safety precautions. 6. Assemble the hydraulic nut on the stud and screw the threaded portion of the hydraulic nut until it is snugged down, then LOOSEN THE HYDRAULIC NUT ONE HALF TURN. 7. Ensure that the hydraulic connection is properly tightened in place. 8. Assemble any further tools as given above. 9. Connect hydraulic hoses, remember to observe safety instructions. 10. Operate the hydraulic pump to pressurize the tools to pressure, P. Closely monitor the extension and pressure during the operation, and do not exceed the required pressure for the application. If the maximum extension is reached before the necessary pressure is attained, immediately stop the pump, release the pressure and tighten the hydraulic nut with a tommy bar until it is fully seated. Continue pressurization. 11. While holding the operating pressure constant, use a tommy bar and a small hammer to rmly tighten the locking ring until it is fully seated. 12. Release the pressure by opening the needle valve on the pump, as uid from each tool has to return to the pump this process may be quite slow, ensure the needle valve is fully open. 13. Remove all hydraulic connections, unscrew hydraulic tting, and install the blanking plug.

DETENSIONING PROCEDURE
1. Remove blanking plug and re-install hydraulic tting. 2. Connect hydraulic hoses, remember to observe safety instructions. 3. Slowly pressurize the hydraulic nut, ensure that you do not exceed the maximum pressure of the system or the maximum extension of the hydraulic nut. 4. Once the pressure has built up enough to free the locking collar, stop the pump and hold the operating pressure. 5. Using a tommy bar, loosen the locking collar until it is even with the top of the hydraulic nut PLUS ONE COMPLETE TURN. 6. Release the hydraulic pressure to the system by opening the needle valve on the pump, as uid from each tool has to return to the pump this process may be quite slow, ensure the needle valve is fully open. 7. Disconnect hydraulic hoses, and unscrew the hydraulic nut from the stud using a tommy bar. 8. Remove hydraulic tting and re-install blanking plug.

MAINTENANCE
The hydrualic nut is of rugged construction and utilizes reliable seals. The only maintenance that may occasionally be required is the repair of a hydraulic tting or replacement of a seal. Hydraulic Fittings BOLTTECH tensioners utilize a dowty seal and hydraulic thread sealant. In the event of leakage from this connection, or if the connection has to be re-made, it is important to remember the following points: (1) Dowty seals should not be re-used. A new seal should always be tted. (ii) The threads should be re-sealed using Loctite hydraulic sealant, or a similar compound.

In the event of any problems, please consult BOLTTECH for advice. Replacement of Hydraulic Seals The following precautions must be taken with assembly: Avoid sharp edges. Entire sealing device and all surfaces, which it will traverse on its way to the groove, must be free of all foreign material. Cleaning procedure should include a solvent rinse of all components (including tools used) followed by a wipe-down with a clean, lint-free cloth. Both the seal and its installation path must be lubricated prior to assembly. Both the inner and outer sealing device is made up of two parts: (1) seal (2) back-up ring Back-up Ring: Bolttech hydraulic nuts are assembled with either a square or two piece cam Backup.Prior to installing the seals install the backup rings as shown on the next page. Please be aware that the two piece cam backups can be installed backwards. Never substitute a two piece cam Backup with a square backup or a square backup with a two piece cam Backup. After the back up is in place insert the seal by folding it, avoid sharp bends. Care should be taken to ensure that the lip edge faces toward the pressure end of the piston. After the back up is in place locate part of the outer seal in the groove, and work around the O/D stretching the seal over the boss until it nally slips completely into the groove. Be advised that a reasonable amount of force may be required to stretch the seal. Do not use sharp instruments to assist, as this may damage the seal. 6

Inner Seal:

Outer Seal:

LOAD CALCULATIONS
Before the tightening process begins the following calculations must be made to determine the pump pressures required to properly seal the joint. The following information is needed to perform the calculations: D Astud Aten L Y E the stud diameter (in) the root area of the stud, see gure B (in2) the ram area of the stud tensioners being used (in2) the joint length (in), see gure C the yield strength of the bolt material (psi) modulus of elasticity of stud material, for steel E = 30,000,000 psi

And one of the following: Bstress nal bolt stress (psi) Bpreload nal bolt preload (lbs) Bstretch nal bolt stretch (in) Additional nomenclature: F relaxation factor P pump pressure The rst calculation is to determine the nal bolt preload if it is not already known: if BOLT STRESS is known: Bpreload = Bstress x Astud if BOLT STRESS as PERCENTAGE of yield is known: Bpreload = Y x %yield x Astud if BOLT STRETCH in known: Bpreload = Bstretch x E x Astud / L The next step is to determine the stud relaxation factor, F, from gure C and then calculate the required pump pressures: P = F x Bpreload / Aten

FIGURE B
Root area of studs with 8 threads per inch Diameter 1 1-1/16 1-1/8 1-3/16 1-1/4 1-5/16 1-3/8 1-7/16 1-1/2 1-9/16 1-5/8 1-11/16 1-3/4 1-13/16 1-7/8 1-15/16 2 2-1/8 2-1/4 2-3/8 2-1/2 2-5/8 2-3/4 2-7/8 3 3-1/8 3-1/4 3-3/8 3-1/2 3-5/8 3-3/4 3-7/8 4 Astud 0.606 0.695 0.790 0.892 1.000 1.114 1.233 1.360 1.492 1.63 1.78 1.93 2.08 2.25 2.41 2.59 2.77 3.15 3.56 3.99 4.44 4.92 5.43 5.95 6.51 7.08 7.69 8.31 8.96 9.64 10.34 11.06 11.81

Joint Length (L) = Flange length, face to face + 1/2 of the stud diameter on each end

STUD RELAXATION
1.7

RELAXATION FACTOR (F)

1.6 1.5 1.4 1.3 1.2 1.1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 FORGED NUTS FULLY MACHINED

RATIO OF JOINT LENGTH TO STUD DIAMETER (L/D)

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TENSIONER HOSE PARTS ORDERING INFORMATION

Item A Item B Item C Item F

Part No '10-116-1202 '19-950-0062 '19-950-1622 4005

BOLTTECH LINK PIPE PARTS LIST Quantity Description 2 Quick Connect Coupling (1/4" F BSP) 4 Rubber Metal Seal (1/4" BSP) 2 Adapter (1/4" BSP-1/4" BSP) 1 ST Hose (1/4" F BSP Swivel Ends 15')

Item A Item B Item C Item D Item E Item F

BOLTTECH INTER-CONNECTING HOSE CONFIGURATION Part No Quantity Description '10-116-1202 2 Quick Connect Coupling (1/4" F BSP) '19-950-0062 8 Rubber Metal Seal (1/4" BSP) '19-950-1622 4 Adapter (1/4" BSP-1/4" BSP) '10-116-6202 1 Quick Connect Nipple (1/4" M BSP) 30-21LF6 1 3 Way Manifold Block (1/4" F BSP) 4005 1 ST Hose (1/4" F BSP Swivel Ends 3')

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8 7 3

5 4

2
ZONE REV.

REVISIONS

DESCRIPTION

DATE

APPROVED

HYDRAULIC FITTING
D

LOCKING COLLAR

PISTON
C

PISTON BACK UP SEAL PISTON SEAL

CYLINDER SEAL CYLINDER BACK UP SEAL

CYLINDER

SOFTWARE: SOLID WORKS

DATE

NAME

UNLESS OTHERWISE SPECIFIED:

DRAWN DIMENSIONS ARE IN INCHES FRACTIONAL +/- 1/32" ANGULAR: +/- 1/2 DEGREE TWO PLACE DECIMAL +/- 0.01 THREE PLACE DECIMAL +/- 0.005
MATERIAL

6/07 BG
CHECKED ENG APPR. MFG APPR.

CUSTOMER: TITLE:

BOLTTECH N/A
HEAT TREAT FINISH

A
Q.A.
PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF BOLTTECH. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF BOLTTECH IS PROHIBITED.

HYDRAULIC NUT ASSEMBLY N/A N/A

7 6 5 4 3

SIZE DWG. NO. HYDRAULIC NUT ASSEMBLY - MANUAL

B
2

REV

SCALE: 1:4

WEIGHT:

SHEET 1 OF 1

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NOTES ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________

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DID YOU KNOW...

Bolttech, Inc. is a world leader in the manufacture of Industrial Bolting Torque and Tension Equipment and Plant On-Site Services for over 27 years. Bolttech specializes in industrial bolting tools and services for most major industries, including the oil renery, petro-chemical, power generation, steel industry, transportation and off-road vehicle services industries. We have and will continue to be a dynamic company committed to engineering innovation, quality assurance, customer satisfaction, and overall committed excellence. Bolttech, Inc. has a national presence with its corporate ofce located near Pittsburgh, PA with seven sales, rental and service locations in Los Angeles, CA; Houston, TX; Chicago, IL; Baton Rouge, LA; Philadelphia, PA; and Toledo, OH.

Seven Nationwide Sales & Services Locations: Baton Rouge, LA Chicago, IL Houston, TX Los Angeles, CA Philadelphia, PA Pittsburgh, PA Toledo, OH 225-291-0766 765-492-4753 281-471-6887 310-830-1600 302-838-8672 724-872-4873 419-478-1583

Products: Hydraulic Torque Wrenches Hydraulic Stud Tensioners Pneumatic Torque Wrenches Hydraulic Nut Splitters Hydraulic Flange Spreaders Hydraulic Nuts Torque & Tensioner Pumps Stud Removal Tools Ultrasonic Bolt Measuring

Services: Industrial Bolting Service Rental Tools Induction Bolt Heating

Bolttech Corporate Headquarters 200 Riverside Drive West Newton, PA 15089 Tel: 724.872.4873 Fax: 724.872.8827 E-mail: sales@bolttech.com WWW.BOLTTECH.COM

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