Bolting Solution for EPC & Construction Industry

EPC stands for Engineering, Procurement, Construction and is a prominent form of contracting agreement in the construction industry.The engineering and construction contractor will carry out the detailed engineering design of the project, procure all the equipment and materials necessary, construct to deliver a functioning facility or asset,to commission and handover of the project to the End-User
While executing the various aspects of projects,a perfect bolting is mandatory. Bolting is required in various applications like Crane foundation Bolt ,Crane Joint Integrity ,Tower Crane ,Surge Vessels ,Deck Cranes, Crane Turret Bolts ,Planetary Drive Gear and many more.

ABS Bolting solution for various application are as following-

1.Application Name- Tower Crane Application
     Tool Name-Avanti-8 with Reaction Fixture

2.Application Name- Crane Foundation Bolt
   Tool Name-Stealth 8 Square Drive Hydraulic Torque Wrench

3. Application Name- Crane Joint Inegrity

     Tool Name- Avanti-3 Square Drive Hydraulic Torque Wrench.

4.Application Name- Surge Vessels

       Tool Name- JGun Duol Speed Pneumatic Torque Wrench

5.Application Name- Desk Cranes

      Tool Name - Avanti Square Drive Hydraulic Torque Wrench

6.Application Name- Planetary Drive Gear Solution

      Tool Name- JGun Duol Speed Pneumatic Torque Wrench

7.Application Name- Crane Turret Bolts 

      Tool Name- Avanti Square Drive Hydraulic Torque Wrench

Interesting facts about Thrill Gun Wrench

The THRILL™ with its impact assisted run off or run down of fasteners overcomes corrosion and thread flaws at high speed. Flipping the stabiliser handle, the THRILL™ turns from an impact gun to a torque power tool, ready to break out fasteners or to torque them within 5% with continuous rotation rather than the intermittent power of impact guns. Overall, this makes the THRILL™ the fastest and most reliable power tool yet!

Impact Pre-Torque

Grab both handles, pull both triggers for a corrosion-overcoming, reaction arm-free, impact assisted pre-torque up to 3,200 rpm.

Safe Precision-Torque

Flip the front handle, push the Safety plate with one hand and pull the trigger with the other to speed up precision-bolting in the safest possible way.

Operations-

Applications-

It is ideal for Oil And Gas, Petrochemical, Power Generation and Infrastructure sector.

Why We Love Flange Closing Tool

The Equalizer™ Flange Closing Tool has been developed to pull flanges together during installation or maintenance. The FC10TE can be used on any flange with a bolt hole diameter of 22mm (7/8”) or greater.

The FC10TE has been designed utilizing tandem hydraulic cylinders to create a very low profile, this allows the FC10TE to be used on small diameter flanges with limited access as well as larger flanges. The tool can be used on any flange with a bolt hole diameter of 22mm (7/8”) or greater, and can pull from a distance of 600mm down to 0 mm with a force of 10T (100kN) per tool. It is recommended that 2 tools are used as a minimum but the FC10TE can be used in greater multiples to achieve the pulling force required.

CLOSING FORCE: 10 T (100 kN) per tool

CLOSING DISTANCE: From 600 mm to 0 mm (23.6” - 0”)

 TOOL WEIGHT: 11 kg (24.3 lb)

RANGE OF APPLICATION

The FC10TE is applicable to all flanges with a bolt hole diameter of 25.4 mm (1”) or greater. This includes ANSI, DIN, SPO, ASME and BS flanges.

Application-

It is ideal for Construction, Shutdown, Petrochemical, Nuclear And Mining Application.

Operation Video-

13 Benefits from Hytorc EDGE you want to know

The 13 special Benifits of Hytorc EDGE are as following-

1.Provide Torque From 161 Nm To 40027 Nm 
2.Universal push through square drive for quick switch from loosening to tightening
3. 3-Moving-Part system for simple  and inexpensive repairs.

4. Perfect for maintenance jobs requiring up to 30,000 ft-lbs
5.360 degree rotatable reaction arm for perfect fit on many jobs 
6.Uni-swivel technology for free movement and positioning of tool and hoses 
7.The most cost effective torque wrench in the world

8.Anti-Lock Ratchet
9.Uni-Body Housing
10.360°Swivel

11.Industrial Grade Tital Steel
12.More Turn Per Stroke
13.Also Available With Safety Handle

Operation Video-

Application-

EDGE is ideal for Oil And Gas, Petrochemical, Power,Shipping, Cement Industries.

15 Benefits of using Juwel Electrical Wrench

An electric torque wrench is a planetary torque multiplier or a "Gearbox" mated to an electric motor. At the end of the "gearbox" is a reaction device that is used to absorb the torque. This allows the operator of the tool to use the electric torque wrench with very little effort.

These tools are primarily used anywhere accurate torque is required on a nut and bolt, or where a stubborn nut needs to be removed.

The 2 Special types of Jewel are as following-

1.Standard Build-

JUWEL-electrical power screwdrivers from the standard series TES, TEWS and TESM are highly compact Electrical power screwdrivers that are highly valued around the world for their robustness and reliability. The units are used where high tightening and loosening torques are required, e.g. in steel construction, crane assembly, power plant and generator construction. 

2.Heavy Load Build-

Combining state-of-the-art high-precision production with use of highest-quality materials has led to a highly resilient and maintenance-friendly gear. The modular gear build permits separate bearings for individual planet stages. This once again strongly reduces operational wear and significantly increases gear service life


15 Benefits of using Juwel Electrical tool are as following-

• 1.Available from 200 to 15,000 Nm
• 2.Proven Gearbox Technology
• 3.Straight And Angle Type Available

• 4.Freely turning drive unit
• 5.Quick and precise
• 6.2-step gear ri./le.
• 7.200 torque settings
• 8.Modular build with bearings for continuous use

• 9.With a torque deactivation system with an accuracy of +/- 3.5% at consistent screwing application
• 10.Quick, precise, safe and low-noise
• 11.Devices available in 230 Volt and 110 Volt versions.
• 12.Newly designed drive motor characterised by its robust and maintenance-friendly structure as well as by high performance reserves

• 
  
• 13.Right- and left-ward rotation and a 2-step gear; adjustable with 200 torque settings.

• 14.Any position of the operating unit possible; drive motor can be freely turned by 360°, which ensures comfortable positioning of the device on the screw connection
• 15.Can optionally be either with a load release. This leads to independent loosening of the torsion between the push-on socket and the support. The drive motor briefly turns into the opposite direction for this. This option is indispensable for short assembly times and offers best work safety.

Applications-

It is used in Multiple applications & sector like infrastructure.

3 Interesting Applications of Xtegrity- Flange Integrity System

Xtegrity™, The Equalizer™ Flange Integrity System is a world first, providing a unique solution to the industry-wide issue of heavily corroded or degraded bolts within flange joints. Xtegrity™ is applicable to those concerned with flange maintenance or integrity issues. In scenarios where bolts are heavily corroded, there can be uncertainty about true bolt strengths and operators are faced with choices over hot bolting or shutdown or postponing the decision on how they will address the issue. This problem now has a solution in the form of Xtegrity™ which provides a means of restoring the flange joint integrity back to its original state in a safe, efficient and cost effective manner.

Problems-

1.Many bolted joints are operating beyond their design life.
 2.Carbon Steel bolts are heavily corroded.
3.True strength of bolts are unknown 
4. Bolts categorized by visual inspection 
5.Shut down and replacement is a substantial task and results in a major loss of production.
6.Budgeting for traditional bolt replacement is almost impossible.

Solution-

Xtegrity™ takes away the need to remove corroded bolts by "replacing" them with a new set of bolts which clamp round the outside of the flange and are then held in place by a floating frame. It can therefore replicate the same bolt size, quantity and specification used during the initial flange joint assembly. Installation of the system is simple and quick, with a typical four bolt flange joint taking less than one hour to set-up. Taking away the need to remove old bolts also reduces the risk of flange joint leakage. The system can be used on carbon or stainless steel, duplex or cunifer flange joints.

Xtegrity has significant operational and commercial benefits. It can be used in situations where alternative solutions cannot be used, for example on high pressure, larger diameter flange joints. In these circumstances the only current solution is to carry out maintenance during shutdown resulting in potential loss of production and revenue. By effectively providing a 'replacement' set of bolts around the flange joint it also provides peace of mind to integrity engineers about the reliability of their bolted joints.

Product Video-

Applications-

1.Integrity-

Leave the corroded flange bolts in place and apply the Flange Integrity System to prevent joint failure.
In the event of flange stud failure, the load will transfer to the Xtegrity system maintaining joint integrity • A “temporary repair” maintaining flange joint integrity until corroded bolts can be replaced.

2.Maintenance-Hot Bolting-

Temporary application to enable the corroded flange bolts to be replaced via hot bolting.
flange bolts are removed, and replaced one by one in accordance with the hot bolting procedure 
• Xtegrity geometry maximises access to the flange bolt for maintenance tools.
• Precision hot bolting
•Utilises ultrasonics and the Xtegrity system to gauge load
•Replicates individual bolt loads
•Restores original gasket compression in the joint
•Allows for a thorough assessment of the joint

Ultrasonic Monitoring-
•Ultrasonic probe is used to accurately measure the System Stud length 
• Changes in length correspond to changes in loading
 • By monitoring the system studs throughout the hotbolting process the flange stud loading can be accurately replicated

3.Intervention-

Apply the Xtegrity System following a loss of joint integrity 
• The Flange Integrity System is available at short-notice for emergency call-out
 • The system may be applied to facilitate increased gasket load as a temporary measure without the risks associated with tightening corroded bolts

Interesting things about Bolt Tensioning

What is Bolt Tensioning
Tensioning is the direct axial stretching of the bolt to achieve preload. Inaccuracies created through friction are eliminated. Massive mechanical effort to create torque is replaced with simple hydraulic pressure. A uniform load can be applied by tensioning multiple studs simultaneously.

Tensioning requires longer bolts, and a seating area on the assembly around the nut. Tensioning can be done using detachable Bolt Tensioners or Hydraulic Nuts.

* Preload (residual load) = Applied Load minus Load Losses *

What is Load Loss
Load loss is a loss of bolt elongation depending on factors such as thread deflections, radial expansion of the nut, and embedding of the nut into the contact area of the joint. Load loss is accounted for in calculation and is added to the preload value to determine the initial Applied Load.

The preload depends on Applied Load and Load Loss (load loss factor).

Manufacturer's rating of pressure and load are maximum safe limits. Good practice encourages using only 80% of these ratings!

Tensioning Operation

Tensioning permits the simultaneous tightening of multiple bolts; the tools are connected in sequence via a high-pressure hose assembly to a single pump unit. This ensures each tool develops the exact same load and provides a uniform clamping force across the joint. This is especially important for pressure containing vessels requiring even gasket compression to affect a seal.

General Procedure

Step 1: The bolt tensioner is fitted over the stud
Step 2: Hydraulic pressure is applied to the tensioner which then stretches the stud
Step 3: The stud's nut is wound down against the joint face
Step 4: Pressure is released and the tool removed

The bolt behaves like a spring, when the pressure is released the bolt is under tension and attempts to contract, creating the required clamping force across the joint.

Less than 100% Tensioning

Not all applications allow for the simultaneous fit of a tensioning device on each bolt, in these cases at least two tensioning pressures are applied. This is to account for a load loss in those bolts already tensioned as the next sets are tightened. The load losses are accounted for in calculation and a higher load is applied to allow the first sets to relax back to the target preload. 



Set-up using a 100% tensioning procedure
All bolts are tensioned simultaneously.

Set-up using a 50% tensioning procedure
Half the bolts are tensioned simultaneously, the tools are relocated on the remaining bolts and they are subsequently tensioned