TENSA Equipment Pty Ltd

www.tensaequipment.com.au
Tel +61 8 9488 4500
ACN 136 952 648

TENSA Equipment Pty Ltd

CONDUCTOR GRIPPER CLAMP (GC SERIES)

OPERATING MANUAL

Document Number: 001-MM-0100-0001

File Location: 001-MM-0100-0001 - GC Series Operating Manual Rev 6 (with Hydratight
Bolt Tensioner)

6 2/10/20 Section 2.2 –GC20 alternative X56 options added. CHP MAD CHP
Section 2.2 – GC958 and GC20 alternative
5 6/2/19 CHP MAD CHP
options added.
4 10/4/18 GC24 detail added CHP MAD CHP
Manual with Hydratight Bolt tensioner – GC1338B
3 9/10/15 CHP MAD CHP
clamp included
2 5/15/2013 Manual Revised for Tentec Bolt tensioner CHP MAD CHP
1 14/02/2011 GCS2030 detail added CHP DGM DGM
0 14/7/2010 Issued for use CHP DGM DGM
Rev Date Description By Chkd App
TENSA CONDUCTOR GRIPPER CLAMP (GC SERIES)

OPERATING MANUAL

CONTENTS

1 INTRODUCTION ................................................................................................................................... 3

2 DESCRIPTION AND OPERATION ...................................................................................................... 3

2.1 Component and Assembly ................................................................................................................ 3
2.2 Gripper Clamp Installation Parameters ............................................................................................. 5

3 TENSA HYDRAULIC BOLT TENSIONER UNIT.................................................................................. 6

3.1 General Operation ............................................................................................................................. 6
3.2 Hydraulic Pump ................................................................................................................................. 6
3.3 TENSA Bolt Tensioner Unit ............................................................................................................... 6

4 INSTALLATION AND REMOVAL PROCEDURE ................................................................................ 8

4.1 Gripper Clamp Installation ................................................................................................................. 8
4.2 Gripper Clamp Removal from the Conductor .................................................................................... 9

5 FAULT FINDING CHART ................................................................................................................... 10

6 MAINTENACE .................................................................................................................................... 11
6.1 Post-use Maintenance .................................................................................................................... 11
6.2 FULL Maintenance/ servicing.......................................................................................................... 12

7 SAFETY NOTE ................................................................................................................................... 12

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TENSA CONDUCTOR GRIPPER CLAMP (GC SERIES)

OPERATING MANUAL

1 INTRODUCTION

The TENSA Gripper type conductor clamps (GC series) are designed to support the jackup rig drilling
conductor on the TENSA conductor tensioning system. This Gripper clamps are also designed to suit other
conductor tensioning system in the market.

The clamps are made in all sizes from 9 5/8” to 36”. Standard sizes are 13 3/8”, 20”, 30” and 36”.

The clamps grip due to the tension applied by the clamp bolt. The bolt is accurately tensioned using an
hydraulic bolt tensioner included in the kit. The clamps are based on a proven design and have been
rigorously designed and analysed to ensure that they do not compromise the strength of the conductor whilst
offering a significant factor of safety against slippage.

Figure 1 – TENSA GRIPPER Clamp (GC Series)

2 DESCRIPTION AND OPERATION

2.1 Component and Assembly

The Gripper Clamp is assembled from separate components with associated fasteners and lifting eyes. These
are shown in Figure 2.
The clamp is stamped to identify the serial number. All the Tensa Gripper Clamps are designed symmetrically
such that they can carry the same load in either direction and can therefore be used with either side upwards.

Figure 2 – Gripper Clamp Assembly

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Figure 3 – TENSA Bolt Tensioning System Components

ITEM
NO. PART NUMBER DESCRIPTION QTY
1 001-0100-002-01 CLAMP BODY 2
2 001-0100-002-02 GRIPPER RING 2
3 001-0100-002-03 2" STUDBOLT – Grade 10.9 2
4 001-0100-002-04 2" NUT 4
5 001-0100-002-05 3/4" EYE BOLT 4
6 001-0100-002-06 M12 SOCKET HEAD CAP SCREW 4
7 001-0100-002-07 MANUFACTURERS LABEL 2
8 001-0100-002-08 M3 BOLTS 8
9 001-0100-002-09 THREAD PROTECTOR 4
10 001-0100-002-10 1600bar Hand Pump 1
11 001-0100-002-11 Bolt Tensioner 2
12 001-0100-002-12 2” Puller Sleeve 2
13 001-0100-002-13 3m hoses 1
14 001-0100-002-14 1m hoses 1
15 001-0100-002-15 Blanking Plug 1
16 001-0100-002-16 Tommy Bar 2

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OPERATING MANUAL

2.2 Gripper Clamp Installation Parameters

TENSA Bolt Minimum Conductor Conductor

Clamp
Conductor Tensioner Wall Thickness Grade
Load
Model Diameter Clamping (minimum
Capacity Imperial Metric
[inches] Pressure requirement)
[Tonnes] [inches] [mm]
[PSI]
¾” 19.05 L80
GC36 36” 250 21,000
1” 25.4 X52/ X56
¾” 19.05 L80
GC30 30” 250 21,000
1” 25.4 X52/ X56

¾” 19.05 L80
GC24 24” 230 20,000
1” 25.4 X52 / X56

¾” 19.05 L80
GC22 22” 230 18,000
1” 25.4 X52 / X56

¾” 19.05 L80
GC20 20” 230 18,000
1” 25.4 X52 / X56

GC20 20” 150 15,000 0.635” 16.13 X56

[NOTE 2]

GC20 20” 100 10,000 0.438” 11.13 X56

[NOTE 2]

¾” 19.05 L80
GCS2030 20” 230 18,000
[NOTE 1]
1” 25.4 X52 / X56

GC1338 13 3/8” 150 15,000 0.48” 12.2 L80

GC1338B 13 3/8” 100 15,000 0.48” 12.2 L80

GC958 9 5/8” 120 13,000 0.472” 12mm P110

Note: Please consult Tensa Equipment if unclear or for other conductor grade and wall thickness.

Table 1 – TENSA Gripper Clamp parameters

Note:

[NOTE 1] - GCS2030 is TENSA custom design gripper clamp to suit National Oilwell Varco Tensioner with the
30” insert ring. An adaptor kit is provided to be installed on the CTU Horizontal centralizer.

[NOTE 2] – For 20” casing with thinner wall and X56 material grade, GC20 clamp load capacity and the
required bolt tensioner clamping pressure are reduced accordingly to suit this application.

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OPERATING MANUAL

3 TENSA HYDRAULIC BOLT TENSIONER UNIT

3.1 General Operation

The purpose of the TENSA Bolt Tensioning System is to apply a pre-determined load in order to grip the
clamp onto the conductor.

The TENSA Bolt Tensioners are used in conjunction with the hydraulic hand-pump. The bolt tensioner is
applied to an extended portion of stud bolt passing through a standard hexagon nut. A Puller Sleeve is then
fitted to the stud bolt protruding above the nut and screwed down until it seats against the tensioner piston.
The bolt tensioner is connected using high pressure flexible hoses, which are then connected to the hand
pump unit.

A pre-determined hydraulic pressure (refer to Table 1 for the hydraulic pressure required for each model) is
applied to the system, thus tensioning the stud bolt as the piston pushes against the puller sleeve. As the stud
bolt is tensioned, the standard hexagon nut lifts from the flange surface.
The bolt load is retained by inserting a toggle bar through the bolt tensioner bridge window, into the nut
rotating disc drilled hole and turning in a clockwise direction until the nut seats against the flange surface.

The hydraulic pressure is released and the load is retained in each bolt whilst the piston automatically retracts
ready for the next tightening operation. The bolt tensioners are then removed as bolt tightening is complete.

3.2 Hydraulic Pump

The clamp kit includes a 1600 bar manually operated hand pump complete with pump head, mounted
pressure gauge and handle/gauge protector. The unit is fitted with a filler breather and a rear drain plug (1/4”
BSP). Refer to Appendix E for detailed specification of the unit.

3.3 TENSA Bolt Tensioner Unit

The TENSA Bolt Tensioner Unit consists of the main components as described below. See figure 3 for cross
section view of the unit.

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OPERATING MANUAL

3.3.1 Bridge / Nut Rotating Disc

This unit fits over the standard hex nut and has a slot to allow access to the nut while the bolt is under tension.
This allows the nut to be tightened or loosened as required, using the rod supplied inserted into the holes in
the nut rotating disc.
3.3.2 Load Cell

The load cell produces the force required to tension the bolt via hydraulic supply from the hydraulic pump. It
acts against the flange and the puller sleeve to produce the bolt tension.

3.3.3 Puller Sleeve

The puller sleeve is threaded onto the bolt, and provides a connection between the load cell and the bolt that
enables the bolt to be stretched.

Figure 4 – TENSA Bolt Tensioner Unit

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4 INSTALLATION AND REMOVAL PROCEDURE

4.1 Gripper Clamp Installation

The following procedure shows the installation procedure for the TENSA Gripper Clamp and tensioning of the
bolts using the TENSA Bolt Tensioning System (IMPORTANT: Always read the Safety Note in Section 7
prior installation):
WARNING: Personnel must never be positioned in the line of projection i.e. along the axis of the stud/
tensioner during bolt tensioning and normal operation.

a) Inspect and ensure the grip rings (item 2) are in serviceable condition.

b) Ensure the Conductor Tensioner System in operation is locked off at half stroke and the conductor is
supported by the top drive.

c) Locate the gripper clamp around the conductor.

d) Insert the 2” studbolts (item 3) and apply liberal amounts of ANTI-SIEZE to the bolt threads.

e) Screw nuts into position. Ensure that the exposed thread length is greater than or equal to the length
of one bolt diameter and an equal amount of thread is exposed on each bolt.

f) Hand-tighten the nuts to produce an initial gap of approximately 20mm.

g) Fit bridge / nut rotating disc and load cell assembly to bolts. Ensure bridge is fully seated on flange
surface.
h) Screw puller sleeves onto bolt threads until sleeve shoulder seats on the load cell piston.
i) Connect the 3m hose between the hand pump and one of the bolt tensioner units. Connect the 1m
hose between the first and second bolt tensioner units. Fit the blanking plug to the remaining port on
the second bolt tensioner unit.

j) Bring the hand pump to the first pressure level of 5,000 PSI and use the Tommy Bar to turn both nuts
hard up against flange. Release the pressure and tighten puller sleeves back onto bolt threads until
sleeve shoulder seats on the load cell piston.

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NOTE: Ensure that hands are kept clear of the clamp to avoid pinch points. Personnel must never be
positioned in the line of projection i.e. along the axis of the stud/ tensioner in case of bolt or tensioner
component failure.

k) Repeat step (j) to have the maximum clamping pressure as defined in Table 1 (Section 2.2) for the
particular model of clamp that you are using. (e.g. GC1338 = 15000PSI, GC20 = 18000PSI/
10000PSI, GC30 = 21000PSI and GC36 = 21000PSI)
Note: it is important to increase the system pressure in stages so as to avoid over stroking the bolt
tensioner unit and releasing hydraulic fluid from the tool.
l) Depressurise system, remove and pack all equipment.

m) Install thread protectors (item 9) to both ends of the studbolts (item 3). WARNING: do not tighten the
thread protector, allow gap (half turn) between the protector and nut. Failure to comply might cause
damage and ejection of the protector due the axial load from the nut due to relaxation of studbolt.

4.2 Gripper Clamp Removal from the Conductor

The following procedure is for removal of the Conductor Clamp and de-tensioning of the bolts:

(IMPORTANT: Always read the Safety Note in Section 7 prior removal)

a) Remove thread protectors.

b) Inspect the condition of bolt threads, clean with wire brush and WD-40 as necessary.

c) Fit bridge / nut rotating disc and load cell assembly to bolts – ensure bridge is fully seated on flange
surface.
d) Screw puller sleeves onto bolt threads until hard up against nut.
IMPORTANT: Back off both puller sleeves through one full turn, ensure that knurled section of
puller sleeve is above top washer of load cell. Failure to do this will lead to the tool becoming
jammed against clamp after nut has been back turned and hydraulic pressure released.
n) Slowly increase pump pressure to the maximum clamping pressure specified defined in Table 1
(Section 2.2) for the particular model of clamp that you are using. (e.g. GC1338 = 15000PSI, GC20 =
18000PSI, GC30 = 21000PSI and GC36 = 21000PSI)
NOTE: Personnel must never be positioned in the line of projection i.e. along the axis of the stud/
tensioner.
e) Use Tommy Bars to turn both nuts back a maximum of 4 – 6 holes ONLY in the nut rotating disc.
IMPORTANT: Failure to do this will lead to the tool becoming jammed against clamp after nut
has been back turned and hydraulic pressure released.
f) Depressurise system and repeat steps d) to e) until nuts are able to be removed by hand.

g) Remove bolts from clamp and remove clamp from conductor.

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OPERATING MANUAL
5 FAULT FINDING CHART
Fault
Hoses difficult to assemble
Tensioner pistons do not stroke
(with no gauge pressure build up)
Tensioner pistons do not stroke
(with gauge pressure build up)
Maximum Pressure cannot be
achieved, even when pump is
running continuously.
Pressure reading erratic
Puller sleeve will not screw down
onto bolt/stud
Hydraulic fluid visible at
top/bottom of tensioner
Pump runs erratically/jerky after
a period of time
Hydratight Bolt Tensioner)
Possible Cause Action
Damaged coupling Replace coupling
Coupling locking collars not fully Screw back collars
screwed back
Internal pressure in load cell due
Unscrew puller sleeve
to over tightening puller sleeve
Open pump hydraulic oil return Close valve
valve
Leaking/burst hose Replace hose
Leaking coupling/seals Replace coupling/seals
Leaking tensioner seals Replace seals
Defective pump unit Check pump for oil delivery
Coupling not assembled Check couplings
Incorrect ‘harness’ assembly Check harness
Leaking couplings. Replace suspect coupling.
Leaking tensioner seals. Replace suspect seals.
Hydraulic oil return valve Fully close valve or replace.
Defective gauge Replace gauge
Oversize bolts Check bolt size
Differing thread form Check thread form
Maximum stroke achieved, Tighten nut and repeat procedure
overstroke eliminator valve
activated
Replace Seals
Leaking Tensioner Seals
Foreign matter in hydraulic oil Replace hydraulic oil
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6 MAINTENACE

6.1 Post-use Maintenance

In order to keep the equipment in good working condition it is important that at the end of each period of use,
prior being replaced into dry storage, a post-use maintenance is carried out.

6.1.1 Gripper clamp

a) Clamp body (item 1) should be cleaned down and coated (touch up) with zinc primer and paint for any
paint damage area.
b) Remove the gripper ring (item 2) from the clamp body and fully clean down and coat with zinc primer
or other rust preventer. Replaced the M12 socket head cap screws (item 6) if necessary.
c) 2” studbolt (item 6) should be cleaned down and coated with lubricant, anti-sieze or an anti-corrosion
compound (eg denso)..
d) Install thread protectors (item 9) to both ends of the studbolts (item 3).

6.1.2 Bolt Tensioner Unit

a) Tensioner parts (item 11) should be cleaned down and coated with lubrication WD40 or equivalent.
Alternatively, rinse in light oil.
b) Replace the dust caps on the quick disconnect coupling to prevent ingress of dirt.
c) If any leakage is noticed within the load cell, then a full strip down will be necessary to change the
seals.
d) If tensioners are subject to a lot of use it is advisable to fully strip them and clean and inspect all
components, at least once a year. It is recommended that repairs and servicing be carried out by
TENSA Equipment.
6.1.3 Hand Pump
a) Inspect the unit for any visible damage/ leak etc.
b) Clean the pump using a mild solvent where necessary.
c) Clean, then coat each quick disconnect coupling in a water repellent spray such as WD40 or similar,
retracting and releasing the collars several times. Ensure that collars do not seize in the retracted
position.
d) Coat all exposed/ unprotected components in a water repellent spray such as WD40 or similar.
e) Check all fluid levels and fill/ drain accordingly.

6.1.4 1m and 3m Hoses

Clean, then coat each quick disconnect coupling in a water repellent spray such as WD40 or similar, retracting
and releasing the collors several times. Ensuring that collars do not seize in the retracted position.

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6.2 FULL Maintenance/ servicing

It is recommended that repairs and servicing be carried out by TENSA Equipment at intervals of at least once
a year. All parts will be thoroughly inspected, specified parts will be non-destructively tested using MPI
techniques and replaced where necessary, certain components (e.g. seal) will be replaced automatically.

Bolt Tensioners will be re-assembled, pressure tested and a test certificate issued.

NOTE: All parts are manufactured, inspected and tested in accordance with TENSA’s stringent requirements.
Any parts failing in use that are found upon inspection not to be Tensa’s genuine spare parts will invalidate
any operative warranty or guarantee.

7 SAFETY NOTE

a) Always ensure that a minimum length of thread to one bolt diameter is protruding above the nut to be
tightened.

b) Do not, under any circumstances, exceed the maximum working pressure of 21750psi (1500bar).

c) Ensure that the hoses are free of obstructions and do not cross such that upon pressurisation,
detrimental loads will be induced on the connectors and adaptors potentially leading to failure.

d) Never pressurise an uncoupled quick-disconnect coupling.

e) Never operate the tensioner without the puller sleeve fitted.

f) Quick-disconnect couplings are susceptible to knocks and damage. Therefore take care when
handling the equipment. A damaged coupling may prove very difficult to connect.

g) Never attempt to disconnect or re-tighten any part of the hydraulic system while at pressure.

h) Keep personnel clear while operating and pressuring the system. Ideally, barricade the area and only
allow relevant personnel to enter when necessary.

i) Personnel must never be positioned in the line of projection i.e. along the axis of the stud/ tensioner
during bolt tensioning and normal operation.

j) Ensuring that hands are kept clear of the clamp to avoid pinch points.

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k) Only use pumps and hoses supplied by TENSA Equipment. These have adequate factors of safety
etc.
l) Ensure that the strengths of the fasteners are known and that the recommended tensioning gross
loads are to be used only (see Table 1).
m) Suitable protective overalls, eye protection, head wear, gloves and foot wear must be worn at all
times when using TENSA equipment.
n) When installing thread protectors to both ends of the studbolts, do not tighten the thread protector,
allow gap (half turn) between the protector and nut. Failure to comply might cause damage and
ejection of the protector due the axial load from the nut.

o) Only use genuine TENSA parts.

p) If any equipment abuse is evident, the warranty will be invalidated and TENSA will not be made
responsible for any injury due to misuse or failure to comply with the above safety notes.
q) READ THE OPERATING PROCEDURE.

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