STARTING AN INDUSTRIAL REVOLUTION IN BOLTING

Transcription

1 WASHER SYSTEM STARTING AN INDUSTRIAL REVOLUTION IN BOLTING

2 NO MATTER IF YOU ARE A: Safety Manager Engineer Productivity Manage Plant Manager Bolting Contractor Asset Owner Procedure Manager Reliability Manager Purchaser FIND OUT THE BENEFITS FOR YOU. JUST IMPLEMENT IT IN YOUR BOLTING PROCEDURE. TESTED, RECOMMENDED AND MILLIONS INSTALLED OVER THE LAST 10 YEARS!

3 THE BOLTING REVOLUTION In the bolting industry there are several methods for tightening and loosening bolted connections. Since 1968 HYTORC has been active on a global scale in finding solutions and developing tools for these industrial bolted connections. HYTORC has introduced ground-breaking innovative solutions to make the bolting process safer, more accurate and faster. In 2014 HYTORC introduced the latest development in bolting technology: the HYTORC WASHER SYTEM. The system characterises itself by a smartly designed throughly hardened reaction and back-up washer which replaces commonly used throughly hardened washers. Sizes ranging from M16 M150. The HYTORC WASHER SYSTEM eliminates several commonly accepted dangers and reduces costs significantly. TIMELINE OF DEVELOPMENT UNTIL 1968 STANDARD BOLTING METHOD VANAF 1969 TOOL MECHANISATION 2014 INTRODUCTION HYTORC WASHER SYSTEM 3

4 INTRODUCTION HYTORC WASHER SYSTEM ACTIVE SIDE The HYTORC WASHER starts its revolution at the side on which the torque wrench is being used. All hydraulically, electrically and air driven torque tools need a reaction arm to abut against a fixed point. The HYTORC WASHER becomes the reaction point and eliminates all risks of hand injuries. The HYTORC WASHER is simple and easy to use. Like every other throughly hardened steel washer the HYTORC WASHER prevents from damaging the flange surface and makes the coefficient of friction of the flange surface a given constant. REACTIVE SIDE At the reactive side of the flange there is often an opposite nut. This nut rotates and needs to be kept stationary by a back-up wrench that abuts against a solid object. HYTORC continues the revolution with the BACK UP WASHER, which eliminates the use of a back-up wrench. Back-up wrenches are potentially dangerous tools; inconvenient and time consuming. The BACK UP WASHER is cheap and has a return on investment after the first use by cutting the bolting time in half. The HYTORC WASHER SYSTEM consists of the HYTORC WASHER combined with the BACK UP WASHER. Both washers can be used independently. Bolting has never been this safe! 4

5 GROUND BREAKING DIFFERENCE LINE OF FORCES USING A CLASSIC REACTION FIXTURE HYTORC WASHER WITH BACK UP WASHER 2000Nm REACTION FIXTURE TORQUE WRENCH TORQUE WRENCH DOUBLE SOCKET DRIVE HYTORC WASHER ACTIEVE FLENSZIJDE PASSIEVE FLENSZIJDE 2000kg BACK UP WRENCH BACKUP WASHER BOLT CENTRE AXIS A reaction fixture induces enormous shearing and bending forces, causing the bolt to stand askew. The HYTORC WASHER enables coaxial torqueing using a double drive socket. Both action and reaction happen around the bolt centre axis. 5

6 CONVENTIONAL METHOD CONVENTIONAL METHOD USING A REACTION FIXTURE THERE ARE THOUSANDS OF REACTION FIXTURES PROVED NECESSARY TORQUE WRENCH CONVENTIONAL REACTION FIXTURE DAMAGED THREAD PINCH HAZARD DAMAGE TO PAINT AND COATING Ra BACKUP WRENCH FLANGE SURFACE DAMAGED BY TURNING HIGH SURFACE PRESSURE NEEDS TO BE HAMMERED LOOSE TILT WHEN ABBUTTING NEARBY THE REACTION FORCES EXCEED LB. CAUSING UNWANTED SHEAR AND BENDING FORCES THAT INFLUENCE THE RESIDUAL BOLT LOAD. PINCH HAZARD 6

7 THE REVOLUTION CO AXIAL DUAL SOCKET DRIVE M16 TO M150 TORQUE WRENCH NO CHANCE OF PINCH HAZARD HYTORC WASHER (TOP SIDE) 90O TO THE FLANGE SURFACE REUSABLE THROUGHLY HARDENED SMOOTH SURFACE GUARANTEES A CONSTANT BOLT LOAD SCRATCH RESISTANT STANDARD SOCKET OUTER SOCKET PROFILE REACTS ONTO WASHER PROFILE OUTER SOCKET = REACTION SOCKET REACTIONPOINTS AND (SPECIAL) REACTION FIXTURES ARE SUPERFLUOUS! M16 TO M150 M16 TO M150 BACKUP WASHER HYTORC WASHER (BOTTOM SIDE) RIDGES APPLIED TO BOTH SIDES PREVENT THE COUNTER NUT FROM TURNING RIDGES APPLIED TO THE BOTTOM SIDE PREVENT THE WASHER AND THE TOOL FROM TURNING 7

8 THE ADVANTAGES CONVENTIONAL METHOD HYTORC WASHER SYSTEEM SAFETY Less personnel. No pinch hazard. BOLT LOAD (LBS) > STANDARD SCATTER NUMBER OF BOLTS > EQUAL BOLT LOAD The coefficient of friction and thus the bolt load, depends on many factors. With the WASHER SYSTEM the scatter in bolt load is cut in half. DURABILITY BOLT LOAD (LBS) > NUMBER OF BOLTS > HALF OF THE SCATTER BOLT LOAD (LBS) > TIJD > MORE RELAXATION Through hardened washers will reduce the surface pressure. Relaxation & settings will decrease. The bolting forces remain upright. BOLT LOAD (LBS) > TIJD > LESS RELAXATION REUSE OF BOLTS AND NUTS Shear and bending forces lead to galling at loosening, especially when loosening corroded bolts. By loosening them coaxially, bolts can be reused more often. 8

9 CONVENTIONAL METHOD HYTORC WASHER SYSTEEM LEAKAGE Equal bolt load leads to even gasket pressure. Leakage and diffuse losses will be reduced and TA Luft standards will be met. SPEED Setting up reaction fixtures and removing the back-up wrench by hammer are no longer necessary. Bolting time will reduce by 50%. FLANGE RE-MACHINED FLANGESURFACE FLANGE SURFACE CONDITION By using a washer the flange surface will remain as new. Costly mechanical re-machining treatments are no longer needed. FLANGE UNDAMAGED FLANGE SURFACE WASHER STANDARD WASHER Choose for the best option; the washers of the HYTORC WASHER SYSTEM. HYTORC WASHER BACKUP WASHER 9

10 TOOL MODELS SQUARE DRIVE TOOLS The HYTORC WASHER can be used with every modern HYTORC tool. The only accessory needed is either a double socket drive or an extra holding plate. Below you can see a cut-out of the double socket drive which can be used on all modern HYTORC tools. DUAL SOCKET DRIVE DUAL SOCKET DRIVE BOTTOM SIDE DUAL SOCKET DRIVE TOP SIDE ICE AVANTI JGUN DIGITAL JGUN LITHIUM FLASH HYDRAULIC PNEUMATIC ELECTRIC 10

11 LIMITED CLEARANCE TOOLS The HYTORC WASHER can be used with every modern HYTORC tool. The limited clearance tools are perfect for situations with limited clearance above the nut or in case of long stud protrusion. A graphical presentation of this is shown below. HOLDING PLATE OFFSET LINK WITH INTEGRATED PROFILE STEALTH HYDRAULIC PNEUMATIC ELECTRIC HYDRAULIC HIGHEST STANDARDS The HYTORC WASHER SYSTEM meets ISO7090, ISO4759, ANSI-B and DIN267. The use of a throughly hardened washer is generally recommended by ASME PCC and VDI CERTIFICATION Available with a 3.1 or a 3.2 certificate. WANT TO KNOW MORE? For technical specifications, dimensions, and norms please contact us or ask for a free demonstration.

12 IT S NOT THE ONE BIG THING, IT S THE MANY LITTLE THINGS WE DO, THAT MAKE HYTORC THE BEST. MATHIEU VAN KORTENHOF, CEO HYTORC BENELUX. HYTORC Nederland BV Platinawerf TL Beuningen The Netherlands T: HYTORC Benelux BVBA Ysselaarlaan 65B 2630 Aartselaar Belgium T: HYTORC is globally active in solutions and tools for industrial bolting. For over 45 years we are taking bolting to a higher level. We strongly believe in specialism combined with innovation and 24/7 service HYTORC, Division UNEX Corporation. All rights reserved.