BOLT TENSIONERS INSTRUCTION MANUAL PST SERIES TOP SIDE TENSIONERS INSTRUCTION MANUAL Sin_atk Migh Technology Wialntenance PST SERIES BOLT TENSIONERS This manual contains IMPORTANT WARNINGS, CAUTIONS and other instructions. Read and understand the instruction manual carefully before use and retain it for reference.BOLT TENSIONERS: afolesia)aateisl(oN|stxs Introduction Safety Precautions Specification Data Sheet RON Operating Procedure Tool Assembly -Tensioning Procedure .De-tensioning Procedure 5 Seal Replacemert Procedure 6 Illustrated Part List 7 | Warranty Certificate 03 04 05 06-09 06 -07 Note :OLT TENSIONERS: | | In order to apply an evenly distributed load to a bolted joint, the sequence in which hydraulic tensioners | ae applied to the joint is important. The exact detail of this sequence is dependant upon the number of Bolts in the joint and the number of Bolt Tensioners available. In order to optimize between cost | of equipment and the time taken to tension the joint, it is generally agreed that the correct Bolt/Too! ratio | is 50%, in certain instances a 25% ratio is acceptable. The general rule is the lower the Bolt/Tool ratio, |_the more time it will take to tension the joint. This operator procedure details a 80% Bol/Tool rato. For detailed information on Tensioning Sequences with different Bolt Tool ratio’s Please refer to ‘Sequence of Operation for top Side Bolt Tensioning’ document from manufacturer. Prior to connecting the hydraulic pump to any bolt tensioning equipment, the user is to ensure that - The working pressure of the hydraulic pump and the equipment to be operated are compatible ‘The reservoir pump capacity is adequate to operate the equipment throughout its range. The hydraulic oll specification used within the pump and the equipment are compatible. The technical specifications of the tensioning tools are known. Ensure sufficient stud protrudes above the hexagon or round joint nut. BOLT TENSIONER TOOL PART IDENTIFIER Lxcleolesielenensieticn i NUT DRIVER/ 7 mt | i HREADED PULLER LOAD CELL eRIDGE HUT ROTATING GocHEr Fig. 2 POSITION LOADCELL | The technical specification of your particular bott tensioning tools can be found hard ae on the Load Cell Body.BOLT TENSIONER: TOP SIDE TEN: PST SERIES BOLT TENSIONERS OPERATING INSTRCUTIONS WARNING: ‘All equipments used must be rated for the same operating pressure ie., 1500 bar (21750 psi) DONOTMIX high andlow-pressure components. fin doubt, contact your local Distributor. | All general on-site safety procedures and precautions must be followed when using this equipment. | Only technicians / engineers trained in bolt tensioning procedures and operation of bolt tensioners should | use the equipment. Never attempt to use this High Pressure equipment if you are in any doubt regarding the correct | assemblyand operation. i Always ensure the equipment used is supplied by manufacturer is in good working order..Do not mix. equipment with any other brand. Always wear eye protection, gloves and safety boots. i __ Non essential staff should vacate the immediate area during the tensipning Always ensure that all personnel in the near vicinity are aware that pressurization of High Pressure Equipment is about to take place. Only when itis certain that the set pressure is holding steady on the pump pressure gauge, should one approach a pressurised Bolt Tensioner. Never attempt to solve leaks in the systern while itis under pressure, Shut the pump down immediately to zero pressure before attempting to resolve system leaks. _ Never exceed the maximum working pressure of the Bolt Tensioner. (See the tensioner specification | hard stamped on the tool). Never exceed the maximum piston stroke of the tool. Never stand in line with the bolts axis, unexpected bolt failure is highly dang erous. Ensure suitable thread engagement between tensioner and bolt is achieved. (1x Bolt Diameter must protrude above the surface ofthe nut and ensure proper bolt engagement ) Contact us if less than 4x Bolt Diameter protrudes from above the Nut Surface. Example : For a M45 bolt, you need at least 45 mm of bolt protruding from above nut surface. Examine hydraulic hose assemblies for crushed or badly kinked hoses, replace damaged hoses Immediately. FAILURETO FOLLOW THESE INSTRUCTIONS MAYRESULT INDAMAGE TOTHE UNITOR MAY RESULT IN OPERATOR INJURY OR EVEN DEATH. IF_YOU ARE IN ANY DOUBT ABOUT ANY INSTRUCTION DETAILED IN THIS PROCEDURE, DO NOT HESITATE TO CONTACT AN AUTHORISED DISTRIBUTOR,BOLT TENSIONERS | INSTI Metric Sizes M140 Eee M36 Ms2_| eo M180. wae ae ae ae | a | re | ote 2 ase [aaa [oa ee Te | sa tae | tae | tate) 2a s [sam |_| sae Imp. Sizes 1 [nae | ae | tse | re | aie | 28 gave | 3.34" Ex 13a" [2 e 5a" yd [in 3a ait | 600 | 748 | 07a | 1300 | 17.08 | 0.44 | 3890 | sta0 [90.04 [40.19 Area | mnr_| 2258 | 2649 | 4250 | 4608 | 6280 | 9028 | 11008 | 13188 | 16485 | 20312 | 25120 | 31604 Wax, [KN.| 398 [397 | 639 | 721 [942 ye51_| 1978 | 2087 [047 4754 Load [Won | 345 | 447 | 718 | 91.4 | 1059 1866 | 222.4 | 2537 | 3426 5344 Max. Dial mm [84 [ea | 115 [128 | tas 80 | 198 | 215 | 244 | 328 ‘Stoke ["mm [2 | 2 | #8 [#6 | 16 [15 | 16 [15 _ 26 [20 | a7 | [ar so} _7o | 7s _| er 24 c 30 | 32 | 40 | 43 | 50 eo | 9 | 8 | 89 128 metic | ™ 3543] 46 | 83) 6 | 75 93 135 on 38. 49_| 58 7 20, 144 “105, we) [aw a | a | [se | | ve | or | ioe [5 c 30_| 32 | 40 [43 | 50 | 67 | 66 | 75 | 80 | 93 | 106 | 135 imp. | mm [30 [35 [as [46 | sao 72 so | tt [144 38 49_| 86 1 305 | 118 | 145 f 21 [se [70 | ef arf ee |e [| feo 106 [26 P 54 62 75, EI 98 wos | 417_| 132 | 150 | 164 | 210 |" 249 Metric | ™ es | a0 | 66 [0a | 419 | 425 [tat 175 | 226 | 280 73 708 129 179_| 233 | 275 195 wea | ear] ee [ie | tae | i390 | tee [e220 Pp 53 | 6a | 74 | 81 [92 | tos | 125 | 199 | 160 | 474 [toe | 254 imp. | ™™ [oss [72 [eof asf 98 a8 iet_| 208” | 266 ar} 40 197_| 222 [276 228 Werning: Ensure sufficient engagoment of Pulero ver Stud. a Pee ‘OK | OPTIMUM ENGAGEMENT MINIMUM ENGAGEMENT | LOW ENGAGEMENT | bokrraiunonatotetap sus efpuler. Bok Pronstn ie grat an oreqafo | ot Proison ss haa bat dant.BOLT TENSIONERS INSTRU OPERATING PROCEDURE uielel SS SELON ane Step 1 : Ensure there is sufficient stud protruding from the top of the joint nuts. A minimum value equal to. the diameter of bolt is essential . For any low engagement application contact authorised dealer manufacturer Step 1 Step 2 ‘Step 2 : If Tommy bar holes are not drilled into hexagon nut faces,assemble. Nut Runners over every alternate Studbolt to be simultaneously tensioned. Tighten down every studbolt on the flange to be tensioned by using the Tommy bars supplied with the tensioning equipment Ensure the two halves of the joint ate pulled firmly together. Step 3Assemble the bridge over the first 50% of studbolts to be tensioned (every altemate bolt). Position the bridge window so that access to either the Nut driver or hexagon nut is comfortably achieved. Itis normal for the bridge window to face radially out from the centre of a circular flanged joint, Examine the bridge base circumference to ensure itis siting flat against the tensioning surface, Step 3 Step 4 Step 4 : Assemble the load cells over the bridge. Position the hydraulic connections so that access is comfortably achieved. It is normal for the hydraulic connections to face radially out from the centre of a circular flanged joint.TENSIONERS INSTRUCTION MANUAL PST. IDE TENSIONERS ‘Step 5 : Assemble the Pullers into each Bolt Tensioner screwing onto the studbolt protruding above the Step6: Step7: hexagon nuts. Ensure the Threaded Pullers are threaded to the same diameter, thread form and pitch as the studbolts to be tensioned. Use the Tommy bars supplied with the tensioning equipment to fully screw down the Inserts, until contact is made with the top face of the Load Cells. Step 5 Stop 6 Remove plastic protection caps from all male and female quick connect couplings. Connect a link hos from the Pump Unit to the first tool. (Connection is made by pulling back the spring loaded collar or the female connection.) Insert the male connector and release’ the femele collar. A gentie tug on th link pipe should be enough to make sure the hose is connected properly. Continue until all of the tensioners are connected together with link hoses. The last tensioner in the system will have an plugged port (Incase male ¢ onnector is fitted to port, remove connector and fit blanking plug supplied with tools). CAUTION NEVER PRE SSURISE AN UNCONNECTED MALE CONNECTOR. Ait Pressure Regulator Air Shut-off valveBOLT TENSIONERS Pees lss mez s)= ta sielacc) TENSIONING PROCEDURE CAUTION: __The tensioning system is now ready to apply a bolt load to the joint. Before applying pressure to the system make sure you understand the following points. ‘© You are aware of the correct operation of the pump unit. (See operation manual for pump.) © You are aware of the maximum working pressure of the tensioners. (See Technical label specification on tensioners.) © You are aware of the maximum stroke of the tensioner. @ You are aware of the required working pressure that must be applied to the tensioners. (Gee Tips ontensioning guide manual for calculating bolt loads and working pressures) © Itis recommended the next procedures are read and under stood prior to starting the tensioning. WARNING: During pressurisation procedure, continuously monitor both piston stroke and maximum working pressure . Never exceed either. piston stroke unit can be seen by @ RED over stroke indicator fine on the Piston emerging from the load cell. Stept ; Close Pressure Bleed Valve on pump unit and pressurize the system to a test pressure of about 10 Close air shut-off valve and check the whole system for sign of any leakage. Release pressure and rectify if required. Step 2: Open the air shut-off valve and gradually increase pressure to required value. When the required pressure is reached, close air shut-off valve to stop the pump (Hold Pressue) Altis stage the bolts will be loaded with the load being held by the tensioners. Step 3 :Checkthe pump gauge to ensure the pressure is holding firm. When sure, approach the tensioners and rotate the hexagonal nuts using the tommy-bar. Ensure hexagon nuts seats firmly against the Joint, Itis recommended that nuts are tightened in sequence to prevent skipping any nut. Slowly release the hydraulic pressure by opening pressure bleed valve on the pump. Re-apply the pressure twice more i.e. apply pressure and turn nuts down three times. Step 4 : The load is now transferred from the tensioners to the nuts. Using tommy-bar turn the pull clockwise to press the load-cell piston down. When piston is fully inserted, unscrew and remove puller using tommy-bar.. @ S | ) TURN DOAN TURN BACK w= PULLER TO PRESS TO REMOVE ‘THE PISTON DOWN PULLER. Step 5 : Reposition the tensioners on the balance 50% bolts to be tensioned. Disconnect hoses if required {for repositioning. Repeat the operation as abov ¢ for balance un-tensioned bolts. Caution : Itis recommended to wait a few minutes between each pressure sequence to allow the gasket to settle in.OLT TENSIONERS INSTRUCTION MANUAL PST SERIES TOP SIDI DETENSIONING PROCEDURE 3. Specific tool pressures are not usually available as itis not always poss le to calculate the pressure at ‘which the flange nut will come loose. As a guide, where original tensioning pressures are available, the detensioning pressure is marginally more than the original tensioning pressure. (but not always.) Case B All salety oe [© Only technicians J nee i terisloners are invowied © The joist thats to ‘ust be at 2670 a CS values 7 press 2 Assemble the tensioners onto the boits. Unscrew the threaded puller by % turn. To prevent the threaded puller becor ig locked on the piston when the bolt tension is released. Inger the tommy bar through the bridge window into a hole on the nut rotating socket. Apply pressure to the system Until the flange nuts can be rotated, ensuring that the piston does not exceed maximum stroke or systam pressure does not exceed maximum allowed pressure. : Tum back each flange nut through 4 full tum with the help of the tommy bar. : De-pressurise and make sure the flange nuts can rotate freely. Remove the tensioners. If the threaded puller cannot be unscrewed and the flange nut is also tight, then the threadec puller has locked onto the top face of the flange nut. — see Case A. If the threaded puller cannot be unscrewed but the flange nut is free then the threaded puller has lock ed onto the top of the piston, - seeCase B Threaded puller locked onto the face of the flange nut - if the flange nut is turned back more than indicated in the threaded puller may get locked onto the flange nut when the system is depressurized, To release, re apply pressu ‘and rotate the flange nut to clockwise and tighten by % rotation. Upon depressurizing the threaded puller should rota Freely. Threaded pullers locked onto the piston - This occurs if the threaded puller is not unscrewed as suggested in STEP (4 tum may not be sufficient for fine threaded bolts ) when the tension is released from the bolt. To release the threaded puller, re-apply pressure and turn down the flange nut. When depressurized, the threaded puller should be free to rotate. Unscrew the threaded puller a further % turn and repeat STEPS 2 to 5.BOLT TENSIONERS INSTRUCTION K Ne SUS aes ke) SBS MeN esas) SEAL REPLACEMENT PROCEDURE There are two seals used in PST series Hydraulic Bolt-Tensioners; one on the inner diameter of the Piston ar another on the outer diameter of the Piston (Fig.1). Each seal comprises of an inner (Acrylonitrile Butadiene Rubber and outer seal (Polytetrafluoroethylene with filers). The replacement procedure is same for both types of seal. SEAL REMOVAL Isolate the failed load-cell, unscrew and remove any one hydraulic quick connect coupling ( Fig.2) Assemble two appropriate piston extraction bolts into the threaded holes (Fig.3). Using these bolts, retrieve piston ‘ree from the cylinder bore. Itis recommended that both seals be replaced at the same time. Firmly hold the piston in a vice fitted with soft jaws. Using a smooth rounded screwdriver, firmly grip the sealing edge of the outer seal and pull it away from the seal housin The same procedure can now be used on the inner seal. Discard the used seals. Fig. 4 Fig. 1 Fig. 2 SEAL REPLACEMENT ‘Thoroughly clean the seal housing and the hydraulic chamber of the load-cell. Place the piston, bottom face up, on a clean flat surface. Offer inner rubber part of the outer seal to the seal housing. Now place and push the seal into the housing by hand (Fig.5)Press seal as far as possible_by hand and then by using any smooth round part on the top fac of the seal. Ensure the seal is fully seated around its complete periphery. The same can now be applied to the inner seal (Fig.6). Before refitting the seal/piston assembly back into the load-cell, smear the sealing edges with _.che hydraulic oil or light grease to ease piston assembly . Place the load-cell body on flat clean surface with the hydraulic chamber facing upwards. Assemble the piston back into the load-cell (Fig.7); making sure that the piston is not tilted during assemblyFinally refit the quick connect couplings. {F required, seal guides may be used to guide the seal/piston into the load-cell (Fig.8)A puller can be used if required for even pressing of piston into cylinder.BOLT TENSIONERS. INSIRI 1 |, Load Get cylinder ot PST -xx-01 ~ Piston o1 PST-xx-02 3 Seal Kit 01 set PST -xx-03 “3a Seal P Inner ot PST -xx-03-1 *3b ‘Seal P Outer ot PST-xx-03-2 4 Dowty Washer (200 Mpa) - | Dw- 06-200 5 Fitting 02 HF -G4-GH 6 Coupler (Male Nipple) 02 HCS - 150-M | 7 Grub Screw 04 Ws-M4-4 8 ‘Threaded Puller ot PAsocyyyy 9 Bridge ot BAooc yyyy 10 | Nut Rotating Socket ot NDS -yyyy eat Kit for Load-cell model PST- 05 ‘Seal Kit, tem: PST <= 05-03" * = Sub Assembly x-Loadeell No. y. Studbolt SizeBOLT TENSIONERS INSTRUCTION MANUAL PST SERIES TOP SIDE TENSIONERS| Nuova Sine High Technolgy Maintenance WARRANTY CERTIFICATE This Is to. certify that the Bolt-Tensioners supplied. against the FINAL INSPECTION AND TEST REPORT have been inspected and four to be correct in all aspects. These _ Bolt Tensioners are warrantied for 12 months roin the date of shipment against defective ed to replacement, ‘without charge of parts found to be jams for labour expense of other loss or damage ‘occasioned. by such defect of material or work ihotized back charges will be acoepted. This warranty does not cover deterioration by corrosion, erosion, or any cause of failure other than defect of material or _workmanship, This waranty daes not cover loss or damage in transit or any other factor beyond our control,Certificate of Compliance Tp ix to Certify that the praduct Boit Tensioner PST 0F to P 12 Manuftiotured by Powermaster Engineers Pvt. Lid. 229, Pragati Industriel Estate, 316, N, M,.Joshi Marg, Chinchpokli, Mumbai-400 O11 India. has been independently assessed and is.comptiant with the requirements of 2006/42/EC Machinery Directive EN 1005-1 : 2001, EN 415-1:2000, BN 563-1994, EN 1037:1995, EN 1050:1996, EN 1299:1997, EN ES 11204: 1995 97/23/EC Pressure Directive EN 983:1996, BN 982:1996 Cortieauitie 2ahie- cis Date oF initial registration < DaRebradey 2070 ‘Duite-ok this vertiGeate 24 February 2010 RDITY (eiecntieneey 23 Janwaty:, 2013, Betti Aare aad ety or] Director LINEAR MANAGEMENT SOLUTIONS & GRRE TCIXtiONS pvr. LID. 253, Lokhnaj Gold, Miansbi Puliva, india Nagar, Lucknow-22601 6, (LP), INDIA ‘e-mail: info@lmscert com, werw,hmscert.comPRESSURE TO LOAD CHART Max Working Prossure. : 1500 Bar. MODEL. : PST-04 +800 — ssa} ‘aah sg 1300 cr ‘69 san} Hyd. Area =7.48 In sa. NUOVA SIMAT [Pressure in Bar LeNUOVA SIMAT Ropar T ie aE fee ot Tesionr Me a oo rm aa loa ne fa PNes [pris ait as z DIMENSIONAL REFORT a naval kena Se a — | — ons aor a [gino a0 ta Bz tat BE Chin Canes m0 oi a3 os a inner o0 tea Ta arom Ti Te (Gini Bae 7 a8 Bar 8 8 etn iar ss rete asi oo 501007 ots ae 78 708 77 7 76 ate 0 a s a a casa 3b = a % 56 (oR Pag re ae age oe Pettis ‘ao oe oR OE oe nas ytnde Mounting Deis fap o« ox ox ox TOAD TEST REPORT a Ge er Sosa [Saar tetonnetant |g 7008 Sra option no xe age jing teen Faltoad | 9 30 Snont opertn ne eveal eaage CALIBRATION ai oo cas Na ae aT ei Tas Tass Ta Tass Tat Ta | i [gang] mesa [ain | ta Tent | FT ies ie 768 8 ‘sano | ar ca ca 7 ‘sr Har} of at iat at iat iia oF or om ca PRESSURE VIS LOAD ° 000 10000 +5000 20000 25000 PRESSURE IN PSI Caliation Tool: Mtatoyo Bore Dil Gage Se No 08/2122, Mitutoyo Micrometer Sr. No, 08/380, Presure Gauge Steers Se 008/008, Load Sensor Se No. 7-111 Accepted —_[f Tajeted (NI a a ey 7 Asher, Sys libero, YYNUOVA SIMAT rae sucicie pa swans ea : pienso Fiat amt Sa aoe an ra | ees a Pe eee a eee ee | eet] ae cece ee ee a a ee ee ie a sp oe 5 loncrriag Pa RE ORC/Piag ORC RE a He eae = aalatnaa te os see ei ox oD TOR aes a See ee Bee eecoecat fol Elica jo eee a wa io aes a | ee aa ee ee ae oe | wor er} ae ae % =e se eS 3 a ie 2 500 as 3 200 : 3 Peete aes renin Catiaton Teo Mitutoyo Bore Dial Gauge Se No 08/212, Mitutoyo Micomatar Se. No, 0/3800, Pressure Gang Stowarts St. no 8/008, Loud Senuor Si No.S7-101 ‘Accepted |e ejected [RE Aocubieiy VB Haspened oy VE [approvedby SKM aden, bse, Saul