groupsceneversiontype safe bolting the safe handling and operation of modern powered torquing tools...

GROUP SCENE VERSION TYPE

SAFE BOLTINGTHE SAFE HANDLING

AND

OPERATIONOF

MODERN POWERED TORQUING TOOLS

Produced by


2

The following material is intended to make you aware of the commonly accepted and recognized

principles and methods used in assembling bolted joints. However, every possible application of

these methods cannot be foreseen and these general guidelines do not supersede any other

applicable rules or regulations.

ALWAYS FOLLOW CURRENT COMPANY AND ALWAYS FOLLOW CURRENT COMPANY AND

LOCAL SAFETY RULES AND PROCEDURES LOCAL SAFETY RULES AND PROCEDURES

WHEN PERFORMING ANY OF THE WORK WHEN PERFORMING ANY OF THE WORK

DESCRIBED IN THIS PRESENTATION. DESCRIBED IN THIS PRESENTATION.


10 to 1… HYTORC’s vs any other brandHundreds of IndustriesThousands of Applications

World’s Largest Manufacturerof Precision Bolting Tools

World’s Largest Manufacturerof Precision Bolting Tools


• Lead the industry by example through innovative tool designs and safety-sensitive methods.

• Promote safety as the primary justification for customers to invest in its products.

• Educate its customers, their employees and contractors, and the general public in why and how to improve safety in their bolting operations regardless of their tooling choices.

• Influence business associations, training schools, safety departments, government and industrial standards agencies to adopt and require safer bolting practices for their constituents.

SAFETY MISSION STATEMENTSAFETY MISSION STATEMENTSAFETY MISSION STATEMENTSAFETY MISSION STATEMENTAs the world leader in precision industrial bolting

technology Hytorc endorses the improvement of bolting safety and commits to:


SAFE BOLTINGSAFE BOLTING TABLE OF CONTENTSTABLE OF CONTENTS

HYDRAULIC WRENCHES

SQUARE-DRIVE TOOLS

LIMITED-CLEARANCE TOOLS

SAFELY USING THE TOOLS

HYDRAULIC PUMPS

ELECTRIC PUMPS

AIR PUMPS SYSTEM OPERATION

TIPS AND TROUBLE-SHOOTING

NEW TOOLS & ACCESSORIES

SOCKET SAFETY

Click an item to view or use the space bar to advance

CHARTS AND HELPS

THANK YOU FOR PURCHASING

GROUP SCENE VERSION TYPENOW LET’S REVIEW THE TOOLS

GROUP SCENE VERSION TYPEUse Personal Protective Equipment

GROUP SCENE VERSION TYPEMany Kinds of Bolting Tools

impact guns

impact guns

bolt heatersbolt heaters

tensioners

tensioners

cheater bars

cheater bars

Hydraulic WrenchHydraulic Wrench


• POWER IN A SMALL SIZE

• PRECISE CONTROL AND REPEATABILITY

• VERSATILITY

Modern Hydraulic Wrenches

GROUP SCENE VERSION TYPETwo Basic Styles

Square Drive Socket Style Wrench with Adjustable Reaction Arm

Narrow Clearance Style with Interchangeable

Ratcheting Links

GROUP SCENE VERSION TYPEChoosing The Right Wrench

DOES IT FIT?

DOES IT HAVE ENOUGH POWER?

Click here to return to Table of Contents, or use the space bar to advance

GROUP SCENE VERSION TYPEThe Square Drive Wrench

GROUP SCENE VERSION TYPETorque Ranges by Wrench Size

1K 5K 10K 15K 20K

RECCOMENDED MAX TORQUE RESERVE

RESERVE

MAX TORQUE RES.

MAX RES.

MAX TORQUE

A-1

A-3

A-5

A-10

A-20

Torque in 000’S FT/LBSClick here to return to Table of Contents,

or use the space bar to advance

GROUP SCENE VERSION TYPENarrow Clearance Wrench


2K 7K 15K 15K 20K

RECCOMENDED MAX TORQUE RESERVE

RESERVE

MAX TORQUE RES.

MAX RES.

MAX TORQUE

S-2

S-4

S-8

S-14

S-22

Torque in 000’S FT/LBS

The same rules apply to thetorque ranges of the

Narrow Clearance Wrenches


GROUP SCENE VERSION TYPEQuestions for Review• The power output of a hydraulic wrench depends

on the diameter of its piston and what other factor? How is that power regulated and controlled?

• How does one change the direction of a square drive wrench from tighten to loosen?

• How does one change the direction of a narrow clearance wrench from tighten to loosen?

Output power is function of the diameter of the piston and the pressureper square inch of hydraulic fluid. The pressure is controlled by adjusting the pressure regulator on the pump.

Remove the drive and place it in the opposite side of the wrench.

Turn the wrench over.


GROUP SCENE VERSION TYPEQuestions for Review

• To minimize “side loading” of a stud, the reaction arm of the tool should rest in the same plane as the nut?

• Why is it generally a good practice to use only up to about ¾ of the capacity of a wrench to tighten?

True or False

True: The reaction arm should abut a solid surface in the same plane as the nut, or as close as possible.

Generally it will take more power to break a nut or bolt loose thanit did to tighten it. In order to use the same wrench for both, it is usually advisable to not use the entire capacity of the wrench to tighten.


GROUP SCENE VERSION TYPEPrinciples & Typesof Hydraulic Pumps


GROUP SCENE VERSION TYPEElectric Powered Pumps


GROUP SCENE VERSION TYPEAir Powered Pumps


GROUP SCENE VERSION TYPESystem Operation


GROUP SCENE VERSION TYPEQuestions for Review

• It would be a good idea to use an electric powered hydraulic pump in an oil refinery because compressed air is not usually available.

• Setting an accurate pump pressure is more important for tightening or for loosening?

False. Most refinery vessels contain flammable liquids or gases. Use of electric motors is not a good idea. An air powered pump is preferred.

Tightening. Loosening only requires enough pressure to break the nut loose but accuracy is not important.

True or False:

GROUP SCENE VERSION TYPEQuestions for Review• Can I tell by looking, if the hydraulic oil is still

serviceable? How?

• Which is the appropriate way to set pump pressure?• Lower to higher• Higher to lower• It doesn’t matter

Yes. Generally if the oil is clear and amber colored it is good.

Lower to higher. This has to do with how gauges accurately measure pressure.



SAFELY OPERATING HYDRAULIC TORQUE WRENCHES

AVANTI (SQUARE DRIVE) WRENCHES

STEALTH (NARROW CLEARANCE) WRENCHES

Click here to return to table of contents

(SELECT TYPE OF WRENCH)

GROUP SCENE VERSION TYPESafely Operating a Hydraulic Wrench


TORQUE CHART for B-7 STUDS

Bolt Dia.Nut A/F

Torque (Ft/Lbs)

1"1-5/8" 876

1-1/4" 2"

11

1-1/2" 2-3/8“ 2

1-3/4" 2-3 4735

2"

7069

2 3-1/2“ 10064

2-1/2" 3-7/8"

13806

GROUP SCENE VERSION TYPETightening this nut and bolt

1-1/4” B-7 stud

2” Nut

TORQUE CHART for B-7 STUDS Bolt Dia. Nut A/F Torque (Ft/Lbs)

1" 1-5/8" 876

1-1/4" 2" 1165 1-1/2" 2-3/8“ 1-3/4" 2-3/4“ 5 2" 3 7069 2-1/4" 10064 2-1/2" 3-7/8" 13806

1165 lbs.

1 foot


Pressure-Torque Chart

4,000 PSI = 1166 Ft. Lbs

Outer Scale – PSI

Inner Scale - BAR

SETTING PUMP PRESSURE

USING AVANTI-3 TOOL DESIRED TORQUE = 1165 FT/LBS PRESSURE = 4,000 PSI

GROUP SCENE VERSION TYPESafely Operating aHydraulic Wrench


GROUP SCENE VERSION TYPESafely Operating a Narrow ClearanceHydraulic Wrench


TORQUE CHART for B-7 STUDS

Bolt Dia.Nut A/F

Torque (Ft/Lbs)

1"1-5/8" 876

1-1/4" 2"

11

1-1/2" 2-3/8“ 2

1-3/4" 2-3 4735

2"

7069

2 3-1/2“ 10064

2-1/2" 3-7/8"

13806

GROUP SCENE VERSION TYPETightening this nut and bolt

1-1/4” B-7 stud

2” Nut

TORQUE CHART for B-7 STUDS Bolt Dia. Nut A/F Torque (Ft/Lbs)

1" 1-5/8" 876

1-1/4" 2" 1165 1-1/2" 2-3/8“ 1-3/4" 2-3/4“ 5 2" 3 7069 2-1/4" 10064 2-1/2" 3-7/8" 13806

1165 lbs.

1 foot


Pressure-Torque Chart

6,200 PSI = 1166 Ft. Lbs

Outer Scale – PSI

Inner Scale - BAR

SETTING PUMP PRESSURE

USING STEALTH-2 TOOL DESIRED TORQUE = 1165 FT/LBS PRESSURE = 6,200 PSI

GROUP SCENE VERSION TYPESafely Operating aNarrow-Clearance Hydraulic Wrench


GROUP SCENE VERSION TYPEQuestions for Review• The wrench will stall when it has reached the target

torque corresponding to the preset pressure?

• If 2500 p.s.i. will produce 300 ft/lbs of torque with a given wrench, how much torque will result at 7500 p.s.i. with that same wrench?

• A nut won’t come loose at the same pressure it was tightened with. What should be done? What if it doesn’t move at 10,000 p.s.i.?

True. It is not necessary to watch the gauge or to stop advancing thepump at a certain pressure.

900 ft/lbs. The relationship between pressure and torque is essentiallylinear, allowing you to interpolate values in the pressure/torque table.

You will need a larger wrench with more power.


Turn up the pressure.

True or False

GROUP SCENE VERSION TYPETHANK YOU

!



TIPS AND TROUBLESHOOTING

•TOOL LOCKED ON

•PUMP PRESSURIZES BUT TOOL WON'T ADVANCE

•PUMP MOTOR RUNS BUT WON'T BUILD PRESSURE

•PUMP MOTOR "CLICKS" BUT WON'T START

•AIR MOTOR RUNS SLOWLY OR PUMP WON'T CYCLE

•PUMP WON'T BUILD FULL PRESSURE OR NEEDLE BOUNCES

Click on an item to view or press space bar to advanceClick here to return to table of contents

GROUP SCENE VERSION TYPETIPS AND TROUBLESHOOTING (ELECTRIC PUMP MOTOR “CLICKS” BUT WILL NOT START)

• PROBLEM: – ELECTRIC PUMP MOTOR WILL NOT START BUT YOU CAN

HEAR A “CLICK” WHEN THE REMOTE IS PRESSED• PROBABLE CAUSES/CURES:

– INSUFFICIENT VOLTAGE/AMPERAGE DELIVERED• CHECK VOLTAGE AND MAKE SURE ON 20 AMP CIRCUIT

• ELIMINATE EXTENSION CORDS OR ENSURE AT LEAST 12 GAUGE CORD IS USED

– LOOSE WIRE IN REMOTE CONTROL OR CIRCUIT BOX• CONSULT YOUR ON-SITE ELECTRICIAN

• CALL YOUR SALES REP, OR 1-800-367-4986 FOR ASSISTANCE OR FURTHER DIAGNOSIS

Click here to return to TIPSOr press space bar to advance

GROUP SCENE VERSION TYPETIPS AND TROUBLESHOOTING (PUMP WILL NOT BUILD PRESSURE)

• PROBLEM: – PUMP MOTOR RUNS BUT WILL NOT BUILD PRESSURE ON

THE GAUGE• PROBABLE CAUSES/CURES:

– NO OIL IN THE PUMP• CHECK OIL AND REFILL IF NEEDED – DO NOT RUN DRY!

– GAUGE CONNECTOR LOOSE• CHECK AND RE-TIGHTEN GAUGE CONNECTOR

– DAMAGE TO ELECTRIC SOLENOID OR AIR VALVE– LOOSE WIRE IN REMOTE CONTROL OR DAMAGE TO AIR

CAPILLARY TUBES• CALL YOUR SALES REP, OR 1-800-367-4986 FOR ASSISTANCE

OR FURTHER DIAGNOSIS


GROUP SCENE VERSION TYPETIPS AND TROUBLESHOOTING (PUMP PRESSURIZES BUT TOOL WON’T ADVANCE)

• PROBLEM: – PUMP PRESSURIZES, HOSES STIFFEN BUT TOOL WON’T

MOVE)• PROBABLE CAUSE:

– ONE OR MORE OF THE CHECK-BALL CONNECTORS HAS LOOSENED OR WAS NOT TIGHTENED FULLY

• CURE:– RE-CHECK THE TIGHTNESS OF THE CONNECTORS BOTH AT

TOOL AND AT THE PUMP– PUSH THE HOSE INTO THE COUPLING AND FINGER-

TIGHTEN THE THREADED COLLAR. DO NOT USE TOOLS, AS YOU WILL BEND THE COLLAR AND MAKE FUTURE CONNECTIONS DIFFICULT!

Click here to return to TIPSOr press space bar to advanceSlide 5

GROUP SCENE VERSION TYPETIPS AND TROUBLESHOOTING (AIR PUMP RUNS SLOWLY OR WILL NOT RELEASE PRESSURE)

• PROBLEM: – AIR PUMP BUILDS PRESSURE VERY SLOWLY OR WILL NOT

RELEASE PRESSURE WHEN THE BUTTON IS RELEASED • PROBABLE CAUSES/CURES:

– LOW AIR PRESSURE OR VOLUME• ENSURE 100 PSI - ¾” MIN. AIR LINE - 50 CU.FT./MINUTE FLOW

– AIR LEAKS OR RESTRICTIONS• CHECK AIR CONNECTIONS, HOSES AND F.R.L FOR PROBLEMS

– MUFFLER CLOGGED• UNSCREW MUFFLER AND CLEAN

• CHECK FOR FROZEN WATER VAPOR IN COLD WEATHER, IF SO ENSURE THAT F.R.L IS CLEAR AND OPERATING PROPERLY

• EVACUATE AIR SUPPLY HOSE OF AIR OR WATER BUILDUP


GROUP SCENE VERSION TYPETIPS AND TROUBLESHOOTING (PUMP WON’T BUILD FULL PRESSURE OR NEEDLE BOUNCES)

• PROBLEM: – PUMP WON’T BUILD FULL 10,000 PSI OR NEEDLE WILL NOT

HOLD STEADY AT THE PRE-SET PRESSURE• PROBABLE CAUSES/CURES:

– EXTERNAL OIL LEAK• CHECK FOR ANY ESCAPING OIL FROM PUMP, CONNECTORS,

HOSES OR

– INTERNAL OIL LEAK IN EITHER TOOLS OR PUMP• DISCONNECT THE HOSE FROM THE PUMP. IF PROBLEM GOES

AWAY THEN THE LEAK IS IN THE TOOL

• IF PROBLEM PERSISTS, INTERNAL PUMP SEALS ARE LEAKING

• CALL YOUR SALES REP, OR 1-800-367-4986 FOR ASSISTANCE OR FURTHER DIAGNOSIS


GROUP SCENE VERSION TYPETIPS AND TROUBLESHOOTING (TOOL LOCKED ON)

• PROBLEM: – AFTER TORQUING, TOOL IS LOCKED ON AND CAN’T BE REMOVED

• PROBABLE CAUSE: – TORSION BUILDUP IN THE BOLT IS PUSHING AGAINST THE

REACTION PAWL IN THE TOOL (NOTE: THE REACTION PAWL ENABLES THE TOOL TO REACH FULL TORQUE ON THE BOLT IN SPITE OF TORSION OR WIND-UP)

• CURE:– WITHOUT CHANGING THE PUMP PRESSURE, START THE PUMP

AND HOLD DOWN THE PUMP REMOTE BUTTON DRIVING THE TOOL FORWARD

– WHILE HOLDING THE BUTTON DOWN, LIFT AND HOLD THE REACTION PAWL LEVER OR SLIDE

– RELEASE THE REMOTE BUTTON, THE TOOL WILL RELAX AND COME OFF WITHOUT A PROBLEM

Click here to return to TIPS


CHARTS AND RESOURCES

•WWW.HYTORC.COM(Must be connected to Internet for these links )


•’PRESSURE-TO-TORQUE’ CHARTS

•TORQUE CHARTS

• FLANGE PATTERN CALCULATOR

•ADDITIONAL TRAINING AND ASSISTANCE


PRESSURE-TORQUE CONVERSION CHARTS

AVANTI (SQUARE DRIVE) WRENCHES

STEALTH (NARROW CLEARANCE) WRENCHES

Click here to return to RESOURCES


TORQUE CHARTS

• UN (unified national) “inch” bolts– Torque in Foot-Pounds

• Metric (ISO) bolts– Torque in Newton-meters

Click here to return to RESOURCES

groupsceneversiontype safe bolting the safe handling and operation of modern powered torquing tools...

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improvement of bolting