• Conventional Tensioning Tool

Page 1

Operator Manual

Œ
Conventional Bolt
Tensioning Tool
Thread Insert Type

Part Identifier. Ž
ŒThread Insert
•Piston

Ž
• Seal kit (Configuration varies) 

• Load Cell


• Bridge “
’
‘Nut Rotating Socket (Optional)
’Hydraulic Connection
(Configuration varies)

“Hydraulic Connection
(Configuration varies)

Tentec Limited
Plymouth House
Guns Lane
West Bromwich. West Midlands
United Kingdom. B70 9HS
Internet: www.tentec.net
Email:tech@tentec.net
Telephone: +44(0)121 524 1990
Telefax: +44(0)121 525 1999
‘
Tentec products are subject to continual development and Tentec reserve the right to make changes in the
specification and design of there products without prior notice.
All rights reserved. Reproduction in whole or in part without the permission of Tentec Limited is prohibited.

• Document: Conventional Tool Published: June 2003

© 2003 - Tentec Limited
 • Conventional Tensioning Tool
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Operator Manual
Safety
All general on-site safety procedures must be adopted when using this equipment.

It is recommended that all operators using this system must be trained in the safe
use of the equipment

Never attempt to use this High Pressure equipment if you are in any doubt regarding
the correct assembly and operation.

Always ensure the equipment used is of Tentec supply and is in good working
order.
Subsitution of others equipment is strictly forbidden

Never use Bolt Tensioning equipment that has been modified or machined by
anyone other than Tentec.

Always wear eye protection, gloves and safety boots.

Non essential staff should vacate the immediate area during the tensioning
sequence

Always ensure that all personnel in the near vicinity are aware that pressurisation
of High Pressure equipment is about to take place.

Only approach pressurised Bolt Tensioners when it is certain that the set pressure
is holding steady on the pump pressure gauge.

Never attempt to solve leaks in the system while it is under pressure. Shut the
pump down immediately to zero pressure before attempting to resolve system
leaks.

Never exceed the maximum working pressure of the Bolt Tensioner. (See the
tensioner specification hard stamped on the tool).

Never exceed the maximum piston stroke of the Tool. (See the tensioner
specification hard stamped on the tool).

Never stand in line with the bolts axis, unexpected bolt failure is highly
dangerous.

Ensure suitable thread engagement between tensioner and bolt is achieved ( 1 x

the bolt diameter of thread should protrude from the joint hexagon nut on the
side that the tensioners will be fitted) i.e for a M45 thread, 45mm of thread should
protrude above the hexagon nuts.

It is recommended that the air pressure blow off valve on the pump unit is set at
such a pressures to avoid over loading the bolts.

Examine hydraulic hose assemblies for crushed or badly kinked hoses, replace
damaged hoses immediately.

• Document: Conventional Tool Published: June 2003

© 2003 - Tentec Limited
 • Conventional Tensioning Tool
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Operator Manual
Conventional Type
Detachable Bolt
Tensioning Tool
IF YOU ARE IN ANY DOUBT ABOUT ANY INSTRUCTION
DETAILED IN THIS PROCEDURE, DO NOT HESITATE TO
CONTACT TENTEC

Introduction
In order to apply an evenly distributed load to
a Bolted joint, the sequence in which Hydraulic
Tensioners are applied to the joint is important.
The exact detail of this sequence is dependant upon
the number of Bolts in the joint and the number
of Bolt Tensioners available. In order to optimise
between cost of equipment and the time taken to
tension the joint, it is generally agreed the correct
Bolt/Tool ratio is 50%, in certain instances a 25% ratio
is acceptable. The general rule is - the lower the
Bolt/Tool ratio, the more time it will take to tension
the joint.

This operator procedure details a 50% Bolt/Tool

ratio.

At the end of the document there are brief

procedures for 25%, 50% and 100% Tensioner ratios

For detailed information to Tensioning Sequences

contact Tentec

Precautions
Prior to connecting the hydraulic pump to any bolt
tensioning equipment, the user is to ensure that -
• The working pressure of the hydraulic
pump and the equipment to be operated are
compatible.
• The reservoir pump capacity is adequate to
operate the equipment throughout its range.
• The hydraulic oil specification used within
the pump and the equipment are compatible.
• The technical specifications of the
tensioning tools are known
• Ensure sufficient stud protrudes above the
hexagon or round joint nut

Technical specification
The technical specification of your particular bolt
tensioning tools can be found hard stamped on the
Load Cell Body

• Document: Conventional Tool Published: June 2003

© 2003 - Tentec Limited
 • Conventional Tensioning Tool
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Operator Manual
Step 1
Ensure there is sufficient stud protruding from the top
of the joint nuts. A minimum of 1 x stud diameter is
essential.
Example – For a Bolt size of M30, the required stud
protrusion is 30 mm.

Also ensure full engagement through the hexagon nut on

the opposite end of the studs being tensioned.

Step 2
If Tommy bar holes are not drilled into hexagon nut faces
assemble Nut Rotating Sockets over every alternate Bolt to
be simultaneously tensioned.
Tighten down every bolt on the flange to be tensioned by
using the special Tommy bars supplied with the tensioning
equipment. Ensure the two halves of the joint are pulled
firmly together.

• Document: Conventional Tool Published: June 2003

© 2003 - Tentec Limited
 • Conventional Tensioning Tool
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Operator Manual
Step 3
Assemble the bridge over the first 50% of bolts to be
tensioned (every alternate bolt). Position the bridge
window so that access to either the Nut Rotating
Socket or hexagon nut is comfortably achieved. It is
normal for the bridge window to face radially out from
the centre of a circular flanged joint.

Step 4
Examine around the circumference of the bridge
base to ensure it is sitting flat against the tensioning
surface. The bridge can be adjusted in relation to the
load cell by means of three setscrews, around the base
of the Load Cell.

• Document: Conventional Tool Published: June 2003

© 2003 - Tentec Limited
 • Conventional Tensioning Tool
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Operator Manual
Step 5
Assemble the load cells over the first 50% of bolts to be
tensioned (every alternate bolt). Position the hydraulic
connections so that access is comfortably achieved. It is
normal for the hydraulic connections to face radially out
from the centre of a circular flanged joint.

Step 6
Assemble the Thread Inserts into each Bolt Tensioner
screwing onto the threads protruding above the hexagon
nuts. Ensure the Thread Inserts are threaded to the
same diameter, thread form and pitch as the bolts to be
tensioned. Use the Tommy bars supplied with the tensioning
equipment to fully screw down the Inserts, until contact is
made with the top face of the Load Cells.

• Document: Conventional Tool Published: June 2003

© 2003 - Tentec Limited
 • Conventional Tensioning Tool
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Operator Manual
Step 7
Remove plastic protection caps from all male and
female quick connect couplings. Connect a link hose
from the Pump Unit to the first tool, connection is
made by pulling back the sprung loaded collar on
the female connection, insert the male connector
and release the female collar. A gentle tug on the
link pipe should be enough to make sure the hose is
connected properly.

Connect to either a Air

Safety Note
Driven Pump unit or a
Hand operated Pump Unit
Blue Link Hose – Max Working Pressure = 21750 PSI
(1500 bar)

Red Link Hose – Max Working Pressure = 33000 PSI

(2275 bar)

Step 8 Never pressurise an unconnected MALE

connector

Continue until all of the tensioners are connected together

with link hoses. The last tensioner in the system will have
and unconnected female coupling, this is correct, and can be
left unconnected.

Never pressurise an unconnected male connector

• Document: Conventional Tool Published: June 2003

© 2003 - Tentec Limited
 • Conventional Tensioning Tool
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Operator Manual
Tensioning Procedure
The tensioning system is now ready to apply a bolt load to the
joint.
Before applying pressure to the system make sure you
understand the following points –
• You are aware of the correct operation of the pump unit.
(See Tentec pump unit Operation manual)
• You are aware of the maximum working pressure of
the tensioners. (See Technical label specification on
tensioners)
• You are aware of the maximum piston movement of the
tensioner. (See Technical label specification on tensioners)
• You are aware of the required working pressure that must
be applied to the tensioners. (For guidance in calculating
working pressures and bolt loads, see Tentec technical
paper ‘Load Transfer and Working Pressures’).
• It is recommended the next procedures are read and
understood prior to starting the tensioning.

Safety Note
During pressurisation procedure, continually monitor
both piston stroke and pressure. Never exceed either.

This diagram indicates piston over stroke. An indicator line can be seen emerging from the load cell. NEVER NEVER EXCEED MAXIMUM WORKING
EXCEED MAXIMUM PISTON STROKE PRESSURE

• Document: Conventional Tool Published: June 2003

© 2003 - Tentec Limited
 • Conventional Tensioning Tool
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Operator Manual
Step 9
Close stop valve on pump unit, then pressurise the system to the
required pressure. When the required pressure is reached, stop
the pump (Hold Pressure).
At this stage the bolts will be initially loaded with the load being
held by the tensioners.

Step 10
Check the pump gauge to ensure the pressure is holding firm.
When you are satisfied the pressure is stable, approach the
tensioners and by using the Tommy bar, rotate the hexagon nuts,
(through the Bridge access windows), back down towards the joint
face. Seat the hexagon nuts firmly against the joint, by use of a
mallet and Tommy bar (If the hexagon nuts are not seated firmly,
the tensioning procedure will take much longer to complete). It
is not important in which order the nuts are tightened but to be
sure of not missing one, it is recommended they are tightened in
sequence.

• Document: Conventional Tool Published: June 2003

© 2003 - Tentec Limited
 • Conventional Tensioning Tool
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Operator Manual
Step 11
Slowly release the return to Tank valve on the pump.
The load is now transferred from the tensioners to the
nuts. Use a Tommy bar in the Threaded Thread insert to
return the Piston to their fully closed position (Note – If
the desired pressure has not yet been reached, continue
from Step 6).

Step 12
Disconnect all of the hydraulic link hoses and reposition
the tensioners onto the final 50% of Bolts to be tensioned,
bolts marked B2 and repeat the tensioning operation on
these un-tensioned bolts

B1

B1

B2
B2
B2 B2

B1
B1 B1
B1

B2 B2 B2
B2

B1
B1

• Document: Conventional Tool Published: June 2003

© 2003 - Tentec Limited
 • Conventional Tensioning Tool
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Operator Manual
Topside Bolt Tensioning
De-Tensioning Procedure
When de-tensioning, specific tool pressures are not
normally available as it is not always possible to
calculate the pressure at which the flange nut will break
free. As a guide, if the original flange bolt tightening
pressures are available, the de-tensioning pressure
is usually marginally higher than the original tensioning
pressure (but not always)
SAFETY: Prior to commencement of bolt de-
tensioning ensure that:
• All necessary safety precautions have been carried out
• Personnel involved in bolt tensioning are competent
and fully trained in the use of bolt tensioners and
tightening techniques.
• The procedure and data to be used is authorised by a
responsible Engineer.
• The joints / pipework to be worked on are not ‘live’.
Joints must be at zero pressure and free from
hazardous substances.
• The maximum pressure that can be applied has been
calculated to ensure that either 95% of bolt
material yield is not exceeded or the maximum tool
pressure is not exceeded, whichever is the lower.
Pump must be pre-set to achieve this.
STAGE 1
Assemble the tensioning tools to the bolts. With the
thread insert component fully screwed down and seated
on the piston, unscrew the thread insert through one half
turn. This will prevent the Thread insert becoming locked
onto the piston when the bolt tension is released.
STAGE 4
De-pressurise the system and check to see that the flange nuts
are still free to rotate.
STAGE 5
Remove the bolt tensioners. If the thread insert cannot be
unscrewed and the flange nut is also tight, then the thread insert
has locked onto the top face of the flange nut - see STAGE 6.
If the thread insert cannot be unscrewed but the flange nut is free,
then the thread insert has locked onto the piston - see STAGE 7.
STAGE 6
Thread Insert locked onto top face of nut - If the flange nut is
unscrewed further than that indicated in STAGE 3, it can cause the
nut to become locked onto the thread insert when bolt tension is
released. To release the thread insert / flange nut, the hydraulic
pressure must be re-applied and the flange nut rotated clockwise
(to tighten) half a turn (3 holes on the nut rotating socket). Upon
de-pressurisation the thread insert should be free to rotate.
STAGE 7
Thread Insert locked onto piston - This occurs if the thread insert
has not been unscrewed sufficiently in STAGE 1 (half a turn may
be insufficient for fine threaded bolts) causing the thread insert
to become locked onto the piston as the tension is released in the
bolt. To release the thread insert, re-apply the hydraulic pressure
and turn down the flange nut. Upon depressurisation, the thread
insert should freely rotate. Unscrew the thread insert a further
half turn and repeat STAGES 2 to 5.

STAGE 2
Insert a toggle bar through the tensioner bridge window
and into a hole in the nut rotating socket.
Apply hydraulic pressure to the system until the flange
nuts can be rotated, ensuring that the piston does not
exceed maximum stroke or system pressure does not
exceed that indicated in the safety notes above.

STAGE 3
Turn back each flange nut through one full turn (6 holes
on the nut rotating socket).

• Document: Conventional Tool Published: June 2003

© 2003 - Tentec Limited
 • Conventional Tensioning Tool
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Operator Manual
Tentec use different seal configurations due to differences in
tensioner specifications and tensioner usage enviroments
This page details the replacement of type S2/K2 high pres-
sure seals

Notice the orientation of the Place outer back-up ring onto piston
triangular sectioned back-ups rings. It outer seal housing.
is very easy to assemble the back-up
rings the wrong way.

Position and stretch over the outer

seal into piston outer seal housing.

With a rounded smooth screwdriver push home the seal until the seal clips
into the seal housing. Ensure the seal and back-up ring are fully seated
around circumference

Squeeze the inner seal into the inner Push home the inner seal with a
seal housing smooth rounded screwdriver

Place the inner back-up ring below the Carefully bend the back-up ring to enable it to
inner seal clip into position. Ensure the seal and back-up
ring are fully seated around the circumference
• Document: Conventional Tool Published: June 2003
© 2003 - Tentec Limited
 • Conventional Tensioning Tool
Page 13
Operator Manual
Topside Bolt Tensioning
Procedure Using 25%
Tool Coverage
The following tensioning procedures are only for use with
Hydraulic Bolt Tensioners and are specifically compiled for
tension tightening of standard pressure containing flanged
joints. The object of each procedure is to accurately
achieve a pre-determined residual bolt stress.
SAFETY: Prior to commencement of bolt tensioning ensure
that:
• All necessary safety precautions have been carried out
• Personnel involved in bolt tensioning are competent and
fully trained in the use of bolt tensioners and tightening
techniques.
• The procedure and data to be used is authorised by a
responsible Engineer.
• The joints / pipework to be worked on are not ‘live’.
Joints must be at zero pressure and free from hazardous
substances.
• Bolt tensioning pressures, specific to the flanged joint to
be tightened, are available.
STAGE 1
Number each bolt 1, 2, 3 etc.
STAGE 2
Square up the flanged joint using hand tools, or if
necessary bolt tensioners.
STAGE 3
Assemble tensioning tools to the first 25% of the bolts
(i.e. select odd numbered bolts, equally spacing the
tensioners) and apply the ‘Pressure A’ as indicated in the
bolt tensioning data.
Whilst maintaining the system under pressure, turn down
the flange nuts using a toggle bar.
Always tap the toggle bar using a hammer to firmly seat
the nut against the flange surface.
Release the system pressure and re-apply twice further,
i.e. apply ‘Pressure A’ and turn down nuts three times.
STAGE 4
Move the tensioning tools to the remaining un-tightened
odd numbered bolts, and apply the ‘Pressure A’ as
• Document: Conventional Tool
© 2003 - Tentec Limited
indicated in the bolt tensioning data. Turn down the flange
nuts.
Release the system pressure and re-apply twice further, i.e.
apply ‘Pressure A’ and turn down nuts three times.
NOTE: It is often advisable to continuously repeat STAGE
3 and 4, especially with Ring Type Joints, until no further
movement of the flange nuts can be obtained. Also, it
may be beneficial to allow a few minutes between each
pressurisation to allow the gasket to bed in.
STAGE 5
Move tensioning tools to first set of even numbered bolts
(ensuring that the tensioners are equally spaced) and apply
the ‘Pressure B’ as indicated in the bolt tensioning data. Turn
down the flange nuts.
Release the system pressure and re-apply twice further, i.e.
apply ‘Pressure B’ and turn down nuts three times.
STAGE 6
Move the tensioning tools to the remaining un-tightened even
numbered bolts, and apply the ‘Pressure B’ as indicated in
the bolt tensioning data. Turn down the flange nuts.
Release the system pressure and re-apply twice further, i.e.
apply ‘Pressure B’ and turn down nuts three times.
STAGE 7
Due to the number of tensioning tool passes, it is inevitable
that load losses will have occurred between each pass. It is
therefore advisable to re-assemble the tensioning tools
back to the bolts tightened in STAGES 3 and 4 (and if
necessary STAGES 5 and 6), apply ‘Pressure B’ and turn down
the flange nuts.
This MUST be constantly repeated until there is no further
nut movement.
STAGE 8
As a final check, using a hammer, ‘ring’ each bolt to ensure
that no loose bolts remain.
Published: June 2003
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Operator Manual
Topside Bolt Tensioning
Procedure Using 50%
Tool Coverage beneficial to allow a few minutes between each pressurisation
to allow the gasket to bed in.

The following tensioning procedures are only for use with

Hydraulic Bolt Tensioners and are specifically STAGE 5

compiled for tension tightening of standard pressure Move the tensioning tools onto the remaining 50% of bolts (all

containing flanged joints. The object of each procedure even numbered bolts) and apply the ‘Pressure B’ as indicated

is to accurately achieve a pre-determined residual bolt in the bolt tensioning data. Turn down the flange nuts.

stress.
STAGE 6

SAFETY: Prior to commencement of bolt tensioning Release the system pressure and repeat STAGE 5 twice further,

ensure that: i.e. apply ‘Pressure B’ and turn down nuts three times.

• All necessary safety precautions have been carried out

• Personnel involved in bolt tensioning are competent and STAGE 7

fully trained in the use of bolt tensioners and As a check to see if an excessive load has been lost in the

tightening techniques. initial 50% of bolts tightened (odd numbered bolts), assemble

• The procedure and data to be used is authorised by a two tensioning tools to randomly selected but diametrically

responsible Engineer. opposite odd numbered bolts. Apply ‘Pressure B’ and attempt

• The joints / pipework to be worked on are not ‘live’. Joints to further tighten the flange nuts. If the nuts cannot be further

must be at zero pressure and free from tightened, then tensioning is complete and the tensioners

hazardous substances. may be removed.

• Bolt tensioning pressures, specific to the flanged joint to be If the flange nuts can be further tightened, then reassemble

tightened, are available. the tensioning tools onto all of the odd numbered bolts. Apply
‘Pressure B’ and turn down the flange nuts once more.

STAGE 1 The bolt tensioners may now be removed.

Number each bolt 1, 2, 3, etc.

STAGE 8

STAGE 2 As a final check, using a hammer, ‘ring’ each bolt to ensure

Square up the flanged joint using hand tools, or if necessary that no loose bolts remain

bolt tensioners.

STAGE 3
Assemble the tensioning tools to 50% of the bolts (i.e. all
odd numbered bolts) and apply the ‘Pressure A’ as indicated
in the bolt tensioning data. Whilst maintaining the system
under pressure, turn down the flange nuts using a toggle bar.
Always tap the toggle bar using a hammer to firmly seat the
nut against the flange surface.

STAGE 4
Release the system pressure and repeat STAGE 3 twice
further, i.e. apply ‘Pressure A’ and turn down nuts three
times.
NOTE: It is often advisable to continuously re-apply ‘Pressure
A’, especially with Ring Type Joints, until no further
movement of the flange nuts can be obtained. Also, it may be

• Document: Conventional Tool Published: June 2003

© 2003 - Tentec Limited
 • Conventional Tensioning Tool
Page 15

Operator Manual
Topside Bolt Tensioning
Procedure Using 100%
Tool Coverage
The following tensioning procedures are only for use with
Hydraulic Bolt Tensioners and are specifically
compiled for tension tightening of standard pressure
containing flanged joints. The object of each procedure
is to accurately achieve a pre-determined residual bolt
stress.
SAFETY: Prior to commencement of bolt tensioning
ensure that:
• All necessary safety precautions have been carried out
• Personnel involved in bolt tensioning are competent and
fully trained in the use of bolt tensioners and
tightening techniques.
• The procedure and data to be used is authorised by a
responsible Engineer.
• The joints / pipework to be worked on are not ‘live’.
Joints must be at zero pressure and free from
hazardous substances.
• Bolt tensioning pressures, specific to the flanged joint to
be tightened, are available.
STAGE 4
Release the system pressure and repeat STAGE 3 twice further,
i.e. apply ‘Pressure B’ and turn down nuts three times.
NOTE: It is often advisable to continuously re-apply ‘Pressure
B’, especially with Ring Type Joints, until no further movement
of the flange nuts can be obtained. Also, it may be beneficial
to allow a few minutes between each pressurisation to allow
the gasket to bed in.
STAGE 5
As a check, apply ‘Pressure B’ once more and attempt to
further tighten the flange nuts. If the nuts cannot be further
tightened, then tensioning is complete and the tensioning
tools may be removed.
If the flange nuts can be further tightened, then ‘Pressure B’
must be continuously re-applied until no further movement of
the flange nuts can be obtained.
The bolt tensioners may now be removed
STAGE 6
As a final check, using a hammer, ‘ring’ each bolt to ensure
that no loose bolts remain

STAGE 1
Square up the flanged joint using hand tools, or if
necessary bolt tensioners.

STAGE 2
Assemble one tensioning tool to each bolt. Occasionally,
depending upon the pitch of the bolting, the tensioners
may be able to be assembled on one side of the flange.
Otherwise, 50% of the tensioners are to be assembled to one
side of the joint with the remaining on the opposite. Upon
hose connection ensure that tensioners from both sides of
the flange are connected into the hydraulic hose harness.

STAGE 3
Apply the ‘Pressure B’ as indicated in the bolt tensioning
data. Whilst maintaining the system under pressure, turn
down the flange nuts using a toggle bar. Always tap the
toggle bar using a hammer to firmly seat the nut against the
flange surface.

• Document: Conventional Tool Published: June 2003

© 2003 - Tentec Limited