Top Collar Hydraulic Nut HNIC6102900D operations

Top Collar Hydraulic Nut HNIC6102900D operations
Hydratight Limited
Bentley Road South
Darlaston
West Midlands
WS10 8LQ
United Kingdom
Tel: +44 121 50 50 600
Fax: +44 121 50 50 800
E-mail: enquiry@hydratight.com
Website: www.hydratight.com
TOP COLLAR HYDRAULIC
NUT HNIC6102900D
Operation and Maintenance
Instructions
www.boltup.com
HYDRATIGHT and BOLTUP are registered trademarks of Hydratight Limited
Operation and Maintenance Instructions
Top Collar Hydraulic Nut
Contents
SAFETY NOTES .................................................................................................................................. 3
OPERATION OF THE HYDRAULIC NUT ............................................................................................ 5
Tightening Procedure for Top Collar Hydraulic Nut .......................................................................................... 5
Release Procedure..................................................................................................................................................... 6
Trouble Shooting Guide........................................................................................................................................... 7
MAINTENANCE INSTRUCTIONS........................................................................................................ 8
Precautions to Replace Hydraulic Seals ................................................................................................................ 8
Hydraulic Seals Component Parts.......................................................................................................................... 8
Hydraulic Seals - Disassembly of Hydraulic Nut.................................................................................................. 8
Seal Assembly............................................................................................................................................................ 8
Hydraulic Seals - Reassembly of Hydraulic Head ................................................................................................ 9
Hydraulic Fittings................................................................................................................................................... 10
STORAGE OF EQUIPMENT.............................................................................................................. 11
Hydraulic Nut.......................................................................................................................................................... 11
Hydraulic Harness and Hoses ............................................................................................................................... 11
Air/Hand Driven Pump.......................................................................................................................................... 11
GENERAL ARRANGEMENT DRAWING........................................................................................... 12
TECHNICAL DATA SHEET ............................................................................................................... 13
PRESSURE LOAD GRAPH ............................................................................................................... 14
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Operation and Maintenance Instructions
Top Collar Hydraulic Nut
Safety Notes
High pressure hydraulics should be treated with respect. Please ensure that the following basic
rules are followed:
1. ALWAYS WEAR SAFETY GLASSES when working near a pressurised hydraulic
system. Your eyesight is important – PROTECT IT.
2. Suitable footwear and gloves should be worn when operating this equipment.
3. ALWAYS check the following points before pressurising a hydraulic system:
a) Check that the hydraulic harness is fully connected. There should be no loose ends and
every male nipple should be connected to its corresponding female coupling.
b) Check that each female coupling is securely locked in position on the corresponding
nipple by physically pulling the connection.
IT IS DANGEROUS TO PRESSURISE THE BACK OF AN UNCOUPLED
QUICK DISCONNECT NIPPLE OR COUPLING. ALL CONNECTIONS MUST
BE CONNECTED OR BLANKED OFF BEFORE PRESSURISING.
c) Check that the bolt material is capable of taking the initial load to be applied. The tools
are powerful and are capable of yielding or breaking bolts if tensile/yield properties are
not sufficient to support the load applied.
d) Check that there is sufficient bolt protrusion above the joint face and ensure that when
screwed onto the bolt the hydraulic nut mates with the joint face.
Note
Thread engagement should be a minimum of one bolt diameter (see data sheet).
4. NEVER exceed the maximum working pressure specified for the equipment (see data
sheet).
Note
The maximum safe working pressure specified for the tool does not necessarily represent the
maximum safe load that may be induced in the bolt.
5. NEVER exceed the maximum extension quoted for the equipment (see data sheet).
Note
An indicator will appear when the tool is close to maximum extension.
6. ALWAYS take care when pressurising a system. Always observe the gauge and be ready.
Pressure can rise faster than you think.
7. NEVER leave a pressurised system unattended. If you must leave the area release the
pressure and ensure that the return to tank valve on the pump unit is fully open.
8. NEVER bend the hydraulic hoses less than six times their own diameter. Do not use
kinked hoses.
9. NEVER stand in line with the bolt axis whilst tensioning is in progress.
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Operation and Maintenance Instructions
Top Collar Hydraulic Nut
Note
Personnel must be aware of this point at all times.
10. When working on site the work area should be roped off and all personnel not connected
with the site operation should be kept clear of the working area.
11. High pressure hydraulic equipment can be very dangerous if misused. Keep away from oil
leakages at high pressure. Liquid escaping from highly pressurised equipment has
sufficient power to penetrate the skin, which can cause blood poisoning. In the case of
such an accident IMMEDIATE medical attention must be sought.
REMEMBER:
TAKE CARE! HIGH PRESSURE HYDRAULICS ARE
PERFECTLY SAFE IF THE BASIC SAFETY RULES ARE
FOLLOWED.
PLEASE NOTE:
MODIFICATION TO ANY EQUIPMENT COVERED BY THIS
MANUAL SHOULD NOT BE ATTEMPTED BY THE
CUSTOMER.
IF MODIFICATIONS ARE REQUIRED TO SUIT A SPECIFIC
APPLICATION, CONSULT HYDRATIGHT LTD BEFORE
MAKING THEM.
INAPPROPRIATE MODIFICATIONS MADE RENDER THE
EQUIPMENT DANGEROUS.
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Operation and Maintenance Instructions
Top Collar Hydraulic Nut
Operation of the Hydraulic Nut
Tightening Procedure for Top Collar Hydraulic Nut
To install the top collar hydraulic nut on to a bolt proceed as follows, refer to drawing
HNIC6102900D as necessary.
1. Check that the bolt has been assembled correctly, and that there is sufficient bolt
protrusion to engage with the hydraulic nut (see data sheet).
2. Screw the fully assembled hydraulic nut onto the bolt.
3. Use either the two tightening holes provided in the top face of the hydraulic nut insert or
the castellation in the top face of the hydraulic nut collar to screw the hydraulic nut down
tightly to the joint face. To aid this use either the tommy bar (HNIC6102904E) or spanner
(HNIC610290900D) provided with the hydraulic nut.
Note
To check that the insert is fully screwed onto the bolt back off (rotate anticlockwise) the collar ½
(half) a turn and screw the insert down (rotate clockwise) using the holes in the top face, once
completed screw the collar down (rotate clockwise) until it makes contact with the body.
4. Check that the hydraulic nut is seated squarely on the joint face, if it is not then this must
be investigated and corrected.
Note
Out of squareness will result in uneven loading and higher load losses.
5. Connect the hydraulic harness to the tool(s) and check that each coupling is securely
connected to each quick disconnect nipple.
Note
If all the hydraulic nuts in the system are not being tightened simultaneously then a sensible
tightening sequence should be used. If in doubt consult Hydratight Limited for advice.
6. Operate the hydraulic pump to pressurise the hydraulic nut(s). Observe the extension and
operating pressure constantly during this operation and do not exceed the maximum
quoted on the enclosed data sheet.
Note
The extension will appear between the body and collar.
7. When the desired operating pressure is reached stop the pump and whilst holding the
pressure constant tighten down (rotate clockwise) the load retaining collar using a tommy
bar and tap down with a copper hammer. Check that the collar is properly seated.
Note
Do not exceed the maximum working pressure of the hydraulic nut (refer to data sheet).
8. Release the oil pressure slowly.
9. Remove the hydraulic harness and fit protective caps to the hydraulic connections.
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Operation and Maintenance Instructions
Top Collar Hydraulic Nut
10. If desired remove the quick disconnect nipple and adaptor from the hydraulic nut(s), using
suitably sized wrenches 22mm (7/8”) and 17mm (11/16”) across flats hexagon
respectively, and plug the hydraulic port(s) with the blanking plug supplied.
Note
Blanking the hydraulic ports will provide added protection for the quick disconnect nipple. The
adaptor and quick disconnect nipple should be kept for future use.
Release Procedure
Proceed as follows to remove top collar hydraulic nuts.
1. If fitted remove the blanking plug and screw in the adaptor and quick disconnect nipple
using suitable torque wrenches.
Note
The across flats of the hexagons of the adaptor and quick disconnect nipple are 17mm (11/16”) and
22mm (7/8”) respectively. To provide an effective seal the torque requirement for the adaptor (1/8”
BSP) and quick disconnect nipple (1/4” BSP) is 40-50 Nm or 354-443 lbf.in..
2. Connect the hydraulic harness and check that each coupling is securely connected to the
corresponding quick disconnect nipple.
3. Operate the pump unit to pressurise the hydraulic nut(s). As the pressure increases fit the
tommy bar (HNIC6102904E) or spanner (HNIC610290900D) to the load retaining collar
and continually check to see if the collar can be unscrewed (turned anticlockwise). As
soon as the collar can be turned stop the pump and turn the collar back sufficiently to
allow tension in the bolt to be released.
Note
Do not exceed the maximum operating pressure and extension of the top collar hydraulic nut.
4. Release the oil pressure slowly.
5. The hydraulic nut assembly should now be free to be unscrewed (turned anticlockwise)
from the bolt. If the collar is still screwed down onto the body and the hydraulic nut
cannot be unscrewed then it is likely that the collar was not screwed back far enough in
operation 3, in this case repeat operations 3 to 5.
Note
If it is still not possible to remove the hydraulic nut from the bolt contact Hydratight Limited for advice
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Operation and Maintenance Instructions
Top Collar Hydraulic Nut
Trouble Shooting Guide
Problem/Symptom
Probable Cause
Corrective Action
Oil is leaking from the
hydraulic connection.
The connection is not seating
properly.
Tighten the connection. Where
applicable replace connection
components (see general
arrangement drawing).
Oil is leaking from the
hydraulic nut body.
Seal failure.
Change the seals.
When detensioning the
bolt the tool becomes
locked onto the bolt.
Thread damage or corrosion of
the bolt above the hydraulic
nut.
Turn the hydraulic nut down
and clean up the threads above
the hydraulic nut.
When detensioning the
bolt the tool becomes
locked onto the bolt.
On an application that has been
tensioned simultaneously and
nuts are being removed
individually the last few nuts
may lock on.
Refit several hydraulic nuts
around the joint and pressurise
until the locked hydraulic nut
becomes loose.
The pump is not
building pressure with
oil return to tank valve
closed.
1. Oil return to tank valve
may be defective.
1. Replace the return to tank
valve.
2. Check valve may be
sticking inside the pump
head.
2. Tap the pump head lightly
with a hide hammer. If this
fails the pump must be
stripped down.
The hydraulic nut
collar is not turning
when the system is
under pressure.
The hydraulic hose is not
connected properly to the tool.
Release the pressure and check
the hose connection.
The hydraulic nut
body will not retract.
1. Oil return to tank valve is
not open.
1. Ensure that the oil return to
tank valve is fully open.
2. One of the connections is
not connected properly.
2. Check that the hydraulic
connections are secure.
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Operation and Maintenance Instructions
Top Collar Hydraulic Nut
Maintenance Instructions
The tool is of rugged construction and utilises reliable seals. The only maintenance that may
be occasionally required is the replacement of seals or repair of a hydraulic fitting.
It is strongly recommended that in the event of seal failure these hydraulic nuts are returned to
Hydratight Limited for seal replacement, if this is not possible then the enclosed procedure
should be followed.
Precautions to Replace Hydraulic Seals
The following precautions must be taken with the assembly of the hydraulic seals:
1. Avoid sharp edges (cover threaded areas).
2. Remove all dust, dirt, swarf and foreign particles.
3. Do not use sharp edged tools.
4. Lubricate all components before assembly.
Hydraulic Seals Component Parts
The seal kit comprises an inner seal and outer seal complete with o-rings.
Hydraulic Seals - Disassembly of Hydraulic Nut
Throughout the following instructions refer to drawing HNIC6102900D.
1. Remove the quick disconnect nipple and adaptor using appropriate sized wrenches or
spanners.
Note
The across flats of the hexagons of the quick disconnect nipple and adaptor are 22mm (7/8”) and
17mm (11/16”) respectively.
2. Unscrew (rotate anticlockwise) the collar and remove it from the insert.
3. Protect the threads of the collar and insert at all times.
4. Using a small bench press remove the insert from the body.
5. Remove the seals and o-rings from the body and insert.
Note
It may be necessary to use a flat bladed tool, such as a screwdriver to remove the o-rings from the
seal grooves.
Seal Assembly
Pictures enclosed are for guidance only and may not be of the actual component parts.
1. Place the nut body on a clean flat surface with the large bore facing upwards.
2. Place the inner seal o-ring into the seal groove.
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Operation and Maintenance Instructions
Top Collar Hydraulic Nut
3. Insert the inner seal into the nut body as indicated in the following picture, ensuring that
the chamfer on the seal is adjacent to the seal groove chamfer, and fold the seal out on top
of the o-ring removing any kinks in the seal.
4. Place the insert on a clean flat surface with the small end facing upwards.
5. Simply stretch the outer o-ring over the boss of the insert into the groove.
Note
If necessary use a flat bladed tool such as a screwdriver.
6. Locate part of the outer seal in the seal groove and work around the outside diameter
stretching it over the boss, as shown below, until it completely slips into the groove.
Note
If the seal is chamfered on both faces it may be inserted either way round, however if only
chamfered on one face the chamfer should be adjacent to the insert seal groove chamfer.
Hydraulic Seals - Reassembly of Hydraulic Head
1. Ensure that all surfaces of the body and insert are free from dirt and other foreign
particles.
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Operation and Maintenance Instructions
Top Collar Hydraulic Nut
2. Lubricate all inner faces concentrating on the seals and seal contact faces, preferably using
hydraulic oil.
3. Position the insert assembly into the body assembly, ensuring that squareness between the
components is maintained, apply pressure until the insert assembly is fully engaged with
the body assembly.
Note
It may be possible to press the two assemblies together by hand but if necessary use a small
bench press.
4. Remove the insert and collar thread protection applied earlier.
5. Screw (rotate clockwise) the collar back onto the insert until it mates with the body.
6. Screw the hydraulic connection adaptor and quick disconnect nipple back into the
hydraulic port in the top of the insert using appropriate torque wrenches (see disassembly
for sizes).
Note
To provide an effective seal the torque requirement for the adaptor (1/8” BSP) and quick disconnect
nipple (1/4” BSP) is 40-50 Nm or 354-443 lbf.in..
Hydraulic Fittings
Hydraulic connections are of the following types:
1. Hydraulic head assembly – the connection in the tool is 1/8” BSP female thread. If there is
a slight leak it can usually be solved by applying the correct torque of 40-50 Nm or 354443 lbf.in.
2. Hose – the hose end connection is a ¼” BSP female swivel with male cone. A seal is
effected by screwing down on to the mating adaptor with sufficient pressure. Any
problems are usually minimal and normally solved by ensuring that the correct torque of
40-50 Nm or 354-443 lbf.in is applied.
Note
If the problem persists then the threads should be checked and repaired if possible. If the threads
cannot be repaired the component part(s) will need replacing. In the event of any further problems
please consult with Hydratight Limited for advice.
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Operation and Maintenance Instructions
Top Collar Hydraulic Nut
Storage of Equipment
Hydraulic Nut
1. Store tools fully retracted.
2. The finish will protect the tools from rust etc but for added protection a light coating of oil
or rust inhibitor should be applied to all plated surfaces.
3. Cover the internal threads on the inside of the collar and adjusting collars with a rust
inhibitor.
4. Store tools upright.
5. Keep dust caps on the oil inlet nipples.
Hydraulic Harness and Hoses
1. Wipe all hoses clean and apply a light coating of oil or suitable rust inhibitor to all
nipples, couplings and tee blocks.
2. Always keep dust caps fitted to nipples and couplings.
Air/Hand Driven Pump
1. Always store the pump upright.
2. Apply a light oil coating or suitable rust inhibitor to all exposed unplated metal items.
3. Leave the oil return to tank valve in the open position.
4. Leave the air control valve in the open position (air pump only).
5. Always keep dust caps on inlet and outlet hydraulic fittings.
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Operation and Maintenance Instructions
Top Collar Hydraulic Nut
General Arrangement Drawing
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Operation and Maintenance Instructions
Top Collar Hydraulic Nut
Technical Data Sheet
CUSTOMER:
Tennessee Gas Pipeline
TOOL SIZE:
1.1/2"-12 UNF
TENSIONER ITEM No.
HNIC6102900D
TENSIONER O.D.
75 mm
2.95 in
SEAL O.D.
67 mm
2.64 in
SEAL I.D.
44 mm
1.73 in
HYDRAULIC AREA:
2005 mm²
MAX OPERATING PRESSURE:
1500 bar
21750 psi
301 kN
67598 lbf
MAX INITIAL LOAD:
MAX STROKE:
MINIUM STUD PROTRUSION
ABOVE JOINT FACE
3.11 in²
6 mm
0.24 in
57 mm
2.24 in
CALCULATION OF REQUIRED OPERATING PRESSURE
Operating Pressure =
Initial load
Hydraulic Area
Initial load
Residual Load x Load loss Factor
=
Note: The Load Loss Factor is based on a theoretical approximation of the amount
of load lost when the pressure in the hydraulic head is released, and the load is
transferred to the permanent nut. The main variable which affects the load loss
factor is the grip length of the application.
IF IN DOUBT CONSULT HYDRATIGHT FOR FURTHER INFORMATION
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Operation and Maintenance Instructions
Top Collar Hydraulic Nut
Pressure Load Graph
HNIC6102900D
1.1/2"-12 UNF
Max Load Capacity
67598
21750
70000
65000
60000
55000
50000
40000
35000
30000
Max Working Pressure
Load (lbs)
45000
25000
20000
15000
10000
5000
0
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
22000
Pressure (psi)
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