Archive for the ‘BOLT TENSIONERS’ Category
The stud tensioning is easy now
Posted on: January 23, 2018
In the modern industry the main load of production is on machines only, and hence the operator needs to keep the machine in perfect condition. However, due to regular use, the normal wear and tear of the machine is much common. There are a few devices that are used to maintain the machines at regular interval. The experts have designed them over a period and offered latest designs with amazing features that these small devices can help with. They are now known as a must in the kit of every operator as without them the whole operation has to be stopped.
The device:
The bolt tensioner is a device used for fixing the bolt with right pressure and movement. The parts of many machines depend on the fixing of machine parts, and that role is played by the nuts and bolts. If manually these bolts are fixed, there are chances of leaving the same with more pressure that directly affect the movement of the machine. In case proper pressure is not there, the parts cannot offer the right effect which is expected. Hence the performance of the same can be directly affected.
The stud tensioner is also the device that can fix the stud as expected. It is a simple yet effective device that can offer accurate tension to the stud and fix the same in a way that can help to have the right fixing of the same. The device is provided by a number of makers in the market with best of the quality and latest features that can help the user to have the task done in a few minutes only. One can check a number of brands that offer the device in the market. The price of the same differs as per the brand and features of the device.
The purchase:
For the buyer who wants to buy this device, the offline and online market are two options for shopping. The buyer if does not have enough time to go to the market and check the device, can check the same in the online stores with the help of a computer or a smartphone. The images provided on the site can help the buyer get the idea, and the rest is done by the provided description. Hence one can see if the same device is matching his requirement or not and place an order accordingly.
In the offline market, the buyer needs to go personally and see if the required device is there with the seller or not. One cannot get a huge variety in the local market and hence choose one product from the available options only. Here the best part is one can directly deal with the seller, and after making the payment, delivery of the device is provided at the same moment. Hence the user who needs the device immediately can go for this option and buy the device. The payment can also be made here in cash and hence for a common man it is the best option.
The role of the machine in the life of a human cannot be narrated in words as during a lifetime there are thousands of machines that prove much helpful to an individual. They are in different sizes, shapes, and material but they can do some wonderful jobs that cannot be done by the human beings, and even if they are done with the human efforts, they are not of the same quality. There are many jobs which can be done with the help of a machine only, and despite all the efforts, it is not possible by the human efforts in any case.
The case of bolt tensioner pump is also the same where the individual efforts have limits, and only a device can perform the expected role. The size or type of the device does not matter when it comes to the performance of such devices. It helps one to complete the task faster and that too with expected quality of the same. There are numerous makers who follow the best standards of the industry to satisfy it with their quality devices. This pump helps the operator to tighten the bolt in a little time which is otherwise known as much time-consuming process and hence for every operator it is a much useful device as it can help to finish the task within a stipulated time as per the provided schedule.
The device:
It is a mechanical device that eases offering the tension to the bolt. There are many devices where to fix the bolt is a challenging task, and this device can help the operator to finish the task faster. It has a hydraulic cylinder in which there is a puller fixed which provide the tension on the bolt. As the pressure increases the nut with zero torque fixes the bolt easily. The device is small in size which one can easily carry to any location as in a large industry one may require it for any machine to tighten the bolt. It is easy to carry and move. Hence a novice can also operate the pump without any great skill.
The easiest way to get the quality device:
The most common option to get such device is an offline or traditional market. Nowadays there are many cities and towns where such quality devices are easily available. The producers also have set their network in a way that their products reach to almost every destination. The buyer can inquire to the local vendor about the availability of the devices, and if the seller has it, he can check the same. There are many producers who produce such devices, and hence the buyer can check various devices under one roof only. If the concerned product is available, he can check the specification and buy it if specification matches to his requirement. In case one does not get a quality device in the conventional market, the next best option is to check the same with the online stores as there is hardly any such device which is not available in these stores.
In industry, there are a number of things which are important. Machines, manpower and marketing are obviously primary areas where one needs to focus, but the supporting tools to the machine are also of great importance. These tools are tiny in size, but when it comes to the performance, they can surely help the operator to make necessary changes easily. The same rule applies to various devices also that help, the power to flow without interruption and with complete safety.
For a smooth flow of machine, one needs to thank the maker of power sockets with the help of which one can rely on the flow of machine and plan the day, month and year also. These sockets are designed in a way that the concerned end of the same is pressed to the other end of the same level and hence the desired force can be executed which helps to move the nut.
The socket: This socket is made of high-quality metal, and there are proper spaces given where one can attach the mover. The quality alloy is an important factor for the exact performance of the socket as the socket made of the low-quality alloy can have the corners bruised, which can harm the socket and over a period makes it completely useless. There are many manufacturers in the market who produce these sockets. One can see the difference of prices among these all sockets of the same size. The prime reason behind the variation of prices is the quality of the socket only. These sockets are available in different sizes and hence for an operator to open a different part of machines at the time of maintenance is also made easy. The socket must fix on the nut or bolt perfectly and then only it can be given a torque to move the nut or bolt. A loose fixing can be harmful to the operator as well as the device. Hence, one has to be a little careful while using this tool in the field.
The advantage of power sockets: there are numerous benefits of this socket.
- It helps to open the jammed nuts easily, and hence the energy and efforts of the user can be saved.
- It can open any nut which means the nut can be reused, which leads to saving of a good amount of maintenance.
- With the help of this socket, the user can move the nut faster which saves his time.
- It is not a much costly device and there is no particular training required to use this device.
- It is just like a plug and play device; hence a novice can also help to open the machine which can lead him to better
Overall, one can say that this device is much useful for the operators as well as engineers who need to move into the field for the maintenance as well as repairing of different devices. It is also compact, so one does not need to carry heavy bags also.
Almost all modern machines, boiler, chillers, and other equipment make use of nuts and bolts. The preferred method of loosening and tightening these bolts and fasteners is through bolt tensioning.
Use of pumps
You can operate bolt tensioners for a wide range of applications such as pressure vessels, heat exchangers, windmills, pipeline flanges, boiler feed pumps, and compressor covers. Good bolt tensioner equipment will offer a host of advantages over traditional nut tightening methods such as:
- The safety and stability of the structure is preserved due to direct loading.
- The fasteners do not experience torsional loads.
- Can be repeated endless times.
- Very accurate reading.
- The operation is fast.
- Automation is possible due to the ease of operation.
- This helps in critical situations.
One may use air powered bolt tensioner pumps when the flow of oil needed is high. This is often the case when the pipe runs under the sea. Or, you may find the similar situation when one uses tensioners of high capacity.
Different varieties of pumps
You can have different kinds of pumps. The choice depends on the applicability and the range of the operation. Choose from the wide range on offer, each suitable for one specific need or situation.
Electric pumps
They are lightweight and portable. They are rubber shod to prevent shock and improve stability. The motor, reservoir, and pump combine beautifully into a neat package. This makes the handling easy. Maximum use is in the wind mill industry.
Hydraulic air driven packs
These are easy to use and utilize hydraulic power. You can have output pressures up to 2500 bar. You can have a stroke counter included but that is optional. Choose from various designs and frames but most of the people choose the stainless steel body. The hoses and tubes can be colour matched.
Hand pumps
These operate in the 700 bar to 2500 bar range. It can operate both low and high pressure pistons. You can read the pressure from the internal pressure gauge. The pressure release valve helps maintain the pressure at the optimum level. The connect coupling is quick and self-sealing.
Rapid retract pumps
When we use a hydraulic bolt tensioner pump, we use the rapid retract pump model. This helps to ease the hard work out off the retreating piston stroke. This makes the easy piston retraction pump very useful.
The advantages in this are that first we do not have to supply energy to maintain hydraulic pressure. You do not require any electrical power, and so, there is no need for plugs and sockets. The model has good safety, is lightweight, and compact in design.
Further, it resists contamination. You can use it for full load stop/start operations. Stall pressure at the outlet is shown by the regulator of the air drive.
Onsite bolt tensioning needs have to be fully met when you make the choice of a pump. Make sure you choose one that has low maintenance needs. Invest in a durable model that will last for a long time.
You don’t always get a tailor made nut or bolt for your applications. Often, you may have to stretch them axially. This task is accomplished by using the bolt tensioner. Here, high pressure hydraulic oil is used to apply the pressure onto the targeted nut. Check out the instructions for safe handling of this equipment.
Prevent personal injuries:
- Trained personnel should operate the device. Before operating the device, one has to know the in and out of the device perfectly. The instruction manuals can guide you better in this context.
- In general, the bolt tensioning equipment is manufactured to work in normal environments. You have to make wise decisions when you choose to employ it in explosive, corrosive or flammable working conditions.
- The operator should wear safety glasses all the time while dealing with the tensioner. Stay protected by making use of other protective equipment like hearing protection, shoe, hat, apron, gloves and face shield.
Pump:
- The power input of the entire device is the bolt tensioner pump. Each pump is manufactured to work in a specified range of working pressure. Never attempt to exceed its maximum rated pressure. In such a case, apart from damaging the equipment, it can result in serious injuries to the operator.
- Never let the pump to get over filled. It can result in excess reservoir pressure, which is highly undesirable. To prevent it, retract the system before injecting the fluid into the pump.
Electric motor:
- Before employing the motor, make sure that it is tested by qualified electrician satisfactorily.
- When setting out to perform maintenance activities of motor, make sure to depressurize the pump before disconnecting it from motor.
- Check out the rated current and voltage of the motor and give the power inputs accordingly.
- Often, the voltage inputs of the motor have to be manipulated to meet the working requirements. Consult the manufacture before rewiring the motor.
- Replace an existing fuse with higher value fuse can result in a net increase of the output power of the motor. However, such unorthodox procedures can result in over heating of the device.
- Provide sufficient protection from corrosion and other harsh environmental conditions to the equipment.
Hose:
- Before operating the pump, use appropriate tools to tighten the hose connections. Over tightening or under tightening is highly undesirable. The first case can increase the stress at that point and the second results in net pressure drop of the system.
- Regular inspect the hoses regular for damages. Replace the burst hoses with new ones. Attempting to hold a leaking hose is a very bad idea. Depressurize the system before doing so.
- The working fluid need not necessarily be water all the time. There are certain applications which call for other fluids. In such a case. Make sure that the hose material is compatible with that fluid. Else, it can either get corroded or fail to handle the high pressure of it.
The bolt tensioner is a high pressure hydraulic tool. The above tips can greatly contribute to achieve a safe working experience. It is to be remembered that these devices are designed to be worked specifically on bolts and studs. Avoid other unintended applications.
The bolt tensioning is a process of applying axial force onto the bolts in order to stretch them in that direction. This process is capable of eliminating the errors, which are caused by the friction. Typical applications of this process include pipeline flanges, pressure vessels, wind turbines, catalyst reactors, diesel engines, heat exchangers, shaft couplings and many others. The benefits of this process include: achieving accurate and repeatable stud loading, time and labor efficient process and increased stud life. Check out the procedure for bolt tensioning here below:
Procedure:
• From the top of the joint nuts, a stud should protrude out, whose length should be equal to one times that of its diameter.
• The tommy bar is coupled with the tensioning equipment. Make complete use of it by tightening every bolt on the flange. Pull the two halves of the joint firmly.
• The bridge has to be assembled over every alternative bolt. It has to be so positioned that, we can have an easy access to all the nuts with ease.
• Inspect the base of the bridge. If you don’t find it sitting flat against the tensioning surface, employ set squares to correct it.
• Now, assemble the load cells, so that it provides access to every alternative bolt, which has to be tensioned.
• Make use of tommy bars to assemble the stud pullers in bolt tensioners. This can be possible only when the threads of the bolts and stud pullers have the same thread characteristics.
• Uncover all the plastic protection caps from the quick connect couplings. Establish a secure connection between the bolt tensioner pumps and the tools using hoses as links.
• After connecting all the tensioners to the link hoses, a plug port is made available for the last tesioner. An air driven pump should be connected to the load cell.
• Apply the predetermined pressure on the system using the pump unit. Higher pressure levels can lead to damage of the bolts.
• Check the pump to ensure that the pressure level is stable. Try rotating the hexagonal nuts by using the tommy bar.
• Using the valves on the pump, transfer the loads from the tensioners to the nuts. Bring the piston back to its completely closed position.
• Disconnect the assembly of the hydraulic links and pumps. Reposition the setup onto the final 50% of the bolts and carry out the same procedure.
This process is a safe and easy, when you take all the necessary precaution steps. When you move out to purchase the tools for this purpose, make sure that they work well with the pump. Never ever exceed the specified pressure limit. Leaks in the flexible hoses can lead to serious injuries. Ensure to check the hoses before pressurizing. Get to know about the required piston stroke for the application and carry out the procedure accordingly. Employ only the specified hydraulic oil to pressurize the system. When you move out to purchase the pump, make sure that it can meet your specified requirements.
Bolting Tools- Providing Better Quality and Safety to Industrial Operations
Posted on: November 16, 2015
The industries, nowadays, face a very high level of competition in the markets. Every industry struggles to have a huge client base with satisfied clients. For this, they need to provide the best quality of goods to the customers and that also in right quantity. When there is a need to produce products in such great quantities and that also with great quality, it is essential to use the best tools and technologies available in the market. The industrial tools are very important for better productivity of the workers as well as the industries. The industrial tools are also essential to produce the best quality of products as well. It is almost impossible to produce best quality products without the use of appropriate tools and equipments.
Bolting tools are among the most important tools that are used in industries. They are mainly used for the movement of fasteners such as studs, bolts and nuts. The bolting tools are important for industries because they are responsible for maintaining the best quality of the products as well as best level of safety in the industries. There are many different bolting tools that are used widely in industries that are discussed below.
Open end Wrenches
Also termed as spanners, the open end wrenches are widely used in industries for performing bolting operations where there is very less need of speed, power or accuracy. These wrenches are manually operated and have two openings at both ends with different sizes. This implies that a single wrench can be used on two different sized fasteners. These ends are inclined a slight angle from the operating shaft, which makes it easy to operate them in tricky places.
Impact Wrenches
Impact wrenches are mainly used for very high speed and high power bolting operations. They are most commonly used in automobile industries, industrial machine manufacturing and so forth. The impact wrenches are used along with specially designed impact sockets that are designed to bear the heavy impact exerted on them while operating.
Torque wrenches
The torque wrenches used for operation that demand high speed and power along with great accuracy. The torque wrenches are provided with an arrangement that helps in monitoring the amount of load applied on the fastener. Additionally, the torque wrenches are also very quite while operation as compared to impact wrenches.
Bolt Tensioner pumps
The bolt tensioned pumps are basically used on the bolts that are applied on a place where there is a lot of vibration. The bolt tensioner pumps are mainly used to give a tension in the bolts and fasteners so that they are not loosened due to any external force or vibration. They are best pneumatically operated and best for the safety of the bolts and fasteners.
Along with these, there are also many other bolting tools used in industries such as pipe wrenches, box wrenches, nut splitters and so forth that make bolting operations in industries efficient and safe.
Produce Best Products and Maintain Best Safety with Efficient Bolting Tools
Posted on: October 23, 2015
In a time when there is a very high competition between industries, it is essential for the industries to employ best production practices that could help them in producing the best quality products. If a company is not providing the best quality of products to the customers, then there is very less possibility of their survival in the market for a long time. This is the reason why most of the industries put a great emphasis on the accurate and perfect execution of every process in their plants. The industrial tools are the best weapon that can help the industries in winning the war of quality. There are many different industrial tools that are used in the industries. The bolting tools are one of the most important tools as they are used for performing the bolting operation that is not only crucial for quality of products but also essential for safety of people working in the industry. Here are some bolting tools that are used widely in industries.
Open End Wrenches
The open end wrenches, as the name suggests, have two openings at two ends for holding the fastener head. Both the openings have different sizes hence a single wrench can be used for two different sized fasteners. The openings are inclined at a slight angle from the shaft, which helps in operating the wrench with ease. The open end wrench is manually operated and hence is used for the operations where there is need for very small force and speed.
Impact Wrenches
The impact wrenches are used in the operations where there is a need for very high amount of speed and force. In that case, the impact wrenches are best for use. The impact wrenches use a very high impact on the fasteners, which is applied on them with jerk or strokes. This gives movement to the fasteners. The impact wrenches are very noisy; hence they are not ideal for an operation where quiet process is required. Additionally, the impact wrenches are used along with power sockets or impact sockets that are specially designed to work with impact wrenches. These sockets can bear the impact forces exerted on them regularly. The normal sockets can easily deform or shatter when used with impact wrenches. The impact wrenches offer high speed and force but are not very accurate.
Torque wrenches
The torque wrenches are sued for the operation where high level of accuracy is required along with high speed and force. The torque wrenches can be used for quite operations too. They are provided with a force measuring device that can help in preventing over tightening of the fasteners.
Along with these bolting tools, there is also another tool used that is bolt tensioner pumps. These pumps are mainly used to give tensions to the bolts so that they do not move or loosen during operation. In this way, they maintain best safety at workplace. With these bolting tools, industries can provide the best quality of products to the customers as well as maintain safe working environments at workplace.
Using fasteners is one of the most reliable ways of joining two or more materials. Internal threaded fasteners are forced onto the external threaded fasteners in this process. There are good chances of the bolt which is externally threaded to elongate or stretch in this process. Prior extension of the bolts can reduce the pressure on them and helps in a secure connection. This can be achieved by employing bolt tensioners. They are efficient, time saving and most importantly, they can be operated with ease. They are power driven by the bolt tensioner pumps which are attached to the tools.
Applications:
Major applications of bolt tensioner pumps are specified below:
- They are widely applied in tensioning of flanges of boiler feed pumps, pressure pumps.
- Employed in power plant equipment like heat exchangers, compressor covers etc.
- Construction industries and petroleum industries make use of these devices.
- They are used in gas, steam and wind turbines.
- Automotives use them extensively in manufacturing and servicing units.
How Do They Work..?
The bolt tensioners are intended to apply force on the bolts axially in an accurate manner. This can reduce the friction between the nuts and bolts to a significant level. This, in turn, leads to reduction of wear and tear of the bolts and increases their lifetime. The operation processed by this device doesn’t result in torsion force. Major steps involved in the operation of these devices are as follows:
- Place the nut driver over the nut. Make sure that it is positioned perfectly.
- Place the bridge and load cell on top of the bolt.
- Predetermined pressure is applied on the bolt using a hydraulic system in order to stretch the bolt axially.
- The nut is turned down and tightened by using nut driver and tommy bar.
- The pressure is relieved from the setup.
Desirable Features:
Check out for the following features while purchasing these devices:
- Least energy has to be consumed by the device.
- The operation has to be safe and explosion proof.
- Lighter weight and compact device can facilitate in easy operation.
- The materials employed must be corrosion resistant and should tolerate the contamination.
- The working pressure has to be adjustable to accommodate different working conditions.
- The installation should be done with ease and in quick time.
- The connection and disconnection of the couplings and hoses must be done with ease.
- Set up shouldn’t call for higher maintenance levels and the expenses incurred in its maintenance should be low.
Safety Instructions:
- Never exceed the maximum working pressure, which is stipulated by the manufacturer.
- The maximum stroke of the tools shouldn’t be exceeded intentionally.
- The vicinity of the work area should be clean.
- The pump must be positioned at a safe distance from the tool.
- Improper handling of tools can lead to accidents.
- Never use flexible hoses to carry or hold bolt tensioning tools.
- Never touch hydraulic hoses in pressurized state. It can lead to injuries.
Application of improper tension on the bolt results in the damage of the thread profile or in imperfect joint. To accomplish this task, bolt tensioners are used. A pump supplies the required energy to the device. Determine the required pressure as per the application and apply the same after activating the pump. The tightening of bolts can be done accurately and quickly. These devices have a very high ratio of power to weight and are easy to handle. When it comes to safety, there is no better way to use other than bolt tensioners.
Applications:
The applications of bolt tensioners are truly versatile. They are widely used in the following sectors:
- Turbines, specifically, wind and gas turbines.
- Pipeline flanges and valves
- Pressure valves
- Hydraulic pressures
- Industrial pumps
- They are also used in power plant equipment like heat exchangers, condensers and boilers
Desirable Features of Bolt Tensioner Pump:
- The pump has to be operated over a wide range of voltages.
- Under any extreme working temperatures and pressures, the pump has to function effectively.
- It is advisable to choose the one which has a pressure and return filter with indicator.
- The operating pressure has to be adjustable. A pressure regulation valve is used for this purpose.
Pumps:
Based on the input power, the motors are classified as follows:
- Air powered: In these devices, energy is not consumed while holding hydraulic pressure. In general, their design is compact and lighter in weight. Installation and operation of this pump is easier. It is recommended to use only specified oils for lubrication.
- Manually powered: the handle stroke generated is comparatively much lower than other systems. Prefer the pumps which have a lighter weight for easy handling. A compact pressure gauge helps you to select the desired working pressure.
- Electric pump: These pumps are usually preferred in applications which require high pressures. As high as 1600 bar pressure can be generated by employing these pumps. We can obtain these pumps with a remote controller, which aids in easy operation.
Specifications:
The specifications help you to choose the best one for the application. The general specifications of the pump are listed below:
- Maximum working pressure
- Motor power
- Voltage
- Frequency
- Maximum flow rate
- Dimensions
Safety Precautions:
- Do not exceed rated hydraulic pressure. High pressure can often result in injuries.
- Overfilling of the fluid can result in a significant increase of operating pressure.
- In case of maintenance or repairing, make sure to disconnect the pump from the power supply to reduce pressure.
- Ensure tight and leak proof hose joints before operating. Over tightening is not preferred as it results in damage of thread profile.
- It is advisable to avoid underground power supply.
- The operator must be equipped with all the safety devices while operating.
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