M/V Liteyny Prospect

Instructions for hydraulic fitted bolts

Documents:

Instructions:
1. Initial instructions and safety.
2. Obtain metallic flange contact.
3. Sleeve Expansion.
4. Bolt tensioning.
5. Nut release.
6. Sleeve release.
7. Checkup procedure.
8. Drawings.
 1. Initial instructions and safety:

When using the hydraulic pump, always wear eye protection.

Inspect all bolt and sleeve for damage before using it.

Make sure that the hydraulic nut is bled of air before the first operation and that the
piston is in its bottom position before each operation.

When releasing the sleeve is expanded by oil injection, the nuts must not be removed.

Use all equipment strictly in accordance with the instructions.

The holes and flange faces must be cleaned and wiped dry before fitting.

Use only pump with a maximal pressure of 1500 [bar].

Use anti-seize compound when assembling nuts and bolts.

Hydraulic bolts and sleeve, prior assembling to be slightly lubricated with oil on the cone parts.
 2. Obtain metallic flange contact:

Hydraulic bolts and sleeve, prior assembling to be slightly lubricated with oil on the cone parts.

Insert all sleeves and two bolts into diametrically opposed holes.

Mount the nuts on both sides and tighten it against the flange by hand.

Mount the hydraulic tensioner over the bolt at the long thread end and screw on tensioning nut.

Mount a dial indicator on one flange and dial on the opposing flange.

Pressurize the hydraulic tensioner until proper metallic contact between flanges is obtained.

Tighten nut with torque-bar through gap in bridge.

 3. Sleeve Expansion:

Hydraulic bolts and sleeve, prior assembling to be slightly lubricated with oil on the cone parts.

Insert the bolts and sleeves into diametrically opposed holes.

Check distance from sleeve to flange: 5 [mm]

With bolt and sleeve in place, Fit the disc for pull-up and the hydraulic bolt tensioner over the long
thread end.

Mount the tensioning nut and tighten so the disc has proper metallic contact with the flange and the
sleeve.

Pressurize the hydraulic tensioner and use a dial-indicator to measure correct pull-up distance:
Min. 2,62 [mm]
Max. 3,15[mm]

When correct pull-up is achieved release pressure on hydraulic tensioner.

Remove the nut, hydraulic tensioner and disc.

Check pull-up measurement again with depth-gauge.

 4. Bolt tensioning:

Mount the nuts on both sides and tighten it against the flange by hand.

Mount the hydraulic tensioner over the bolt at the long thread end.

Screw on the nut for the hydraulic tensioner.

Pressurize the hydraulic tensioner the specified tensioning pressure. 1311 [bar]

Tighten nut with torque-bar through gap in bridge.

Release pressure on hydraulic tensioner and repeat last 2 operations.

Release pressure on hydraulic tensioner and remove tools.

 5. Nut release:

Mount the hydraulic tensioner over the bolt at the long thread end.

Screw on the nut for the hydraulic tensioner.

Pressurize the hydraulic tensioner the specified tensioning pressure: 1311 [bar]

Loosen nut with torque-bar through gap in bridge.

Release pressure on hydraulic tensioner and remove tools.

6. Sleeve release:

Loosen the nut at the long thread end to a gap of 8 [mm] between the nut and the flange.

Remove the nut on the opposed side.

Screw on the nipple at the long thread end and the hydraulic nut.

Pressurize the connection with grease and pressurize the hydraulic nut

release pressure as soon as the sleeve is loose and remove tools, nuts and bolt with sleeve.
 7. Checkup procedure:

fter first sea trials, and of operation check tightness on all nuts.

Mount the hydraulic tensioner over the bolt at the long thread end.

Screw on the nut for the hydraulic tensioner.

Pressurize first the hydraulic tensioner to ½ the specified tensioning pressure: 655,5 [bar].

Check the tightness on the nut.

If nut is tight pressurize the hydraulic tensioner to ¾ the specified tensioning pressure: 983,25

[bar].

Check the tightness on the nut.

If nut is tight pressurize the hydraulic tensioner to the specified tensioning pressure: 1311 [bar].

If loose nut is observed at specified tensioning pressure 1311 [bar], tightening the nut and release
pressure on hydraulic tensioner and remove tools.

If loose nut is observed at ½ or ¾ the specified tensioning pressure, then loosen and remove nuts,
bolt and sleeve in the particular connection, clean and apply new anti-seize compound then
proceed with the fitting procedure from top.

Repeat checkup procedure on all connections.