Monday, 26 December 2016

World First FRL-Free Torque Gun with LCD Display- Digital JGun

The new digital jGun series from HYTORC is the world’s first torque-adjustable pneumatic multiplier with a digital readout and FRL-free operation. Unlike other systems that require a separate filter, regulator and lubrication system between the air line and the tool, the patented design of the digital jGun eliminates the need for this add-on for the highest level of portability and convenience.


1. Digital Readout
The digital jGun is the world’s first industrial torque multipler with a digital readout for instant confirmation of selected torque. No more pressure-to-torque conversions or calculations. Select between ft-lbs and Nm or PSI and BAR.

2. Built in torque Adjustment
Other pneumatic multipliers require the use of a separate air regulator to adjust the output. The Digital jGun is the first of its kind with an on board air regulator for simple torque adjustment with a twist of the connector at the bottom of the handle. This feature is especially convenient when switching from tightening to loosening, giving you the ability to quickly adjust to full power for fast and easy break-out.

3. No lubrication required
The new motor featured in the Digital jGun is a workhorse designed for heavy industrial use. With maximum power to weight and a rugged corrosion resistant design, this motor eliminates the need for separate air filters and lubrication systems making the Digital jGun the most portable air powered torque gun on the market.

4.High torque Deliver- 
The Digital jGUN pneumatic torque wrench is designed to safely and accurately deliver up to 8,000 ftlbs of torque onto a fastener. This is accomplished using a patented planetary gearbox torque multiplier system and an appropriate reaction arm or HYTORC Reaction Washer™ and HYTORC Nut™

3 Benifits from Hytorc Washer

Replacing your standard washer with a HYTORC Washer makes your job safer, faster and more accurate while increasing the lifespan of your tools. This upgrade can be used on nearly every bolting application without changing your existing bolts and nuts.

Application of Hytorc washers-
1.Ammonia Button Flange

2.Manhole of Combustion Chamber-

3.Sewage Plant Applications-
4.Haul Truck Application

5.Rolling Stand Roll Guide in Steel Industry

6. H2 Exchanger-Simultorc Application
Benefits with Hytorc Washer-
1.Increase Job Safety -The elimination of external moving parts and the intuitive design of the HYTORC Washer system make it the safest bolting method in the industry.

2.Increase Joint Integrity -The HYTORC Washer ensures even and accurate bolt load to eliminate joint failure and unintentional nut loosening.

3.Increase Tool Longevity -Other bolting systems put the reaction arm and square drive on opposite sides of the tool causing high stress in the body of the tool, which can lead to failure over time. The HYTORC Washer puts the action and reaction on the square drive axis to eliminate the majority of internal stress, and increase the lifetime of your tools

Monday, 21 November 2016

Bolting Applications For Cement Industry you want to know

 In order to make the work more productive, safer, and easier to perform, a effective bolting is mandatory.We need to tighten the bolt to the exact required level.Bolt shouldn’t be loose that the joint is not kept together & it shouldn’t be too tight that the bolt loses its elastic property and no longer springs back.A prefect bolting is always needed.

In this blog,we will talk about bolting applications in Cement Industry.

As we know India is the second largest producer of cement in the world.Bolting is required in multiple applications of Cement Industry like Ball Mill , Base Bolts ,Vertical Roller Mill Foundation Bolt, Coupling flange ,Crusher,Finish Mill,Vertical raw mill foundation bolt application.

Lets have a look for  various applications & their effective bolting solutions-
1.Ball Mill Application
Bolting Tool -Avanti-1 Hydraulic Torque Wrench

2.Base Bolts Application
Bolting Tool-Avanti-10 & J Gun

3.Vertical Roller Mill Foundation Bolt
Bolting Tool-MXT and Stealth

4.Coupling flange Application
Bolting Tool-Avanti Hydraulic Torque Wrench

5.Crusher application
Bolting Tool-MXT Hydraulic Torque Wrench

6.Finish Mill application
Bolting Tool-Stealth Hydraulic Torque Wrench

7.Vertical raw mill foundation bolt application
Bolting Tool-Avanti-10 Hydraulic Torque Wrench

Friday, 14 October 2016

3 way to Tension the Load

What is Tensioning?
Tensioning is the direct axial stretching of the bolt to attain preload. Inaccuracies created through friction square measure eliminated. Massive mechanical effort to form torque is replaced with straight forward hydraulic pressure. the same load can be applied by tensioning multiple studs at the same time.

Tensioning needs longer bolts, and a seats on the assembly around the nut. Tensioning will be done victimisation clastic Bolt Tensioners or Hydraulic buggy.

There are 3 way to Tension:-

2.Hydraulic Tensioners
3.Mechanical Tensioners

1. Tensioning with Heat:-

Gas Bolt Heater:-

Correctly setup a gas bolt heater
Properly adjust oxy-acetylene flame
Correctly adjust air flow
Safely operate a gas bolt heater

Heating causes a bolt to grow in length
Relieves tension on bolt
Gas Bolt Heater is machined from solid Stainless Steel
A single bolt heater can be adapted to fit most bolt sizes by changing the heating tube diameter and length

Select a heating tube that is 1/8” smaller than the hole in the bolt and approximately 3” shorter than the depth of the hole
Install heating tube in bolt heater
Use stainless steel reducing bushing for smaller heating tubes
Use high temperature thread compound
Tighten hand tight
Connect air line to bolt heater
Air pressure should be between 50-100 PSI
Set oxygen pressure to 14 PSI
Set Acetylene pressure to 7 PSI
Use Victor #5-W gas welding tip
Always use check valves
Adjust flame to obtain a carburizing flame
Carburizing flame has an acetylene feather
Insert bolt heater into bolt
Purge bolt cavity with air
Turn air valve off
Insert welding tip into gas bolt heater
Gradually open air valve approximately 1/8 turn
Observe color of heating tube through vent holes in gas bolt heater
Maintain a cherry red color by adjusting air valve
More air is cooler
Less air is hotter
For proper operation a balance of pressure must be maintained between welding tip and heating chamber back pressure
Excess back pressure will result in welding tip back-fire 
If back-fire occurs, close acetylene valve, remove welding tip from bolt heater, purge bolt cavity with air, and restart heating process

Minimum Muscle

Hard on Studs
Must have hole
Rough on gaskets

2.  Hydraulic Tensioners 

Various type of Hydraulic Tensioners 

1.Top Connect
2.Side Connect
3.Hydraulic Nut

                     Top Connect                                  Side Connect                           Hydraulic Nut    
3.Mechanical Tensioner:-

-Multiple Work
-Takes Forever
-Tiny Load Points
-Cant check Results


Gas Bolt Heater

Monday, 26 September 2016

Why We Love TTX Square Drive Torque Wrench

 A torque wrench is a tool used to apply precisely a specific torque to a fastener such as a nut or bolt.A torque wrench is used where the tightness of screws and bolts is crucial. It allows the operator to measure the torque applied to the fastener so it can be matched to the specifications for a particular application. This permits proper tension and loading of all parts. A torque wrench measures torque as a proxy for bolt tension. The technique suffers from inaccuracy due to inconsistent or uncalibrated friction between the fastener and its mating hole. Measuring bolt tension (indirectly via bolt stretch) is actually what is desired, but often torque is the only practical measurement which can be made. 

TTX torque wrench provide torque from 228 Nm to 40194 Nm.Its Reaction Arm Mounted On The Square Drive Eliminating Torsional Force On The Cylinder. It Also Enables To Customize The Reaction And Suit The Application

4 Special Feature of TTX-

  • 180/360 degree muliti-positon hose couplers: For no hose interference on all jobs
  • Efficient mechanical design with 3 moving parts: For simple and inexpensive repairs of internals
  • Highest quality aluminum and steel alloys: For durability and longevity
  • Manufactured & assembled in the U.S.A.: Highest level of material and quality control
It is extensively used in Petrochemical, Offshore Subsea , Power Generation, Shipping industry bolting applications.

Thursday, 15 September 2016

MXT-Most used hydraulic torque wrench in the World.

The MXT™ series is the all-time most requested square drive hydraulic torque equipment by maintenance, service and construction personnel worldwide! The MXT equipment includes features that set the standard by which all other manufacturers strive to measure up to.

HYTORC presents the high-strength MXT-SA versions of its ¾-inch, 1-inch and 1 ½-inch square-drive tools. Providing an unmatched level of strength in a quality torque tool, the MXT-SA has been designed for heavy production use. Although the SA versions have the same dimensions as their standard MXT counterparts; they are built with redesigned internal parts made of stronger materials to increase the tool longevity under continuous us
The MXT-SA units feature a polished chrome finish and a torque output equal to the standard square drive model MXT. These units are also offered with a remarkable no-questions-asked 5 year warranty with free annual inspections – an industry first!
10 special Benefits are as-
1.The most used hydraulic torque wrench in the World.
2. Continuously upgraded technology for unbeatable durability perfect fit on many jobs.
3. Hundreds of add-on fixtures available for perfect fit on any job.
4. Compact, ergonomic design for torque output up to 37,000 ft-lbs.
5. Uniswivel technology for free movement and positioning of tool and hoses.
6. 360 degree rotatable reaction arm for perfect fit on many jobs.
7. High strength metal square drive for performance & reliability
8. Heavy Duty
9. Powerful & Versatile

10. Provide  torque from 167 Nm To 50293 Nm 


It is ideal for Petrochemical, Shipping and Oil And Gas sector.

Thursday, 25 August 2016

4 Major Phases of Plant Turnaround

In any industrial plant, inspection and minor maintenance work are taking place “on line” but it has to undergo a scheduled process outage for the major maintenance work and this outage is referred to as “plant shutdown”. Turnaround management is primarily concerned with repair, replacement, alteration and refurbishment of malfunctioning items.

A turnaround is a cyclical process with four phases which starts with initiation and passes through preparation, execution and termination. 
The 4 Major Phases of Turnaround are as following-

Phase 1 – Initiation 

The initiation phase of the next turnaround must follow on from the present termination phase.
The initiation phase of a turnaround starts from the moment the senior manager considers the necessity of the turnaround and continues over a period of months. In some cases it continues for 20-24 months before the event. During this phase all parameters of the turnaround are defined in detail i.e. analyses breakdown and production problems from the historic data and past events. Strategic issues and objectives are addressed in this phase.
Some of the critical issues and activities are tabulated below. 

Phase 2 – Preparation

 Preparation is the most important phase of the turnaround process and may continue for a period of 3 to 18 months depending upon the scale of the event. Members of the preparation team accumulate a large quantity of technical and non-technical data to specify, schedule, resource and cost the large volume of tasks required to execute the turnaround event by validating and transforming those data into a set of plans. The work list is one of the most important elements of this phase and is the foundation of safety, quality, costs, equipment, materials, resources, logistics and turnaround duration. It contains an element of uncertainty as it involves some degree of prediction of the unforeseen activities related to plant equipment that can be minimised by systematic questioning as a part of an analysis of contingencies. Some of the typical questions used for the analysis are: What may go wrong? What faults are likely? What is the cost implication? How much time is required to set that right? What are the contingencies available? 
The preparation team along with the plant team challenges and validates the work list that is finalised by the turnaround manager. The plant team and TA team have to communicate regarding the requirements of the turnaround from time to time by means of a series of briefings involving each and every person across the levels.

Phase 3 – Execution 

During the execution phase all the planning and preparation are tested against reality and is characterised by the performance of a large number of people of different skills and disciplines within the framework of restricted money and time. Execution continues two to eight weeks, which involves co-ordination of all activities. It is characterised by close monitoring and controlling of event-wise schedule, safety, quality and cost.
There will be a designated person as a first person responsible for each and every sub phase. Single point responsibility ensures effective coordination and the designated person confirms proper completion of the previous stage of the task. Successful completion of the present task as per the specification and subsequently handing over to the next stage at the earliest possible time are also part of the designated person’s responsibility. The execution phase involves following critical issues and activities: 

Phase 4 – Termination 

The termination phase continues one to two weeks during which time the entire turnaround work is closed and performance is to be reviewed against the plan. It includes reviewing of all completed jobs and re-commissioning activities to ensure safety. 
This phase ensures that the plant is handed back in a fit condition while ensuring proper debriefing of every member of the turnaround organization to capture the lessons learned from the turnaround that may be useful for future requirement. De-briefing is also useful to control the change in plant operation that has happened due to turnaround. Cost and inventory statements are to be prepared. It is a most crucial phase as most of the accidents usually take place during start-up. Before handing over the plant it is required to clean the plant. Critical activities:
 • Start-up team cleans the site and removes all equipment especially brought for turnaround work.
• The plant manager takes charge of the plant after thorough inspection while the turnaround manager demobilizes the start-up team. 
• De-briefing can be arranged jointly by the plant and the turnaround manager. 
• The turnaround manager generates the final report.  

ABS holds competence in managing complex situations like Plant Turnaround & Shutdown Maintenance with utmost precision, speed and safety.ABS successfully executed shutdown projects of Reliance Industries, CPCL, BPCL,IOCL, MRPL, HMEL, GE International etc.