petrochem - inpatech
TRANSCRIPT
PETROCHEMAPPLICATIONS
T H E S O L U T I O N T O B O LT I N G P RO B L E M S
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
INC.
T h e S o l u t i o n T o B o l t i n g P r o b l e m s
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
Problem: Every five years the reactors have to be inspected and taken apart for maintenance. The large bolts tend to corrode with the heat and weather, causing the disassembly to be very difficult. The hydraulic tensioning devices failed to untighten the nuts, costing the customer many hours of production at great expense.
Application: Reactor Cover
Solution: Superbolt® medium temperature Tensioners can be installed in just two hours: 2 men for 24 pieces (M80). The small torque guarantees an accurate preload and the bolts are perfectly stretched in pure tension. Only hand tools are required for installation and removal, eliminating bulky hydraulic wrenches. The assembly can be untightened anytime and reused. Covers can be purchased to help protect against the weather.
Installation:84 pieces H650-M80x4/w
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
INC.
T h e S o l u t i o n T o B o l t i n g P r o b l e m s
Target Torque 169 ft-lbs per jackboltPreload 2 million lbsTime savings per job 132 man-hours
Ammonia Reactor (22) 11” Studs
Problem:This large ammonia reactor required the use of two very expensive, very large hydraulic tensioners. Prior to the use of Superbolt®, tensioning or detensioning required 3 days, working around the clock. The 6,500 lb. tensioners had to be manipulated by two cranes, and each stud required several passes. Work was reportedly very strenuous in addition to being time consuming.
Solution:Not only was the initial cost for the Superbolt® Tensioners only a fraction of the cost of the hydraulic tensioners, but the installation time was much faster. Total tightening time with two laborers was only 5 hours! Only 169 ft-lbs per jackbolt was required to tension the studs to 2,000,000 lbs!
The plant saved several times the cost of the tensioners in labor and downtime as the reactor had to be closed and opened several times due to problems with internal components.
LEFT: Two laborers worked at 180° apart for even gasket compression.
ABOVE: Air impacts were used for the major-ity of the work. Torque wrenches were used for final step.
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
INC.
T h e S o l u t i o n T o B o l t i n g P r o b l e m s
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
Heat Exchanger (Oil Refinery)
Specifications:Existing Stud Size. ............................... 2-1/4”Number of Studs per flange ....................... 28
Time for Installation:•Hydraulic Torquewrench .............17 man hrs•Superbolt® Tensioners .................... 4 man hrs
Problems: This heat exchanger head was a constant problem in this oil refinery. The original equipment hex nuts, which were tightened with a hydraulic torquewrench (see picture at right) could not maintain a leak free seal on the head. Lack of accuracy and inconsistency of stud preloads was another major concern. The largest single problem was the time and labor required to remove and replace the head.
Solutions: Replacement of the original hex nuts with Superbolt® “Classic” ST-225-8/w Torquenuts has reduced installation/removal time to one quarter of the previous time. Hand torquewrenches are much easier to handle than the old hydraulic units, and the need for hydraulic pumps and hoses has been eliminated. Best of all, there have been NO LEAKS!!
After: After pretightening with air wrenches, workers systematically verify jackbolt torques with hand wrenches.
Before: Heavy cumbersome hydraulic wrenches were required for hex nut tightening.
Positive Proof: This refinery had two identical heat exchangers side by side. Superbolt® Tensioners were installed on one, while the other was closed by the previous method with hydraulic torquewrenches on the original hex nuts. After installation, both units were hydrostatically tested - the hydraulic tensioning service was called back due to leaks, while the Superbolt® equipped unit passed the test.
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
INC.
T h e S o l u t i o n T o B o l t i n g P r o b l e m s
Specifications:Existing Stud Size ................................. 2-1/4” x 8 tpiOperating temperature .......................... 1,000°FOperating Pressure ............................... 2,000 psi
Problems: These valve flanges are located overhead in confined spaces under this Hitachi turbine. Traditionally, these studs have been stressed using the “hot bolting” method, incorporating the use of stud heaters, hammer wrenches, and other apparatus. Obtaining a leak free seal has always been difficult.
Removal has been more of a problem than assembly, often requiring cutting the hex nuts off with a torch, destroying the nuts and sometimes damaging the stud.
Old versus new - Superbolt® tensioners on the right.
Overhead work is less strenuous with simpler tools.
Tensioner fits in same space as old nut. Note stud damage from old methods.
Solutions: Replacement with Superbolt® High Temperature Tensioners took two men with hand-held torque wrenches only one hour and twenty minutes to close this valve, leak free. The customer measured stud stretch and confirmed that the new tensioners did achieve the designed 0.25mm stretch. This confirmation means this measuring will not be needed in the future. Only 81 ft•lbs of torque was required on each jackbolt in the tensioners. Time and labor savings are dramatic proof.
Elimination of the need for stud heaters will save cost of that apparatus and offer cost advantages when studs are replaced ( no need for heating holes).
Historically, stressing the studs on these valves has taken three workmen up to three complete shifts.
Installation complete. Note stud heater holes.
Application: Turbine Control Valves
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
INC.
T h e S o l u t i o n T o B o l t i n g P r o b l e m s
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
INC.
T h e S o l u t i o n T o B o l t i n g P r o b l e m s
35 MW Steam Turbine Split Horizontal Joint Using Superbolt® High Temperature Nuts
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
INC.
T h e S o l u t i o n T o B o l t i n g P r o b l e m s
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
Westinghouse Steam Turbine Split Casing
Service Conditions:Temp: 850 FPressure: 2200 psi
Problem: The inverted position of these nuts make it difficult to obtain the required preload (45,000 psi). Several nuts located further underneath the ends of the unit, are even awkward to reach.
Before the studs can be preloaded, initial clearances in the horizontal joint are taken up, usually by hammer wrenching. Galling of thread surafces and spot faces, promotes seizure of the nut on the stud.
Solution: The use of High Temperature Mechanical Tensioners from Superbolt® made it possible for two workmen to accurately stress the studs in only 3 hours. This was accomplished by tightening the jackbolts in the tensioners with a 3/8” hand-held torquewrench. The need for heavy tightening equipment is eliminated. Preload is applied in pure tension thus eliminating galling. Removal of tensioners is just as easy. Once preload is released, the studs are hand tight. Therefore, the studs will not seize into the housing. Superbolt® Tensioners are reusable making them a permanent and economical solution.
Existing Fasteners:24- 2”, 12- 1-3/4”, 2 - 1-1/2”Studs - A193-B16
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
INC.
T h e S o l u t i o n T o B o l t i n g P r o b l e m s
Various Applications:
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
INC.
T h e S o l u t i o n T o B o l t i n g P r o b l e m s
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
Problem: Traditional methods of bolting, such as stud heaters and hammer wrenching, are inaccurate and often jeopardize employee safety.
Previous to the installation of Superbolt® Torquenuts, this application was not only time consuming to bolt, but dangerous.
Solution: Superbolt® has taken great steps in increasing the safety
Estimated time savings this turnaround = 2 days!
of employees while providing fast and effective ways of bolting. Our patented multi-jackbolt design makes installation quick and safe, only requiring simple hand tools to reach desired torque. The awkward, overhead position of these studs proved to be ideal for the use of Superbolt® products. Complete tensioning time was only 6 hours!
Westinghouse M32 Steam Turbine
Split Casing Bolting900 PSIG/925° F steam•45,000 psi bolt stress•installed: (10) H1050T-250s, (6) H1050T-275s, and (8) H1050T-300s
Application: Steam Turbine
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106 • www.superbolt.com1-800-345-BOLT (USA) • 1-412-279-1149 (International) • Fax: 412-279-1185 • [email protected]
INC.
T h e S o l u t i o n T o B o l t i n g P r o b l e m s
Photos are from a Natural Gas Plant in Canada.
Problems:Contaminated, or sour, natural gas leaking from these tower-top flanges was among the reasons for shutting down this new plant after only two days operation. Up to three days were wasted in attempts to stop the leaking.
The temperature of these joints changes radically and rapidly from 40°C to 300°C in five minutes. Since the flanges are made of different materials (carbon steel vs. stainless steel), they expand and contract at different rates as the temperature changes. As they expand and contract, the bolt stress and gasket compression also vary. The resultant leakage was extremely dangerous due to the high concentration of H S in the sour gas flowing through the flanges.
These flanges are located atop the large tower-tanks, posing safety hazards in the use of conventional large wrenches, sledgehammers and/or hydraulic tightening methods. Potentially flammable leaking gas could mean serious problems from sparks caused by hammering or hydraulic systems.
Specifications:
Flange Size ........................... 8” at 1,500 lbsVessel Flange Material ........... Carbon SteelMating Flange Material ........... 316 StainlessGasket ................................. 316 Stainless RTJ Ring Type
Existing Studs: 1-5/8” 8 TPI ... A193-B7MExisting Hex Nuts ................. A194-2HM
H S Concentration ................ 33%Operating Pressure ................ 2,000 psiOperating Temperature ........... 40°C to 300° C (104°F to 572°F)
Solution:Installation of special sour gas Supernut™ Tensioners results in improved preload on each stud, and provides consistent tension around each entire flange and better gasket compression. Accurate preload and inherent elasticity of the tensioner have proven to compensate for the thermal expansion/contraction.
The reduced torque and smaller wrench requirements were well suited for this elevated location. Two men, using hand held torque wrenches completed the tensioner installation on one tower in only 45 minutes.
All leaks at these tower-top flanges were eliminated.
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Application: Dehydration Towers
We have solved many difficult bolting applications for the petrochemical industry (as well as many other industries).
For more information on our company and our unique bolting products, please visit our website at www.superbolt.com or call us now to discuss your application.
P.O. Box 683 • 1000 Gregg St. • Carnegie, PA 15106(412)-279-1149 • FAX (412)-279-1185 • 1-800-345-BOLT (2658) USA
E-Mail: [email protected] • www.superbolt.com
Superbolt® tensioners are protected by trademark rights and one or more U.S. patents: 5,083,889; 6,199,453; 6,381,827; 6,112,396; 6,263,764;
other patents pending and corresponding foreign patents.
©2009 Superbolt®, Inc.