CS 5200 SC01 Ope PRC 253007 - A - C2

Find the CTR comment enclosed.
The comment sheet is available separately.
COMPANY: TULLOW
PROJECT: JUBILEE SOUTH EAST
DOCUMENT NUMBER: CS-5200-SC01-OPE-PRC-253007
DOCUMENT TITLE: JSE - ORSAM - IN-COUNTRY LARGE FABRICATION -

BOLT TENSIONING & TORQUING PROCEDURE
Arnaud
VENDOR DOCUMENT REVIEW VENDOR DOCUMENT REVIEW Machefel
VENDOR DOCUMENT REVIEW
2022.02.17
1 REVISE AND RESUBMIT 1 REVISE AND RESUBMIT 1 REVISE AND RESUBMIT
2 TO BE ISSUED AS FINAL 2 TO BE ISSUED AS FINAL 2 TO BE ISSUED AS FINAL
PROVIDED COMMENTS ARE PROVIDED COMMENTS ARE PROVIDED COMMENTS ARE
10:59:43 +01'00'
INCORPORATED INCORPORATED INCORPORATED
3 NO COMMENT - FINAL ISSUE 3 NO COMMENT - FINAL ISSUE 3 NO COMMENT - FINAL ISSUE
'LJLWDOO\VLJQHGE\
$UVHQH Written By
$UVHQH76$*8(
'1FQ $UVHQH
76$*8(
Checked By
76$*8
1XPpULTXHPHQWVLJQpSDU7XORXS
5HDVRQ,KDYH 9LFWRU
7XORXS
Digitally signed by Emre Edizer '1FQ 7XORXS9LFWRUJQ 7XORXS
UHYLHZHGWKLVGRFXPHQW DN: C=FR + CN=Emre Edizer + 9LFWRUF )5)UDQFHO )5)UDQFH
(
O=Orsam Oil & Gas +
/RFDWLRQ Emre Edizer E=emre.edizer@orsam-oil-gas.com
R 257(&*URXSHRX &RQWUDFWLQJ
,QWHUQDWLRQDO
'DWH
9LFWRU
+ OU=Quality Assurance & Control
Department H YLFWRUWXORXS#RUHWFIU
5DLVRQ-
DLH[DPLQpFHGRFXPHQW
= Date: 2022.01.28 15:18:16Z00'00'
(PSODFHPHQW
'DWH
A 28/01/2022 Issued for Review Arsene TSAGUE Emre EDİZER

Approved By Victor TULOUP
Rev Date Reason for issue Written By Checked By Approved By
Page footer text | 1
DOCUMENT REVISIONS
Sections d in last revision are identified by a vertical line in the left margin
PROPERTY OF TULLOW
DO NOT DISTRIBUTE without first referring to the MASTER DOCUMENT REGISTER ref 300032C-000-NM-0000-0001 to ensure that this document is not marked
“Blackbox document” and that it can be shared.
JSE - ORSAM - In-country Large Fabrication -
Bolt Tensioning & Torquing Procedure
SCTR Document Number Revision Rev. Date: 28/01/2022
CS-5200-SC01-OPE-PRC-253007 A Page 2 / 78.
Table of content
1. INTRODUCTION .......................................................................................................... 3
2. PURPOSE.................................................................................................................... 4
3. SCOPES ...................................................................................................................... 4
4. REFERENCE DOCUMENTS ....................................................................................... 4
4.1. Reference International Standards ........................................................................ 4
4.2. Reference Company Documents .......................................................................... 5
4.3. Reference Contractor Documents ......................................................................... 5
4.4. Reference Supplier Documents ............................................................................ 5
5. DEFINITIONS AND ABBREVIATIONS......................................................................... 6
6. RULES AND RESPONSABILITIES .............................................................................. 7
6.1. PROJECT MANAGER .......................................................................................... 7
6.2. QUALITY CONTROLLER ..................................................................................... 7
6.3. SITE SUPERVISOR.............................................................................................. 7
6.4. HSE SUPERVISOR .............................................................................................. 7
7. SAFETY REQUIREMENTS .......................................................................................... 7
8. HYDRAULIC PRESSURE ............................................................................................ 9
8.1. 50% Tensioning Coverage .................................................................................... 9
9. BOLTS TENSIONING DATA ...................................................................................... 10
ATTACHMENT 1 – BOLTS TENSIONING TASK PLAN ...................................................... 12
ATTACHMENT 2 – JOB SAFETY ANALYSIS ..................................................................... 15
ATTACHMENT 3 – HYDRATIGHT PUMP CERTIFICATE .................................................. 17
ATTACHMENT 4 – BOLT TENSIONING REPORT ............................................................. 18
ATTACHMENT 5 – PUMP OPERATING MANUAL ............................................................. 19
ATTACHMENT 6 – TENSIONER OPERATING MANUAL .................................................. 20
PROPERTY OF TULLOW
DO NOT DISTRIBUTE without first referring to the MASTER DOCUMENT REGISTER ref 300032C-000-NM-0000-0001 to ensure that this document is
not marked “Blackbox document” and that it can be shared.
1. INTRODUCTION
The Jubilee Partnership has developed hydrocarbon reserves from the Jubilee Field in the West Cape
Three Points and Deepwater Tano blocks offshore Ghana, West Africa. The field, split into east and west
sides by a subsea canyon, consists of the Upper and Lower Mahogany reservoirs in water depths ranging
from 900 to 1,700 meters, located some 130 km WSW of Takoradi, Ghana.
An isometric field layout detailing the existing facilities together with the proposed Jubilee South East
Development Project (JSE) extension area – highlighted in yellow) is shown in Figure 1.
Figure 1 – Jubilee field schematic
The Jubilee South East Development Project (JSE) is further connecting the Jubilee field to a new
production drill centre at P6 location (with 3 new production wells + 3 future wells) and new water
injection drill centre at WI6 location (with 1 new injection well + 3 future wells).
PROPERTY OF TULLOW
2. PURPOSE
This procedure is applicable for the Jubilee southeast Development Project (JSE).
The purpose of this document is to define all the steps to achieve the bolts tensioning and torquing
operation during the final assembly of permanent items on the Jubilee southeast Development Project
(JSE).
3. SCOPES
This Procedure is applicable to the Water Injection and Gas Injection Jumpers on the Jubilee southeast
Development Project (JSE).
Item LIST
1 6’’ Production Jumper
2 6’’ Water Injection Jumper
3 6" Production Gooseneck insulated

4 10" Production Gooseneck insulated
5 8" Water Injection Gooseneck
6 10" Water Injection Gooseneck
7 WI5 Goosenecks
4. REFERENCE DOCUMENTS
4.1. Reference International Standards
Documents Reference
Occupational health and safety management system pdf ISO 45001- Edition 2018
Quality Management Systems - Requirements ISO 9001- Edition 2015

Petroleum, petrochemical and natural gas industries — Sector-specific
quality management systems — Requirements for product and service ISO/TS 29001- Edition 2020
supply organizations
PROPERTY OF TULLOW
4.2. Reference Company Documents
Documents Reference
SCOPE OF WORK Section 3(A) _Rev1
QUALITY REQUIREMENTS Section 3(G) _Rev1
Handling Procedure for TQ, DR and CR TGJSU002-PM-PRO-0001 _Rev0
Company Provided Items (CPI) Receipt and Handover Procedure TGJSU002-QA-PRO-0001 _Rev0
Specification for Welding of Carbon Steel and CRA Clad
00002-INT-PL-SPE-1118_Rev4
Linepipe
Specification for Structural Steel 00002-INT-ST-SPE-1110_Rev1
4.3. Reference Contractor Documents
Documents Reference
EXHIBIT A - SCOPE OF WORK 300032C-000-CSA-5200-0001_rev3
Exhibit I - HSE Requirements 300032C-000-CSI-5200-0001_rev1

Exhibit D - Free-Issued Drawings 300032C-000-CSD-5200-0001_rev1
EXHIBIT H - QUALITY REQUIREMENTS 300032C-000-CSH-5200 0001_rev0
4.4. Reference Supplier Documents
Documents Reference
JSE - ORSAM - In-country Large Fabrication - Project Quality Plan CS-5200-SC01-HSE-PRC-193024
JSE - ORSAM - In-country Large Fabrication - Work Permit
CS-5200-SC01-HSE-PRC-193025
Procedure
JSE - ORSAM - In-country Large Fabrication - Hazard Identification
CS-5200-SC01-HSE-PRC-193026
Risk Assessment
JSE - ORSAM - In-country Large Fabrication - Emergency response
CS-5200-SC01-HSE-PRC-193028
plan - TGL Yard
JSE - ORSAM - In-country Large Fabrication - Emergency response
CS-5200-SC01-HSE-PRC-193029
plan - SCTR Yard
JSE - ORSAM - In-country Large Fabrication - Equipment Calibration
CS-5200-SC01-EQP-REG-152931
Register & Certificate
PROPERTY OF TULLOW
JSE - ORSAM - In-country large fabrication - Factory Acceptance

CS-5200-SC01-OPE-PRC-253010
Test and Dimensional Procedure for Goosenecks & Jumpers
JSE - ORSAM - In-country Large Fabrication - Inspection and Test
CS-5200-SC01-QCI-ITP-331737
Plan for Pipeline (incl. Integration)
5. DEFINITIONS AND ABBREVIATIONS

DEFINITIONS
COMPANY TULLOW
CONTRACTOR TECHNIPFMC
SUPPLIER ORSAM OIL and GAS
SUB-SUPPLIER ORSAM’s SUPPLIER
PROJECT Jubilee South East Development Project
Means all and any part of the works and services required to be performed by
WORK CONTRACTOR under the CONTRACT for the full and complete realization of the plan
ABBREVIATIONS
HIRA Hazard Identification & Risk Analysis
JSA Job Safety Analysis
mT Metric Ton
PTW Permit To Work
S/C SUB-SUPPLIER (ORSAM’s suppliers)
PTW Permit To Work
JSA Job Safety Analysis
MPFM Multi-Phase Flow Meter
SPFM Single Phase Flow Meter
BST Back Seal Test
FJC Field Joint Coating
GE Gas Export
GI Gas Injection
PROPERTY OF TULLOW
6. RULES and RESPONSABILITIES

6.1. PROJECT MANAGER
The Project Manager should provide all the necessary instructions and equipment needs on site.
He should ensure that all documentation related to this scope of work (procedure, task plans, checklists,
risk assessment, etc.) has been issued and approved by CTR/CPY before start the operation.
6.2. QUALITY CONTROLLER

The assigned ORSAM quality controller is in charge of witnessing the test and ensure it is carried out in
accordance with the procedure.
Assigned QC has to make all pertaining records ready and available for review by all parties concerned.
They have to prepare pertinent records after the test.
6.3. SITE SUPERVISOR

The site supervisor is responsible for the implementation of this procedure, the preparation and carrying
out of the bolt tensioning.
He should check that all equipment involve in bolt tensioning is fit for purpose, working as described in
equipment operating manuals (see Attachment 5 & 6 for Hydraulic pump and Bolt Tensioners manuals)
and that all equipment is certified and calibrated when applicable.
6.4. HSE SUPERVISOR

The assigned ORSAM HSE supervisor is in charge of all safety requirements related to the bolts
tensioning. He ensures that all safety measures required for the work are put in place.
7. SAFETY REQUIREMENTS
Prior to the start of the work on site a pre-job safety meeting will be conducted to ensure that all parties
involved are well aware of their activities and all the involved hazards. This meeting shall be held onsite
and should cover an outline of the work to be conducted. It should also cover all recognised hazards and
the plans to control them and emergency response contingency plans. Those attending should include
all supervision and personnel dedicated to the bolt tensioning.
Refer to Attachment 4 for Job Safety analysis template.
In addition to the Job Safety Analysis, a Toolbox Talk will be conducted on site before each bolt
tensioning operation.
All S/C personnel involved in bolt tensioning operations shall attend the Toolbox Safety Talk, with details
of the works, the hazards and the precautions being discussed. Where shift work is in operation, the
Toolbox Safety Talk will be given to personnel on both shifts.
Bolt tensioning operations will be conducted by S/C Site Construction Manager, in conjunction with
CONTRACTOR QA/QC representatives.
PROPERTY OF TULLOW
Description of the bolt tensioning
Figure 1 – Bolt tensioner & Air driven Hydraulic Pump
Refer to Attachment 3 for Hydraulic Pump calibration certificate.
PROPERTY OF TULLOW
8. HYDRAULIC PRESSURE
The hydraulic pressure given here-below is applicable for the tensioning of all bolting
assemblies (MPFMs, SPFMs and Sampling Vessels):
Description Bolt Tensioning Torque Tightening
Hydratight Residual Applied
50% Cover
Pressure Tool Ref Load load Torque Lubricant
Joint ID
Class 1st 2nd Values (COF)
Pass Pass
PG- 1243
180 kN 995 Bar
001/76352 Bar
residual 180 kN 268,4 kN
10000 -72- 930 Nm 0,13 μ
load + µ 41,2% Ys 61,4% Ys 18 031 14 425
09/PRV-
=0,13 Psi Psi
001
Figure 2 - Hydraulic pressure for bolt tensioning
8.1. 50% Tensioning Coverage

The tensioning of the flanges will be done using 50% coverage.
This method of installation is normally used where studbolts are required to be tensioned from one side
of the flange only, due to an access restriction on the opposite.
It is basically a two stage tensioning operation where 50% of the studbolts are tensioned in the first
stage, followed by the remaining 50% of studbolts in the second stage. In order to adopt this method
the studbolts must be assembled with the protrusions on the same side of the flange as illustrated in
next figure.
In this case, the bolts of the face A of the flanges (1st side) will be pressurized to the 1st pass pressure as
indicated in
Figure 2 - Hydraulic pressure for bolt tensioning.
Then, the bolt tensioners will be setup on the other face (face B – 2nd side) of the flanges and will be
pressurized to the 2nd pass pressure as indicated in
Figure 2 - Hydraulic pressure for bolt tensioning.
PROPERTY OF TULLOW
Studbolts
arrangement for 50%
tensioner coverage
tensioning
Figure 3 - Typical Hydraulic Tensioner Arrangement (50% coverage)
9. BOLTS TENSIONING DATA
PROPERTY OF TULLOW
PROPERTY OF TULLOW
DO NOT DISTRIBUTE without first referring to the MASTER DOCUMENT REGISTER ref 300032C-000-NM-0000-0001 to ensure that this document is not marked “Blackbox document” and that it can be shared.
ATTACHMENT 1 – BOLTS TENSIONING TASK PLAN
PROPERTY OF TULLOW
PROPERTY OF TULLOW
PROPERTY OF TULLOW
ATTACHMENT 2 – JOB SAFETY ANALYSIS
1- System Description
Perform bolt tensioning

2- Scope
This sheet JUST concerns bolt tensioning

3- Checklist before bolt tensioning job
Concerning materials:
All used material (gauge, bolting, flanges, valves and fittings…) must be fit for purpose.
All used material (gauge, bolting, flanges, valves and fittings…) must be in good condition.
Screwed fittings: the number of thread are in good condition
Concerning work area:
Facility access to area for operators during operations
Area is barriered and indicating as Bolt Tensioning Work Area
Operator present in his job
Nobody unauthorized in the work area
4- Procedure – Good rules
Working execution:
ALWAYS WEAR SAFETY GLASSES when working with or near the pressurized hydraulic
system
When pressurizing the system, observe the gauge, and be ready to stop, at the required
pressure
Read both Tooling and Hydraulic Hand Pump and Control Console Operation and
Maintenance Manuals prior to operation
Ensure anti-whip are in place for each hoses / flexibles and are tightened to a strong
and fix point
5- Don’t do this
Concerning the material:

Don’t use materials in poor condition or not adapted
During the operation:

Don’t exceed the maximum working pressure for each stud size or tensioner
PROPERTY OF TULLOW
Don’t exceed the maximum extension for the equipment
Don’t Leave the pressurized 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
Don’t pressurize the Control Console or Hand pump unless the outlet is either connected to the
tensioning system or is safely blanked with a blanking plug
PROPERTY OF TULLOW
ATTACHMENT 3 – HYDRATIGHT PUMP CERTIFICATE
PROPERTY OF TULLOW
ATTACHMENT 4 – BOLT TENSIONING REPORT

Equipment identification
Jumper n°:
Date :
Assembly Type :
Test done by :
Inspection of the equipments : Conform No conform
Pump :
Gauge :
1 TENSIONING
Gap measurement
Flats turned (turn Nb)
Pressure (mm)
3 6 9 12 1 2 3 4 5 6 7 8 9 10 11 12
Initial
FIRST PASS (50%) Bolt N° 1 / 3 / 5 / 7 / 9 / 11
18 031 psi / 1 243 bars
18 031 psi / 1 243 bars
18 031 psi / 1 243 bars
18 031 psi / 1 243 bars
18 031 psi / 1 243 bars
SECOND PASS (50%) Bolt N° 2 / 4 / 6 / 8 / 10 / 12

14 425 psi / 995 bars
14 425 psi / 995 bars
14 425 psi / 995 bars
14 425 psi / 995 bars
14 425 psi / 995 bars
NOT ACCEPTED
ACCEPTED
Comments: …………..............................................................................................
ORSAM TFMC TULLOW
Date : Date : Date :

Name : Name : Name :
Signature : Signature : Signature :
PROPERTY OF TULLOW
ATTACHMENT 5 – PUMP OPERATING MANUAL
PROPERTY OF TULLOW
10-6 AIR DRIVEN PUMP UNIT
OPERATION AND MAINTENANCE INSTRUCTIONS
Hydratight Limited
Bentley Road South
Darlaston West Midlands
WS 10 8LQ England.
Tel: +44121 5050 600

Fax: +44 121 5050 800
(0-25000 psi / 0-1700 bar gauge)
www.hydratight.com
HYDRATIGHT is the registered trade mark of Hydratight Limited

SECTION: DESCRIPTION:
1 SAFETY
2 DESCRIPTION OF THE HYDRAULIC PUMP

UNIT
3 OPERATION
4 SERVICING OF HYDRAULIC PUMP UNITS
5 SERVICING INSTRUCTIONS
6 STORAGE AND SPARES
7 DIAGRAMS:-
1. Pump Unit: PAMPCA106H20SS
PAMPCA106H20SS – REV 6 Page 2 of 30

1. SAFETY NOTES
1.1 NEVER exceed the SAFE WORKING PRESSURE for the Harness, Tools or Pump.
1.2 ALWAYS wear safety glasses while operating the pump.
1.3 Before connecting the DRY

AIR SUPPLY, ensure that
a) the ON/OFF (air flow)
valve is closed. (i.e. handle
in vertical position) and b)
the Oil Return-To-Tank
valve is open. Connecting
the air supply with the air
flow valve open and Oil
return valve closed will
immediately start the pump
and could lead to excessive
system pressures, especially
if the pump has not been B
regulated as recommended
in section 3, Pump A
Operation – Setting Stall
Pressure.
A) Close ON/OFF (air flow) valve
B) Open return to tank valve
1.4 ALWAYS ensure that the quick disconnect CEJN COUPLINGS are properly connected by
physically pulling on them.
1.5 Keep pressurised times to a minimum, work quickly and efficiently while the system is
pressurised.
1.6 ALWAYS De-pressurise when leaving the system unattended.
REMEMBER - TAKE CARE! HIGH PRESSURE HYDRAULICS ARE PERFECTLY

SAFE IF THE BASIC SAFETY RULES ARE FOLLOWED.

2. DESCRIPTION OF HYDRAULIC PUMP UNIT

The Hydraulic Pump Unit is compact, robust, and designed for simplicity and speed of operation.
The unit measures 3 80mm x 380mm x 440mm high, and weighs approx. 27 kg (with oil). It
comprises of a reciprocating piston pump mounted in a tubular frame with drip tray, containing an
oil reservoir and all air/oil valves and fittings.
It consists of the following components:
Air Filter
Ensures that a clean, dry air supply is maintained. Any water is collected in the bowl and can be
drained off by turning the filter drain screw clockwise.
Air Regulator
Complete with its own pressure gauge, regulates the air pressure to the pump. To increase air
pressure, screw the air regulator into its body.
Air Lubricator
Lubricates air supply and should be set to give one drop for every 40 strokes of the pump, by turning
adjusting the red knob. Top up when required using a lubricating oil of ISO Viscosity
Grade 10.
Air Flow Valve
Controls air supply to pump and gives variable pump speed control.
Reservoir
Capacity 9 litres, has coarse filter at filler neck and fine filter at outlet pipe. Level indication tube
should be at least half full. Top up when required using an anti-wear hydraulic oil of ISO Viscosity
Grade 32. Appropriate viscosity grades of oils shall be selected dependant on operating temperatures.
Oil Return-to-tank Valve
When open allows oil to flow back to reservoir. To open, turn handle anti-clockwise.
Pump
Piston type unit. Full breakdown details and spare seal kits available on request.
Oil Pressure Gauge
0-/1700 Bar (0-25,000 psi). Accuracy should be checked and calibrated periodically.

Oil Outlet Connection
Quick release type, which is self-sealing to prevent dirt penetration and oil drips.
Air Inlet Connection
Standard 1/2 inch, reduced to 1/4 inch BSPT, via an adaptor.
IMPORTANT NOTE
THE PUMP IS SHIPPED FROM FACTORY WITHOUT HYDRAULIC OIL.

ADD HYDRAULIC OIL BEFORE OPERATING THE PUMP!
USE ISO VISCOSITY GRADE 22 MINIMUM –68 MAXIMUM
AIR CONSUMPTION SPECIFICATION
Air consumption is approximately 28 CFM (Cubic Feet per Minute) of free air at 100 psi, for an oil
discharge pressure of 25000 psi. At lower air pressures and higher hydraulic pressures, air
consumption will be reduced proportionally to the flow rates indicated.
Approximate Air to Hydraulic Pressure Ratios - Static Conditions
10
AIR PRESSURE 20 30 40 50 60 70 80 90 100
(PSI
3
HYD. PRESSURE 6 9.5 12.6 16 19.1 22.3 25.6 29 32.3
(x1000 PSI
0.7
AIR PRESSURE 1.4 2.1 2.8 3.5 4.2 4.9 5.6 6.3 7.0
(Bar
207
HYD. PRESSURE 414 655 869 1103 1317 1538 1766 2000 2228
(Bar
AIR PRESSURE 0.07 0.14 0.21 0.28 0.35 0.42 0.49 0.56 0.63 0.7
(Mpa
HYD. PRESSURE 20.7 41.4 65.5 86.9 110.3 131.7 153.8 176.6 200 222.8
(MPa

Approximate Rate of Discharge

CIPM (Cubic Inch per Minute) and CCMPM (Cubic Centimetres per minute)
OIL DISCHARGE AIR INLET PRESSURE

PRESSURE 
60 PSI 80 PSI 100 PSI
6000PSI 43CIPM 51 54
9000PSI 38 46 49
12500 PSI 31 40 44
15000 PSI 27 37 40
20000 PSI 0 30 34
25000 PSI 0 10 28

PRESSURE 
4Bar 5.5Bar 7Bar
414Bar 705 CCMPM 836 885
620 Bar 623 754 803
862 Bar 508 656 721
1034 Bar 443 606 656
1379 Bar 0 492 557

1724 Bar 0 164 459

PRESSURE 
400000 Pa 550000 pa 700000 Pa
41.4 Mpa 705CCMPM 836 885
62.0 Mpa 623 754 803
86.2Mpa 508 656 721
103.4 Mpa 443 606 656
137.9 Mpa 0 492 557

0 164 459
172.4 Mpa

3. OPERATION
OBSERVE PUMP SAFETY AND OPERATING INSTRUCTIONS

BEFORE OPERATING
It is recommended that the pump be regulated to stall at the pressure required to
operate the hydraulic tools.
3.1. SETTING STALL PRESSURE (with the Air Regulator)
It is recommended that the pump is regulated to stall at the pressure required to operate the hydraulic
tools. To regulate the pump, proceed as follows:
3.1.1. Check Oil level in reservoir and fill if necessary.
3.1.2. Fit a blanked off nipple / coupling or a self-connected interconnecting pipe to the Pump
Outlet Coupling. (NEVER pressurise an unconnected CEJN Connection).
3.1.3. Open Oil return-to-tank valve.
3.1.4. Close the ON/OFF (Air Flow) valve
3.1.5. Connect main AIR SUPPLY to pump.
3.1.6. Check that the air gauge is giving a reading.
3.1.7. Open the ON/OFF (Air Flow) valve and allow the pump to operate for approximately 1
minute or until no air bubbles can be seen in the system.
3.1.8. Turn air pressure regulator screw to give zero pressure reading on air pressure gauge (pump
ceases to operate when air pressure reaches zero).
3.1.9. Close Oil return-to-tank valve.
3.1.10. Screw in air pressure regulator until the desired operating pressure is indicated on the oil
pressure gauge.
3.1.11. Close ON/OFF (Air Flow) valve.
3.1.12. SLOWLY open Oil return-to tank valve, releasing pressure. The pump is now set to stall at
the desired operating pressure and is ready to be coupled to the hydraulic harness.

WARNING
WITH ONLY A BLANKED OFF NIPPLE / COUPLING FITTED TO THE PUMP OUTLET
THE OIL PRESSURE WILL BUILD UP VERY QUICKLY. ENSURE THAT AIR
PRESSURE IS REGULATED (STALL PRESSURE SET) TO A LEVEL THAT WILL NOT
ALLOW OVER PRESSURISATION OF THE SYSTEM.
3.2. PUMP OPERATION
3.2.1 PRESSURISE the system by closing the Oil return-to-tank valve and opening the ON/OFF
(air flow) valve.
3.2.2 DE-PRESSURISE the system by closing ON/OFF (air flow) valve and SLOWLY opening
return-to-tank valve.
3.3. PUMP DISCONNECTION

3.3.1. Ensure system has been De-pressurised, by closing ON/OFF (air flow) valve and SLOWLY
opening return-to-tank valve.
3.3.2. Disconnect air supply.
3.3.3. Ensure Oil return to tank valve is open.
3.3.4. Open ON/OFF (air flow) valve.
3.3.5. Drain off any Oil from the air filter.
3.3.6. Store as detailed in section 6, Storage.

SETTING THE PUMP STALL PRESSURE (Air Regulator)
1. Open return to tank valve. 2. Close on/off (air flow) valve.
1/2” BSP
Port
3. Connect to DRY AIR SUPPLY. 4. Check a pressure reading is given on gauge.

5. Open on/off (air flow) valve, allow 6. Adjust air regulator valve to
pump to operate for approximately give an air pressure gauge
one minute until air has been removed reading of zero – pump stops
from system operating.
7. Close the return to tank valve. 8. Open air regulator valve so that
pump operation starts.

9. Adjust air regulator valve until the required 10.0 Close on/off (air flow) valve.
stall pressure on the “high pressure” gauge is
achieved.
11. SLOWLY open the return to tank valve.

4. SERVICING THE HYDRAULIC PUMP UNIT
We would recommend that in the event of failure or of general maintenance, the pump is
returned to Hydratight Limited, where our experienced Service Engineers can carry out the
necessary repairs

FOR HYDRAULIC PUMP - MODEL No.: 10-6
5.1. TO DISASSEMBLE THE MOTOR - Refer to Parts List for part numbers and cross section
of the pump.
5.1.1 Remove the eight 5/16" bolts that clamp the Air Cylinder (Item 2) between the head
Casting (Item 12) and the Air Cylinder End (Item 1). Remove the Head by tapping on a
fitting screwed into either the "AIR IN" or "AIR OUT" ports with a soft hammer.
5.1.2 Remove the Retaining Ring (Item 20) from the bottom of the Air Piston (Item 3) and
remove the Hydraulic Piston. The Pilot Valve Assembly (Item 15) may then be
pushed out through the bottom of the Air Piston.
5.1.3 Remove the Retaining Ring (Item 18) from the Head assembly. Remove the Bearing
Assembly (Item 7) by lifting or prying it out with a hammer handle or similar tool.
The Air Piston Actuating Valve, (part of Item 8, Valve Assembly) may also be
removed at this time. The Bearing Assembly has a moulded rubber seat and should
be replaced if worn or damaged. The "O" Ring (Item 19) in the Bearing Assembly,
the "O" Ring (Item 14) in the upper part of the Air Piston Actuating Valve, and the
"O" Ring * on the Pilot Valve Assembly Head should be replaced as a routing matter
while the pump is disassembled as they are especially important for maximum
performance.
(* This "O" Ring is Part 14-6227N019, see Pilot Valve Assy 1 1-6027A000).
5.1.4 The Head has a Rubber Bumper (Item 10) inserted in the upper portion of the body.
This acts as an air seal and also a cushion for the Air Piston Actuating Valve. If worn
or damaged it should be replaced.
NOTE: When worn or damaged the Air Piston Actuating Valve and the Sleeve in which it
operates are supplied as a Valve Assembly, Part 1 1-6127A000 (see Parts List). The sleeve
may be removed from the Head Casting by means of an internal puller engaging the slots in
the sleeve. Install a new set of "O" Rings Part 12-8775N144 (4 required and included with
Valve Assembly when ordering as a replacement part). Also coat the "O" Rings and the
Sleeve O.D. with Petroleum Jelly or other suitable lubricant to avoid possibility of damage to
the "O" Rings when installing the new Sleeve.

CAUTION: DO NOT remove the sleeve from the Head Casting unless replacement is to be
made. The Valve Assembly is precision ground and honed to very close tolerances and the
Sleeve may be damaged when removed from the Head Casting.
.
5.2. TO REPLACE THE PACKING IN THE HYDRAULIC CYLINDER
It is not necessary to dismantle the Air Motor. Proceed as follows.
5.2.1 Disconnect the Air Supply Line, remove the muffler if necessary and loosen the Set
Screw in the Air Cylinder End (Item 23).
5.2.2 Unscrew the Air Motor from the Hydraulic Cylinder. The Hydraulic Piston will be
removed with the Air Motor, permitting convenient replacement of the packing in the
Hydraulic Cylinder.
5.2.3 Replace the Backup Rings and the "O" Rings. The Parts List will give the size and
kind of packing required, and when installing the new packings, be sure that the
Backup Rings are properly in place. If they are damaged or not installed correctly,
the "O" Ring will malfunction, with resultant loss of pressure and packing failure
5.2.4 When replacing the Air Motor, install a new Gasket Part 1 1-5028N000 and see that
the Hydraulic Piston is in proper alignment before screwing the Air Motor down into
position. Tighten the Air Motor securely and also the Set Screw (Item 23) in the Air
Cylinder End.
NOTE: Models with Isolator Attachment or "V" Ring packing in the Hydraulic Cylinder
will require removal of the Isolator or the Adaptor on the "V" Ring packed cylinders to
replace packings.

5.3 THE HYDRAULIC PISTON

This has a Rubber Bumper, Part 1 1-5051P000, in the Head. If replacement is required
remove capscrew and install new Rubber. Apply "LOCTITE" sealant to the capscrew threads
when replacing and tighten securely, but not to exceed five foot pounds of torque.
NOTE: The Piston Stem is chrome plated, honed and lapped to a very close tolerance with
the Hydraulic Cylinder. Should it show indications of wear or being scored (usually due to
foreign matter being present in the hydraulic fluid), the entire Hydraulic Piston and Cylinder
Assembly, Part 11 -5027XXXX, should be returned to the factory, for repair or replacement
as required.
5.4 REPAIRING OR REPLACING THE HYDRAULIC CHECK VALVES

These Valves should not give any trouble unless foreign matter such as dirt or grit are present
in the fluid supply. If a leak develops remove the Check Valves from the Hydraulic Cylinder.
Remove the "O" Rings and replace with a new one. Inspect the ball seat in the Valve while
the "O" Ring is removed. If it shows any indication of wear or damage, the entire Valve
Assembly should be replaced. Refer to Parts List for Part Numbers and cross section of the
Valves.
NOTE: There are several different model pumps. When ordering parts, give the Part
Number, the Pump Model Number and Serial Number.
5.4.1 When operations described in paragraphs 5.1 through to 5.2.4 have been completed, the
entire unit will have been dismantled and all parts inspected for wear and damage. It is
especially important that all parts that operate in "O" Rings or Packing be free from pits,
scoring, or any other defects that may cause excessively rapid wear of "O" Rings and Packing,
since leaks will develop almost immediately under these conditions and satisfactory
performance will not result.
5.5 REASSEMBLING THE PUMP

Reverse the procedure used for dismantling, making sure that all Retaining Rings are
properly in place and that no "O" Rings have been damaged in reassembly.
IMPORTANT
When reassembling the Air Motor be sure that the Air Cylinder, Part 11 -5004A000 is in
proper position against the flanges on the Pump Head and the Air Cylinder Ends before
tightening the bolts that clamp the Air Motor together. Use a soft hammer to position the
flanges tightly against the Air Cylinder Ends BEFORE tightening the bolts. Failure to do
this can result in over-tightening the bolts initially and when the bolts on the opposite side are
drawn up this may result in the bolt lugs being broken or twisted off when the assembly is
drawn down into position. Bolts should be secured lightly at first then drawn up in sequence
until uniform torque has been applied to all of the bolts around the perimeter of the pump
(10-12 foot lbs).

5.6 PUMP NOT RUNNING PROPERLY
If for any reason the pump does not run properly, look for one of the following causes.
5.6.1 If the pump appears to be short stroking and running too fast without pumping
properly, it usually indicates that the Air Check Assembly is not working as it should
be. (See section 5.2 for Correction Procedure). Refers to hydraulic packing
replacement
5.6.2 Loss of pressure may be caused by one of two reasons:-
i) the Hydraulic Check Valves have developed a leaky condition

or
ii) the hydraulic fluid is bleeding past the packing in the Hydraulic Cylinder.
(See section 5.2 for Repair Instructions).
5.6.3 Should the pump commence to run erratically and in a jerky manner after a period of
time, it is usually an indication that a seizing action is taking place in the Hydraulic
Piston and Cylinder Assembly. (See section 5.1 for Disassembly Instructions). This
is usually caused by foreign matter such as alkali, dirt, grit or chemicals that do not
have sufficient lubrication qualities being present in the fluid supply. If the Hydraulic
Piston and Cylinder have not been damaged, a thorough cleaning will normally place
the pump in operation again.
5.6.4 For maximum volume of flow, make sure that a sufficient flow of air is supplied to
the pump. Hooking the pump up to a smaller pipe size than the "AIR IN" port on the
pump will not allow it to run at its full rated capacity. Long runs of relatively small
pipe supplying air to the pump will have the same effect.
5.6.5 If an excessive amount of oil or water is coming through the pipe air exhaust, check
the following:-
5.6.5.1 The Lubricating Unit in the air supply is delivering too much oil. Adjust to about one
drop of oil for every 20 strokes of the pump.
5.6.5.2 The Filtering Unit in the air supply is not functioning properly. The bowl should be
cleaned periodically to assure delivery of clean air to the pump.
5.6.5.3 The Hydraulic Fluid being pumped (oil or water) may be leaking past the packing in
the Hydraulic Cylinder into the Air Motor. (See section 5.2 for Correction Procedure).

6. STORAGE AND SPARES
6.1. STORAGE OF EQUIPMENT

Harness and Fittings
6.1.1. Wipe all hoses clean and apply a light coating of oil or suitable rust inhibitor to all nipples,
couplings, and tee blocks.
6.1.2. Always keep dust caps fitted to nipples and couplings when hoses are not in use.
Air Driven Pump Unit
6.1.3. Always store the pump upright.
6.1.4. Apply light oil coating or suitable rust inhibitor to all exposed un-plated metal items.
6.1.5. Leave the oil Return-To-Tank valve in the open position.
6.1.6. Leave the air control valve in the open position.
6.1.7. Always keep dust covers on inlet/outlet hydraulic fittings.
6.2. RECOMMENDED SPARES

6.2.1. Complete Seal Kit for SC10-600-20 Pump Pack. Hydratight LTD Part No: PASC6HPSK.


Air Filter Regulator 35 73 71 70 43 42 50

& Lubricator Unit
51
48
44
Oil Reservoir 27
Filler – Breather Cap 28 49 48

0-25000psi – 1 700bar
Hydraulic Pressure
Gauge
11
69
70
71
11
12
75
R es e rv oi r
Hydraulic distribution
assembly fastened 29 9 3
76 outlet block
to frame utilising
the following Drain plug located on
10 66
77 fasteners located under side of frame. See
on the under side parts list for description
78 of f r a m e. Se e
parts list for
description

Hydraulic pressure release
valve (return to tank) 24
70 71 72 25 Air Shut Tubular

Off Valve frame
15 9 2 26
36 61
45
16
17
18
19
20
21
78
6 5
1 63 22
Hydraulic outlet fitted
with CEJN 116 coupling 7 13
64 65 23
8 14

REF. QTY. PART No. DESCRIPTION

1 1 SC-600W200 HYDRAULIC PUMP
2 1 30-12HF4 PRESSURE RELEASE VALVE
3 1 3173 HYDRAULIC OUTLET BLOCK
4 1 - 0-25,000 PSI PRESSURE GAUGE
5 1 1421 HM6 S/P x 3/8”NPT ADAPTOR
6 1 207 HM4 x 1/4”BSPP(M) ADAPTOR
7 1 10.116.1202 QUICKCONNECTCOUPLING
8 1 400.021.4490.41 1/4”BSP DOWTY SEAL
9 1 60-2HM4 1/4”HP GLAND
10 1 60-2H4 1/4”HP COLLAR
11 2 60-2HM2 1/8”HP GLAND
12 2 60-2H2 1/8”HP COLLAR
13 1 60-2HM6 3/8”HP GLAND
14 1 60-2H6 3/8”HP COLLAR
15 1 3229-2 HM4 X 3/8”O/D S/P ADAPTOR
16 1 1/8”HP TUBE BLOCK-GAUGE
17 1 1/4”HPTUBE BLOCK-VALVE
18 1 LS8 SUCTION FILTER
19 1 2895/4 SUCTION FILTER HOUSING
20 1 2895/3 GASKET
21 1 BS112 ‘O’ RING
22 1 Dk ELBOW 1/2”BSP x 1/2”O/D
23 1 1/2 ” NYLON TUBE TANK-PUMP
24 1 P1 031 2S 3/8”O/D EQUAL ELBOW
25 1 P1481 222S 3/8” O/D x 1/4” NPT MSE
26 1 3/8” NYLON TUBE VALVE-TANK
27 1 2897 OIL RESERVIOR (POLY)
28 1 TAP90 FILLER/BREATHERCAP
29 1 3/8”BSP PLUG
35 1 MC202-C-25-A FILTER/LUBRICATOR/REGULATOR
36 1 VC8-PC1F AIRSHUTOFF VALVE
42 1 P1011604S 1/2”BSPT MALE x 1/2”DIA FEMALE PUSH FIT
43 1 RA024 1/2-1/2 1/2” MALE FEMALE FEMALE BRANCH TEE
44 1 GFN094 1/2 ” 1/2 ” SWEPT MALE ELBOW
45 1 2550BSP AIR PRESSURE RELIEF VALVE
48 1 GF721 -91 0-842 1”BSP(M) x 1/2”BSP(F) REDUCER
49 1 AN400-04 SILENCER
50 1 P103165S 1/2”ID EQUAL PUSH FIT ELBOW
51 1 P1051604S 1/2”BSPT MALE x 1/2”DIA MALE STANDPIPE
ADAPTOR
ITEMS 50 & 51 SHOULD BE ORDERED TOGETHER
61 1 2458A-SS FRAME
62 1 NOT SHOWN GAUGE PROTECTION GUARD
63 2 3/8”UNF x 3/4” HEX HD SCREW
64 2 3/8”UNF PLAIN WASHER
65 2 3/8”UNF SPRING WASHER
66 2 M6x15CAPSCREW
69 3 M5x15CAPSCREW
70 9 M5 PLAIN WASHER
71 9 M5 SPRING WASHER
72 2 M5x35HEXHEADSCREW
73 1 M5x20HEXHEADSCREW
75 4 M8x16HEXHDSCREW
76 4 M8 PLAIN WASHER
77 4 M8 SPRING WASHER
78 4 No.8 x 5/8” SELF TAPPER







AMENDMENT RECORD FOR THIS DOCUMENT IS SHOWN BELOW:
Rev 1 Original Issue. 07-Mar-2005

References to Hydratight Sweeney updated to
Rev 2 21 -Jul-2006 MH
Hydratight Drawing Updated.
Rev 3 Point 6.2 seal kit part number updated from PASC5HPSK. 12-Sep-2006 MH
Rev 4 Paragraphs 1.5, 1.6 & 1.7 renumbered as 1.4, 1.5 and 1.6 23-Apr-2007 MH
Updated to suit new frame design & layout plus new
Rev 5 27 July 2007 TF
(Parker) FRL unit
Rev 6 Updated to suit new (Camozzi) FRL and part changes 11 April 2008 TF

ATTACHMENT 6 – TENSIONER OPERATING MANUAL
PROPERTY OF TULLOW
HYPUR-MATE
PS BOLT TENSIONER
OPERATING MANUAL
INDEX
1 - INTRODUCTION ................................................................................................................................................. 3
1.1 GENERAL.................................................................................................................................................... 3
1.2 NORMAL USE OF THE MACHINE ........................................................................................................... 3
1.3 INCORRECT USE OF THE EQUIPMENT ................................................................................................. 3
1.4 TENSIONER FEATURES (FIG 1)............................................................................................................... 4
2 - TECHNCIAL SPECIFICATION......................................................................................................................... 6
2.1 PS BOLT TENSIONER................................................................................................................................ 6
2.2 PUMP REQUIREMENTS ............................................................................................................................ 7
3 - JOINT/FLANGE PREPARATION ..................................................................................................................... 8
3.1 STUDBOLT PREPARATION ..................................................................................................................... 8
3.2 FLANGE AND STUDBOLT ASSEMBLY .................................................................................................. 8
4 - TENSIONING TOOL ASSEMBLY .................................................................................................................. 10
5 - BOLT TENSIONING PROCEDURES ............................................................................................................. 14

5.1 HYPUR-MATE PS BOLT TENSIONING PROCEDURE-100% TOOL COVER..................................... 14
5.2 HYPUR-MATE PS BOLT TENSIONING PROCEDURE -50% TOOL COVER...................................... 15
5.3 HYPUR-MATE PS BOLT DE-TENSIONING PROCEDURE ....................................................................... 16
6 - AIR OPERATED PUMP UNIT ......................................................................................................................... 17
6.1 GENERAL.................................................................................................................................................. 17
6.2 OPERATION.............................................................................................................................................. 18
7 - MAINTENANCE ................................................................................................................................................ 20
7.1 POST-USE MAINTENANCE .................................................................................................................... 20
7.1.1 PS TENSIONER (Standard Service) .................................................................................................. 20
7.1.2 PS TENSIONER (Full Service) .......................................................................................................... 20
7.2 CHANGING THE SEALS.......................................................................................................................... 20
7.3 PS TENSIONER FULL MAINTENANCE/SERVICING .......................................................................... 22
7.4 PUMP UNIT FULL MAINTENANCE/SERVICING ................................................................................ 23
8 - SAFETY NOTES................................................................................................................................................. 24
9 - FAULT FINDING CHART ................................................................................................................................ 25
10 - ANCILLARY/SPARE PARTS......................................................................................................................... 26
10.1 ANCILLARY EQUIPMENT...................................................................................................................... 26
10.2 RECOMMENDED SPARE PARTS (SALE EQUIPMENT ONLY) .......................................................... 26
10.3 SPARE PART ORDERING INFORMATION ........................................................................................... 26
11 – APPROVED DISTRIBUTORS ....................................................................................................................... 27
2 PS/OP/1095/Iss. 4
1 - INTRODUCTION
1.1 GENERAL
The aim of the PS Bolt Tensioning System is to quickly and accurately apply a pre-determined load to a nut and bolt
assembly. It has been primarily developed for use where safety, speed, ease of operation and reliability are
paramount.
In use, a PS Tensioner is attached to every other stud bolt (every stud for 100% cover) in the joint assembly allowing
simultaneous and uniform bolt tightening. The PS Tensioner is applied to an extended portion of stud bolt passing
through a standard hexagon nut. A Puller Sleeve is then fitted to the stud bolt protruding above the nut and screwed
down until it seats against the tensioner piston. Each PS Tensioner is connected together using high pressure flexible
hoses to form a hydraulic ‘harness’, which is connected to the pump unit via the feed hoses.
A pre-determined hydraulic pressure is applied to the system, thus stretching the stud bolt as the piston pushes
against the puller sleeve. As the stud bolt stretches, the standard hexagon nut lifts from the flange surface. The bolt
load is retained in each bolt by inserting a toggle bar through the PS Tensioner bridge window, into the nut rotating
disc drilled hole and turning in a clockwise direction until the nut seats against the flange surface. The hydraulic
pressure is released and the load is retained in each bolt whilst the piston automatically retracts ready for the next
tightening operation. The PS Tensioners are then removed as bolt tightening is complete.
1.2 NORMAL USE OF THE MACHINE
1. For tensioning threaded fasteners:
a) With the appropriate thread protrusion above the top of the nut (minimum to be 1 x bolt diameter).
b) With UN8 or metric coarse thread forms (other thread forms are available upon request).
c) With heavy series hexagon nuts (i.e. nut height 1 x bolt dia.) (other nut configurations and of different
proportions can be accommodated, but with modifications to tooling).
d) Where the landing area for the bridge is flat and complete (i.e. if washers are used then they must be through
hardened and have a diameter greater than the bridge diameter)
e) Where the tool is removed from the application once the load has been induced into the threaded fastener. The
tool is not designed to induce and maintain the load in the fastener for a long period of time (i.e. used as a
hydraulic nut).
f) Where the appropriate adapters are used in conjunction (i.e. specified bridge and puller sleeve).
g) Uncoated (i.e. not hot dip galvanised or PTFE or similar coated). These processes can be accommodated upon
request.
h) On standard ANSI B16.5, MSS-SP44 & API 6A flanges. Although the compact design enables use on many
other applications. However, if the application is non-standard, dimensional clearances shall be checked.
i) On non LIVE joints (i.e. no line pressure or medium present).
1.3 INCORRECT USE OF THE EQUIPMENT
The equipment must not be used:
a) Without the correct bridge fitted as the load cell spigot may be damaged.
b) As multiple units on the same fastener (i.e. one tensioner being placed on top of another to increase the load in
the fastener). Load will be transferred to the bottom tensioner possibly resulting in tool failure.
c) When the bridge is not sitting squarely on the flange surface i.e. the axis of the tool is not parallel to the axis of
the fastener. Possible causes are due to the flange/pipe weld obstructing the load cell or the flange hub radius
obstructing the bridge. Upon pressurisation the tensioner will have a tendency to self align which may result in
damage to the tensioner or plant.
d) Without a puller sleeve, whereby a standard hex nut is used as a reaction nut. The piston will be damaged unless
a suitable washer is provided between the reaction nut and piston. (Contact Hydratight).
3 PS/OP/1095/Iss. 4
1.4 TENSIONER FEATURES (FIG 1)
Considering the working environment for both equipment and operator, the PS Tensioner has been purposely
designed to include a host of features to benefit it’s use and operation.
1. OVERSTROKE ELIMINATION
Tensioners PS2 to PS10 incorporate a valve in the piston to prevent overstroking thus eliminating unnecessary seal
damage and downtime. The valve is activated when the piston exceeds maximum stroke and safely vents the
hydraulic fluid inside the tool without risk to the operator. The PS1 has a limiting ring fitted to prevent overstroking.
2. RAPID POWER RETURN STROKE
Automatic, spring assisted piston retraction reduces the duration of tensioning programmes.
3. COMPACT DESIGN
Compact tool design allows easier access into restricted applications and low headroom clearances.
4. MISALIGNMENT COMPENSATION
Unique floating piston design allows tilt in any direction, thus eliminating piston seizure and aiding tensioner
retraction.
5. PISTON STROKE INDICATOR
The integral piston stroke indicator allows piston stroke to be viewed, measured and controlled.
6. SEALS
Low friction, anti roll/non spiralling seals and rigid back-up rings are incorporated within a unique piston/cylinder
design for improved life and reliability.
7. NUT ROTATING DISC
A range of nut rotating discs are incorporated to eliminate the need for and preparation of pre-drilled nuts.
4 PS/OP/1095/Iss. 4
FIG 1: THE PS BOLT TENSIONER
5 PS/OP/1095/Iss. 4
2 – TECHNICAL SPECIFICATION
2.1 PS BOLT TENSIONER
TOOL REF BOLT DIA TOOL HYD. AREA MAX. TOOL LOAD MAX. RECOMMENDED
PUMP PRESSURE
(NOTE 1)
in mm tonf kn. psi

in2 mm2
PS0 ¾” (M20) 18684 (20249)
1.48 954 14.4 143.5
7
/8” (M22) 21750 (21750)
PS1 1” (M24) 17079 (14692)
2.95 1903 28.6 285.0
1 1/8” 21750
1” (M24) 10629 (9136)
(M27) (12089)
PS2 1 1/8” (M30) 4.74 3058 46.0 458.3 13990 (14691)
1 ¼” (M33) 17822 (18381)
1 3/8” (M36) 21750 (21558)
PS3 1 ¼” (M33) 12243 (12614)
1 3/8” (M36) 15200 (14795)
6.9 4452 67.0 667.8
1 ½” (M39) 18468 (17832)
1 5/8” (M42) 21750 (20411)
PS4 1 ½” (M39) 12241 (11822)
1 5/8” (M42) 14614 (13532)
1 ¾” (M45) 10.41 6716 101.1 1007.3 17193 (15882)
1 7/8” (M48) 20029 (17848)
2” (M52) 21750 (21469)
PS5 2” (M52) 17831 (16620)
13.45 8677 130.6 1301.2
2 ¼” (M56) 21750 (19164)
PS6 2 ¼” (M56) 19652 (16469)
(M60) (19286)
15.71 10135 152.5 1514.2
2 ½” (M64) 21750 (19735)
2 ¾” (M68) 21750 (22653)
PS7 2 ¾” (M72) 20024 (18607)
21.67 13980 210.5 2097.3
3” (M76) 21750 (21003)
PS8 3” (M76) 20428 (17863)
(M80) (20024)
25.49 16445 247.5 2466.0
3 ¼” (M85) 21750 (21750)
3 ½” (M90) 21750 (21750)
PS9 3 ¾” (M95) 21750 (21750)
(M100) 34.09 21991 331.0 3297.9 (19287)
4” 21750
PS10 4 ¼” (M105) 21750 (18201)
(M110) (20124)
40.15 25935 389.9 3884.8
(M115) (21750)
4 ½” 21750
Notes
1. The maximum recommended pump pressure shown will induce a gross bolt stress not exceeding 85% of yield
strength for bolt materials B7, L7, L43 & B16 only.
For other bolt materials contact Hydratight.
6 PS/OP/1095/Iss. 4
2.2 PUMP REQUIREMENTS
AIR SUPPLY ½” nominal bore supply line
AIR CONSUMPTION 28 CFM at 100psi
AIR PRESSURE 80 - 100 psi (80 psi optimum)
Carry out the following fluid level checks prior to use (See section 6 - Fig 5)
a) HYDRAULIC FLUID RESERVOIR
Ensure tank is full, top up if necessary. Use Houghtosafe 620 (available from Hydratight).
b) AIR LUBRICATOR
Check level. To fill, unscrew bowl and fill to within ¼” of the top. Use pneumatic tool oil, typically Silkolene
Icefree (available from Hydratight). Check the lubricator oil drip feed rate. With the pump running, (ensure the
hydraulic oil return valve is open) adjust the drip rate to give one drop of oil to every twenty strokes of the pump.
c) AIR FILTER/REGULATOR
Drain water from the filter bowl before it reaches the level of the lower baffle. Use drain plug/valve situated on
the bottom of the filter bowl.
7 PS/OP/1095/Iss. 4
3 - JOINT/FLANGE PREPARATION
3.1 STUDBOLT PREPARATION
Simple studbolt preparation, will significantly reduce the risk of problems occurring during tensioner application and
operation. Therefore, we would recommend that the following preparations and checks are adopted whenever
possible.
a) To accommodate the PS tensioner an extended portion of studbolt is required above the hexagonal nut. It is
recommended that this extension be a minimum of 1 x bolt diameter.
b) The hexagonal nut must be free-running on all bolts over the length protruding through the flange faces. The
Puller Sleeve must be free running on all bolts over the extended portion above the nut.
c) Protect the stud bolt protrusion using sleeves, adhesive tape, etc. This will protect the threads from knocks and
damage during installation.
d) Ensure that the nut rotating disc fits over the nut (machined nuts generally have sharp A/C and hence may foul
the nut rotating disc).
e) It is advisable that upon completion of the tensioning operation protector caps be fitted to the nut/thread
protrusion. This will minimise corrosion and therefore assist in future disassembly.
3.2 FLANGE AND STUDBOLT ASSEMBLY
Prior to installation of the flange studbolts, it is recommended that the flange is squared and brought into close
contact using methods such as the Hypur-mate flange puller. Once the flange faces are square and in close proximity
the studbolts and gasket may then be installed.
The studbolts must be installed in a specific manner depending upon whether 100% tensioner coverage or 50%
coverage is adopted.
a) STUDBOLT INSTALLATION FOR 100% TENSIONER COVERAGE (Fig 2A)
Using this method of assembly all studbolts are tensioned in one operation. In order to achieve this, the studbolts
must be assembled with the thread protrusions staggered over each side of the flanged joint as illustrated in Fig
2A.
b) STUDBOLT INSTALLATION FOR 50% TENSIONER COVERAGE (Fig 2B)
This method of installation is normally used where studbolts are required to be tensioned from one side of the
flange only, due to an access restriction on the opposite. It is basically a two stage tensioning operation where
50% of the studbolts are tensioned in the first stage, followed by the remaining 50% of studbolts in the second
stage. In order to adopt this method the studbolts must be assembled with the protrusions on the same side of the
flange as illustrated in Fig 2B.
8 PS/OP/1095/Iss. 4
9 PS/OP/1095/Iss. 4
4 - TENSIONING TOOL ASSEMBLY
ASSEMBLING THE PS TENSIONER
IMPORTANT NOTE: If de-tensioning refer to section 5.3
a) Ensure the bridge and puller sleeve sizes are compatible with the thread form of the fastener to be tightened.
Also ensure that the piston in the load cell is fully retracted.
b) With the nut rotating disc held inside the bridge by the retaining pins, place the bridge over every other nut
(every nut for 100% coverage) ensuring that the slot for the tommy bar faces outwards away from the flange hub
(Fig 3a).
c) Assemble the load cell onto the bridge ensuring that the spigot is correctly located. Align the load cell so the
hydraulic couplings straddle the tommy bar slot in the bridge. Tighten the bridge fixing screws (Fig 3b).
d) Locate the end of the stud with the puller sleeve and screw down until the puller sleeve shoulder seats on the
piston. The knurled section of the puller sleeve should be level with the top washer (Fig 3c).
e) The PS Tensioners are now assembled, remove the dust caps ready for hose connection.
IMPORTANT NOTE: When tensioning application is upside down it is easier to attach the bridge to the load
cell before placing on the stud. The load cell/bridge assembly can then be placed on the stud and the puller
sleeve screwed down until the bridge contacts the flange/joint and the puller sleeve seats on the piston. (The
knurled section of the puller sleeve should be level with the top washer).
HOSE CONNECTION
Due to the PS Tensioner coupling arrangement hose connection is very simple.

Fig. 4a illustrates a typical harness assembly for 100% tensioner coverage).
Fig. 4b illustrates a typical harness assembly for 50% tensioner coverage).
HOSE CONNECTION – RESTRICTED ACCESS – USE OF BANJO ASSEMBLIES
In certain situations, where access is restricted, it may not be possible to attach the hydraulic hoses to the tensioner as
shown in figs 4a and 4b. In such situations, it may be necessary to attach the hoses at 90° to that shown. This is
achieved using banjo assemblies. Reference must be made to section 7.2 for instructions regarding the assembly of
these fittings onto the tools.
HOSE CONNECTION NOTES
a) Ensure the pump hydraulic oil return valve is fully open.
b) Always connect the tensioners together working either in a clockwise or anti clockwise direction around the
flange. This will minimise incorrect connections.
c) For 100% tensioner coverage ensure that a link hose exists connecting tensioners on one side of the flange to the
other. (Refer to Fig 4a).
d) Both feed hoses from the power pack must be connected to the tensioners to complete the hydraulic harness.
e) When the hydraulic harness is complete, no unconnected couplings should exist.
f) All hoses are fitted with self-sealing quick disconnect couplings ensuring that hydraulic fluid will not flow
through the coupling unless fully connected. Therefore it is extremely important to check for complete coupling
connection and ensure the locking collars are tightened against the coupling collar prior to pressurisation of the
system.
Should any of the quick disconnect couplings prove difficult to fully assemble, then it may be due to the
following:
Damage to the coupling

10 PS/OP/1095/Iss. 4
Coupling locking collars not fully screwed back
Internal pressure within the load cell, produced by screwing down the puller sleeve onto a piston which has
not been allowed to fully retract. Unscrewing the puller sleeve will reduce the internal pressure enabling the
quick disconnect coupling to be assembled. Allow the piston to retract then screw down the puller sleeve.
11 PS/OP/1095/Iss. 4
12 PS/OP/1095/Iss. 4
13 PS/OP/1095/Iss. 4
5 - BOLT TENSIONING PROCEDURES
5.1 HYPUR-MATE PS BOLT TENSIONING PROCEDURE-100% TOOL COVER
The following procedure is extracted from Hydratight bolting specification

HPL-ES018.
Scope
This is a general tightening procedure for use with HYPUR-MATE PS type bolt tensioners for the tension tightening
of standard pressure containing flanged joints fitted with standard gaskets. (i.e. Spiral Wound, RTJ, CAF, etc.). The
procedure has been compiled to accurately and efficiently achieve a pre-determined residual bolt stress.
Pre-Requisites
The Client must be satisfied that:
a) Risk to personnel and assets have been assessed and all necessary safety precautions are being carried out.
b) All personnel employed in using this procedure are competent and trained in the use of the equipment and joint
tightening procedures
c) The Client must approve this procedure prior to commencement of work
d) Tensioning pressures to be used are those as recommended or compiled by
HYDRATIGHT.
STAGE 1 Using tensioning tools (if necessary), square up the flanged joint.
STAGE 2 Assemble one tensioning to each bolt. Depending upon the pitch of the bolting, the tensioner
cylinders may foul each other if attempting to assemble all tensioners to one side of the flange
only. If this occurs it will be necessary to assemble 50% of the tensioners to one side of the flange
and 50% to the other. When connecting hoses ensure that the tensioners on both sides of the flange
are connected into the hydraulic loop.
STAGE 3 Apply the 2nd* Pass pressure as specified in the tensioning data and turn down the flange nuts using
a toggle bar (whilst tensioners are under pressure). Always tap the toggle bar using a hammer to
firmly seat the nut against the flange surface.
NOTE*: If both 1st and 2nd pass pressures are listed the 1st Pass pressure should be ignored when
adopting 100% tool coverage. +
STAGE 4 Release the system pressure and repeat STAGE 3 twice further, i.e. Apply pressure and turn down
nuts three times.
STAGE 5 As a final check, apply the pressure once more and attempt to further tighten the flange nuts, if the
nuts cannot be turned, then tensioning is complete and the system may be depressurised and the
tensioners removed.
If the nuts can be turned, then STAGES 4 & 5 must be repeated until no further movement is
obtained.
STAGE 6 Using a hammer, ‘ring’ each nut to ensure that each bolt has been correctly loaded and that no
slack bolts remain.
The above tensioner procedure is typical only. Should the operator wish to adopt their own ‘tried and tested’
tensioning procedure with the HYPUR-MATE PS equipment then Hydratight will be pleased to advise accordingly.
14 PS/OP/1095/Iss. 4
5.2 HYPUR-MATE PS BOLT TENSIONING PROCEDURE -50% TOOL COVER
The following procedure is extracted from Hydratight bolting specification HPL-ES018.
Scope
This is a general tightening procedure for use with HYPUR-MATE PS type bolt tensioners for the tension tightening
of standard pressure containing flanged joints fitted with standard gaskets. (i.e. Spiral Wound, RTJ, CAF, etc.). The
procedure has been compiled to accurately and efficiently achieve a pre-determined residual bolt stress.
Pre-Requisites
The Client must be satisfied that:
a) Risk to personnel and assets have been assessed and all necessary safety precautions are being carried out.
b) All personnel employed in using this procedure are competent and trained in the use of the equipment and joint
tightening procedures.
c) The Client must approve this procedure prior to commencement of work.
d) Tensioning pressures to be used are those as recommended or compiled by
HYDRATIGHT
STAGE 1 Number each bolt consecutively, 1, 2, 3 etc.
STAGE 2 Using tensioning tools (if necessary), square up the flanged joint.
STAGE 3 Assemble tensioning tools to 50% of the bolts (i.e. all odd numbered bolts), apply the 1st Pass
pressure as specified in the tensioning data and turn down the flange nuts using a toggle bar (whilst
tensioners are under pressure). 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 5 twice further, i.e. Apply the 1st Pass pressure and
turn down nuts three times.
NOTE: When tightening flanges fitted with RTJ gaskets it is advisable to continuously re-apply the
1st Pass pressure until no further movement of the flange nuts can be obtained. It may also be an
advantage to allow a few minutes between each pressure application to allow the gasket to ‘bed in’.
STAGE 5 Move tensioning tools to the remainder of the bolts (i.e. all even numbered bolts), apply the 2nd
Pass pressure as specified in the tensioning data and turn down the flange nuts.
STAGE 6 Release the system pressure and repeat STAGE 5 twice further, i.e. Apply 2nd Pass pressure and
turn down nuts three times.
STAGE 7 As a final check to see if an excessive load has been lost in the bolts tightened on the 1st Pass,
assemble two tensioners on bolts randomly selected but diametrically opposite (from 1st Pass only),
apply the 2nd Pass pressure and attempt to further tighten the flange nuts. If the nuts cannot be
turned, then tensioning is complete and the system may be depressurised and the tensioners
removed.
If the nuts can be turned, then re-assemble the tensioning tools to remainder of the bolts (i.e. all
odd numbered bolts), apply the 2nd Pass pressure and turn down the flange nuts once more.
STAGE 8 Using a hammer, ‘ring’ each nut to ensure that each bolt has been correctly loaded and that no
slack bolts remain.
The above tensioner procedure is typical only. Should the operator wish to adopt their own ‘tried and tested’
tensioning procedure with the HYPUR-MATE PS equipment then Hydratight will be pleased to advise accordingly.
15 PS/OP/1095/Iss. 4
5.3 HYPUR-MATE PS BOLT DE-TENSIONING PROCEDURE
A hydraulic tool pressure for de-tensioning is not normally provided as it is not always possible to predict the
pressure at which the nut will break free. However, it is beneficial to be aware of the original ‘make-up’ tensioning
pressure before the de-tensioning procedure is carried out as generally, the de-tensioning pressure is marginally
higher than the original make-up pressure.
A general de-tensioning procedure is described below.
STAGE 1 Pre-set the pump unit to deliver the maximum system working pressure of 21750 psi (1500 bar).
STAGE 2 Assemble the tensioners and harness as per section 4. With the puller sleeve screwed down and
seated on the piston, now unscrew the puller sleeve through one half turn. This will raise the
knurled section of the puller sleeve above the top washer, to prevent the puller sleeve becoming
locked on to the piston when the bolt tension is released.
STAGE 3 With the tensioners assembled and the hydraulic harness connected, close the hydraulic oil release
valve and apply a nominal hydraulic tool pressure of 1000psi. Check the Tensioners for
squareness and centralisation.
STAGE 4 Insert the toggle bar through the bridge window and into a hole in the nut rotating disc. Increase
the hydraulic pressure to the system, ensuring that the piston does not exceed its maximum stroke
thus activating the overstroke eliminator valve (if the overstroke eliminator valve is activated a
significant reduction is oil pressure will be observed on the pressure gauge). Apply the hydraulic
pressure to the system until the hex nuts within the bridge insert can be rotated.
If overstroking occurs then repeat stages 2 to 4.
STAGE 5 Turn back each nut through a minimum of two thirds of one full turn (approx. 4 holes on the bridge
insert) and no more than one full turn (approx. 6 holes on bridge insert).
STAGE 6 Depressurise the system allowing the pistons to automatically retract. Check to see if the nuts are
still free to rotate.
STAGE 7 Remove the tensioners. If the puller sleeve cannot be unscrewed, and the nut is also tight, then the
puller sleeve has locked on the top face of the nut (see stage 8). If the nut can be rotated, then the
puller sleeve has locked onto the piston. (See stage 9).
STAGE 8 Puller Sleeve Locked on the Top Face of the Nut
Unscrewing the nut further than specified in stage 5 can cause the puller sleeve to become locked
on the top face of the nut when the tension in the stud is released. To release the puller sleeve the
hydraulic pressure must be re-applied and the nut rotated via the bridge insert until the nut seats on
the flange/joint face. Depressurise the system, the puller sleeve should now be free to be turned, if
not repeat until it can be unscrewed.
STAGE 9 Puller Sleeve Locked onto the Piston
This situation may only arise on studs with fine pitches whereby unscrewing the puller sleeve
through one half turn (stage 2) has been insufficient and upon releasing the hydraulic pressure
(tension in the stud) has caused the puller sleeve to become locked on the piston.
To release the puller sleeve the hydraulic pressure must be re-applied and the nut rotated via the
bridge insert until the nut seats on the flange/joint face. Depressurise the system, the puller sleeve
should now be free to be turned by hand.
16 PS/OP/1095/Iss. 4
6 - AIR OPERATED PUMP UNIT
6.1 GENERAL
The air operated pump unit consists of the following main components, Ref fig 5.
Pump
An air operated reciprocating piston type pump, which operates on the principle of pressure intensification via
differential areas, i.e. a large, low pressure air piston drives a much smaller hydraulic piston to provide oil flow at
high pressure.
Air Filter/Regulator
A combined unit consisting of an air filter, air pressure gauge and air pressure regulator assembly. The air filter
removes water and foreign particles from the inlet air supply, and should be periodically cleaned and drained.
The air regulator is used to regulate the incoming air pressure and can be used to set the pump to stall when a
pre-determined hydraulic pressure is attained.
The inlet air supply is connected directly to the air filter/regulator unit via a quick disconnect coupling.
Air Lubricator
Connected directly onto the air filter/regulator unit, it is used to lubricate the incoming air supply and hence lubricate
the pump unit.
Pump Start/Stop Valve
A simple manual on/off valve to start and stop the air supply to the pump. The speed of operation of the pump can
be finely regulated using this valve.
Hydraulic Oil Return Valve
A high pressure valve allowing hydraulic pressure to be built up when closed, and released when opened, diverting
the hydraulic oil back to the reservoir.
Pump Exhaust/Silencer
A muffle/filter connected to the pump exhaust port to reduce the operating noise level.
Pressure Gauge
A 0-25000 psi hydraulic oil pressure gauge positioned behind a protective wire guard.
Hydraulic Reservoir
A tank of approximately 5 litres capacity incorporating an external transparent tube type level indicator. Filters are
fitted into the filler neck and the oil outlet port.
17 PS/OP/1095/Iss. 4
6.2 OPERATION
It is always good practice to regulate the pump to stall at the pre-determined hydraulic pressure required to achieve
the desired bolt load. Failing this Hydratight demand that the pump is regulated to stall at 21750 psi. This can only
be carried out on-site as the air consumption and pressure determine the pressure out-put. The recommended pump
operating procedure is indicated as follows.
a) Connect two blanked-off female quick disconnect coupling (as supplied in the ancillary equipment) to the pump
hydraulic oil outlets.
b) Open the hydraulic oil return valve to tank (anticlockwise). Ensure the valve is fully open.
c) Close the pump start/stop valve (handle in vertical position).
d) Connect an external air supply line to the pump unit.
e) Turn the air filter/regulator adjusting screw anti-clockwise until zero pressure reads on the air pressure gauge.
f) Open the pump start/stop valve (handle in horizontal position). The pump should not operate as the regulator has
been set to produce zero air pressure. Should the pump operate, then re-adjust the air pressure regulator until the
pump stops.
g) Close the hydraulic oil return valve (clockwise).
h) Turn the air filter/regulator adjusting screw slowly clockwise until the pre-determined hydraulic oil pressure
reads on the oil pressure gauge.
i) Close the pump start/stop valve (handle in vertical position).
j) Slowly open the hydraulic oil return valve (anticlockwise) to release the system pressure. Ensure the valve is
fully opened.
The pump is now ready to be operated by using the pump start/stop valve. When the pre-determined required
hydraulic oil pressure is reached then the pump will automatically stall.
SAFETY NOTES ON PUMP OPERATION
1) Although the pump has been set to stall at the desired hydraulic pressure, it is always advisable to monitor the
pressure as it is applied.
2) Never pressurise the pump unit without either a blank quick disconnect coupling or the completed hydraulic
harness feed hoses attached.
3) Wear safety glasses at all times during pump operation.
4) Always depressurise the system when leaving unattended.
18 PS/OP/1095/Iss. 4
FIG 5: AIR OPERATED PUMP UNIT ARRANGEMENT
19 PS/OP/1095/Iss. 4
7 - MAINTENANCE
7.1 POST-USE MAINTENANCE
In order to keep the equipment in good working condition it is important that at the end of each period of use, prior
to being replaced into dry storage, a post-use maintenance is carried out.
7.1.1 PS TENSIONER
a) Assemble the tensioner onto a suitable stud (see section 4) and pressurise in accordance with maximum
recommended tensioning pressure quoted in table 2.1, for approximately one minute. Piston stroke should be
minimised to prevent the overstroke eliminator valve being activated.
b) If the tensioner passes this test, then the tensioner parts should be cleaned down, and coated with WD40 or
similar. Alternatively rinse in light oil.
c) Replace the dust caps on the quick disconnect couplings to prevent the ingress of dirt.
d) If any leakage is noticed within the load cell, then a full strip down will be necessary to change the seals, as
described in section 7.2.
e) If tensioners are subject to a lot of use it is advisable to fully strip them and clean and inspect all components, at
least once a year. Refer to section 7.3.
7.1.2 PUMP UNIT
a) Inspect the unit for any visible damage/leaks etc.
b) Clean the pump using a mild solvent where necessary.
c) Clean, then coat each quick disconnect coupling in a water repellent spray such as WD40 or similar, retracting
and releasing the collars several times. Ensure that the collars do not seize in the retracted position.
d) Coat all exposed/unprotected components in a water repellent spray such as WD40 or similar.
e) Check all fluid levels and fill/drain accordingly (see section 2.2).
7.1.3 HOSES
a) Clean, then coat each quick disconnect coupling in a water repellent spray such as WD40 or similar, retracting
and releasing the collars several times. Ensure that the collars do not seize in the retracted position. Visually
inspect the entire length of the hose for damage. Test to maximum working pressure (ensure blanking plugs
inserted into end of coupling).
7.2 CHANGING THE SEALS
Hydraulic seal replacement must only be carried out should the seals become damaged. The seals should not be
removed during post - use maintenance.
CYLINDER/PISTON SEALS
a) Remove the piston as described in section 7.3 PS TENSIONER (b) and (c).
b) Remove the back-up rings then using a flat screwdriver remove the piston/cylinder seals ensuring that the housing
groove is not damaged.
20 PS/OP/1095/Iss. 4
c) Inspect the seal housing grooves ensuring that they are clean and free from debris.
d) Install the new seal assembly and fit the appropriate back-up rings ensuring that the scarfed joint does not
overlap.
e) Lubricate the seals and tensioner bores with silicone grease or clean hydraulic oil (Houghtosafe 620). Push the
piston into the cylinder bore ensuring that the seal/back-up rings do not become nipped.
f) Refit the springs, top washer and quick disconnect coupling.
QUICK DISCONNECT COUPLING SEALS – ¼” BSP FITTINGS
A simple sealing arrangement exists between the PS tensioner body and the quick disconnect coupling. The seal
consists of a simple O-Ring surrounded by a steel back-up ring located inside a counterbore on the tensioner body
behind the coupling. Should the seal leak or become damaged then it should be replaced as follows.
a) Unscrew the male quick-disconnect coupling
NOTE: A ¼” BSP threaded adapter is fitted into the male quick-disconnect coupling.
Under normal circumstances this will remain an integral part of the coupling and should not be removed. However
should the adapter and coupling become separated or unscrewed, then the adapter must be reassembled into the
coupling and re-tightened. The ¼” BSP adapter must never be installed into the tensioner body before the male
quick-disconnect and seals are attached.
b) Remove and discard the O-Ring and steel back-up ring.
c) Clean any dirt and debris from the tensioner body counterbore and the quick disconnect coupling face.
d) Insert the new back-up ring inside the counterbore followed by the O-Ring into the back-up ring.
e) Lubricate the quick disconnect coupling thread with Omega 95 (or similar lubricant with
coefficient of friction (Mu) = 0.12) and tighten to a torque of 45 lbf.ft (61Nm). Ensure that the
seal and back-up ring do not become dislodged or nipped.
QUICK DISCONNECT COUPLING SEALS – 1/8” BSP FITTINGS
On smaller PS tensioners (PS0 and PS1 tools), the tools have 1/8” BSP ports in place of the ¼” BSP ports on the
larger tools. For these tools, a ¼” BSP (male) x 1/8” BSP (male) adaptor is used between the male quick disconnect
coupling (1/4” BSP) and the PS tensioner body (1/8” BSP).
A 1/8” BSP bonded seal is used between the adaptor and the tensioner body. Should the seal leak or become
damaged then it should be replaced as follows.
a) Unscrew the adaptor from the tensioner body.
b) Remove and discard the bonded seal.
c) Clean any dirt and debris from the tensioner body counterbore and the sealing face on the adaptor.
d) Insert the new bonded seal inside the counterbore on the tensioner body.
e) Lubricate the 1/8” BSP thread on the adaptor with light oil and assemble onto the tool. The fitting should be
tightened to a torque of 41lbf.ft (55Nm).
IMPORTANT NOTE: Care must be taken not to overtighten the adaptors into the tensioner and to use the
hexagon on the adaptor to pull it in rather than the hexagon on the male quick disconnect coupling which could
induce bending, leading to failure.
ASSEMBLY OF BANJO FITTINGS
Banjo fittings are used as a method of re-orientating the quick disconnect couplings when access is difficult. The
general configuration is shown below:
21 PS/OP/1095/Iss. 4
a) Remove the standard male quick disconnect coupling and associated adaptor from the tensioner.
b) The banjo block is fitted with a male quick disconnect coupling, ¼” BSP adaptor and ‘O’ ring seal with steel
back up ring. If these items are not already fitted to the banjo block, then the block should be gripped in a soft
jawed vice and the coupling / fitting assembled in accordance with the instructions given above entitled ‘QUICK
DISCONNECT COUPLING SEALS’.
c) Ensure that the tensioner body counterbore is clear of dirt and debris and insert a bonded seal (1/8” BSP) or ‘O’
ring and back up ring (1/4” BSP).
d) Insert the banjo bolt through the bore of the banjo block, after ensuring that the bonded seal (1/8” BSP) or ‘O’
ring and back up ring (1/4” BSP) have been inserted into the counterbore on the outside face of the banjo block.
e) The threads on ¼” banjo bolts should be coated with Omega 95 (or similar lubricant with a coefficient of friction
(mu)=0.12). The threads on 1/8” BSP banjo bolts should be dry.
f) Insert the banjo bolt into the port on the tensioner body and when the banjo block is in the desired orientation, the
banjo bolt should be tightened to the following torques:
1/8” BSP: 35lbf.ft (47Nm)

1/4” BSP: 45lbf.ft (61Nm)
7.3 PS TENSIONER FULL MAINTENANCE/SERVICING
It is recommended that repairs and servicing be carried out by Hydratight at intervals agreed by Hydratight and
customer. All parts will be thoroughly inspected, specified parts will be non-destructively tested using MPI
techniques and replaced where necessary, certain components (e.g. Seals) will be replaced automatically.
Tensioners will be re-assembled, pressure tested and a test certificate issued.
NOTE: All parts will have been manufactured, inspected and tested in accordance with Hydratight’s stringent
requirements. Any parts failing in use that are found upon Hedley Purvis Limited’s inspection not to be
Hydratight’s genuine spare parts will invalidate any operative warranty or guarantee.
a) Unscrew the bridge retaining screws and detach the bridge assembly from the load cell. Inspect each sub
assembly for any visible damage/leaks etc.
b) With the piston fully retracted in the load cell, unscrew the quick disconnect couplings. Unscrew the top washer
retaining screws and remove the top washer and associated springs.
22 PS/OP/1095/Iss. 4
NOTE: As a nominal load is retained in the piston retraction springs, care must be taken when removing the
final screw.
c) Pull the piston free from the cylinder bore.
d) Using either a clean cloth or compressed air, remove all dirt and debris from the piston and cylinder. It is very
important that all dust and debris be removed from the seal/back-up rings as failure to do so may result in seal
failure (if necessary remove the back-up rings).
e) Lubricate the seals and tensioner bores with silicone grease or clean hydraulic oil (Houghtosafe 620). Push the
piston into the cylinder bore ensuring that the seal/back-up rings do not become nipped.
f) Refit the springs, top washer and quick disconnect coupling.
g) Clean the puller sleeve (in particular the thread) and bridge assembly (if necessary remove the retaining pins and
hence nut rotating disc).
h) Assemble the tensioner onto a stud (see section 4) and pressurise in accordance with maximum recommended
tensioning pressure quoted in table 2.1, for approximately one minute. Piston stroke should be minimised to
prevent the overstroke eliminator valve being activated.
i) Having removed the tensioner from the stud coat each sub-assembly in a water repellent spray such as WD40 or
similar. Alternatively rinse in light oil.
j) Replace the dust caps on the quick disconnect couplings.
7.4 PUMP UNIT FULL MAINTENANCE/SERVICING
Other than post-use maintenance, repairs and servicing should be carried out by Hydratight at intervals agreed by
Hydratight and customer. It is not recommended that the customer services or repairs their own pump unit, but
should return it to Hydratight where the pump can be serviced and repaired by qualified technicians. New
components will be fitted where necessary and the pump calibrated and tested.
NOTE: Any pump parts failing in use that found upon Hydratight’s inspection not to be Hydratight’s genuine spare
parts will invalidate any operative warranty or guarantee.
23 PS/OP/1095/Iss. 4
8 - SAFETY NOTES
a) Always ensure that a minimum length of thread equal to one bolt diameter is protruding above the nut to be
tightened.
b) Ensure that the nut height is equivalent to the diameter of the stud (except metric).
c) Ensure that the fastener thread form and size correspond with that stamped on the top of the puller sleeve .
d) Ensure that the load cell tool reference (i.e. PS4) corresponds with that stamped on the top of the puller sleeve.
e) Ensure that the bridge and insert correspond to that of the nut A/F.
f) Ensure that the tensioner load cell is situated correctly and securely onto the appropriate bridge.
g) Ensure that no loose objects are lodged between the piston and top washer.
h) When assembled, ensure that the knurled section of the puller sleeve is level with the top washer.
i) Ensure that the tensioner is appropriately situated on the application i.e. bridge sitting square on the flange
surface, load cell has adequate clearance, bridge not sitting on a washer (for example) of smaller diameter etc.
j) Do not, under any circumstances, exceed the maximum working pressure of 21750psi (1500 bar).
k) Ensure that the hoses are free of obstructions and do not cross such that upon pressurisation, detrimental loads
will be induced on the connectors and adapters potentially leading to failure.
l) Never pressurise an uncoupled quick-disconnect coupling.
m) Never operate the tensioner without the puller sleeve fitted.
n) Quick-disconnect couplings are susceptible to knocks and damage therefore, take care when handling the
equipment. A damaged coupling may prove very difficult to connect.
o) Never attempt to disconnect or re-tighten any part of the hydraulic system while at pressure.
p) Frequently check, top up or drain the pump unit fluid levels and ensure the lubrication drip rate is
adequate. Failure to do so will cause premature wear resulting in improper running of the pump,
necessitating repairs.
q) Keep personnel clear while pressurising the system. Ideally rope off the area and only allow relevant
personnel to enter when necessary (e.g. to turn down the nuts).
r) Personnel must never be positioned in the line of projection i.e. along the axis of the stud/tensioner.
s) Only use pumps and hoses supplied by Hydratight. These have adequate factors of safety etc.
t) Ensure that the strengths of the fasteners are known and that the recommended tensioning gross loads are
well within the safe limits.
u) Suitable protective overalls, eye protection, head wear, gloves and foot wear must be worn at all times when
using hydraulic equipment.
v) Only use genuine Hydratight parts.
w) If any equipment abuse is evident, the warranty will be invalidated and Hydratight will not be made responsible
for an injury due to misuse or failure to comply with the above safety notes.
x) Ensure that the joint being tensioned is not live (i.e. no medium present/line pressure reduced to zero).
y) READ THE OPERATING INSTRUCTIONS

24 PS/OP/1095/Iss. 4
9 - FAULT FINDING CHART
Fault Possible Cause Remedy

Hoses difficult to assemble Damaged coupling Replace Coupling
Coupling locking collars not Screw Back Collars

fully screwed back
Internal pressure in load cell Unscrew Puller Sleeve

due to over tightening puller
sleeve
PS pistons do not stroke (with Open pump hydraulic oil Close valve
no gauge pressure build up) return valve
Leaking/burst hose Replace hose
Leaking coupling/seals Replace coupling/seals
Leaking tensioner seals Replace Seals
Defective pump unit Check pump for oil delivery

PS Pistons do not stroke (with Coupling not assembled Check Couplings
gauge pressure build up)
Incorrect ‘harness’ assembly Check Harness
Pump does not operate Air supply connected? Connect Air Supply
Air regulator closed Set Air Regulator
Start/stop valve closed Operate Valve

Pump stalls prior to reaching Insufficient Air Supply Increase Air Supply
required pressure
Air Pressure Regulator Adjust Air Regulator
Maximum Pressure cannot be Leaking Couplings Replace Suspect Couplings
achieved, even when pump is
running continuously Leaking Tensioner Seals Replace Suspect Seals
Hydraulic Oil Return Valve Fully Close Valve or Replace
Pressure Reading Erratic Defective Gauge Replace Gauge
Puller Sleeve will not Screw Oversize Bolts Check Bolt Size
Down Bolt/Stud
Differing Thread Form Check Thread Form
Hydraulic Fluid Visible at Maximum Stroke Achieved, Tighten Nut and Repeat Procedure
Top/Bottom of Tensioner Overstroke Eliminator Valve
Activated. (PS2 - PS8)
Leaking Tensioner Seals Replace Seals

Pump Runs Erratically/Jerky Foreign Matter in Hydraulic Renew Hydraulic Oil
after a Period of Time Oil
25 PS/OP/1095/Iss. 4
10 - ANCILLARY/SPARE PARTS
10.1 ANCILLARY EQUIPMENT
Pump Unit
A high delivery air powered pump unit used to supply hydraulic oil to the PS tensioner.
Feed Hoses
3 metres long, used to connect pump unit to PS tensioners.
Interconnecting Hose
1 metre long, used to link the tensioners together constructing a ring main harness.
Blank Female Quick-Disconnect Coupling*
Used to blank the pump hydraulic oil outlets when pre-setting the pump hydraulic pressure.
*Included in recommended spare parts list.
10.2 RECOMMENDED SPARE PARTS (SALE EQUIPMENT ONLY)
2 off Open ended female quick disconnect couplings (Part No: SY46)
2 off Open ended male quick disconnect couplings (Part No: SY45)
2 off Blank female quick disconnect couplings (Part No: E1-8)
2 off Elbow couplings (Part No: E1-9)
Quick disconnect coupling seals (Part No: E2-104)
Quick disconnect coupling Back-up ring M0451
Cylinder seal (for specific tensioner, refer to GA and parts list)
Piston Seal (for specific tensioner, refer to GA and parts list)
Toggle Bar (for specific tensioner)
Allen Key (for specific tensioner)
1 Gallon Houghtosafe 620
½ litre Silkolene Icefree
1 can WD40
10.3 SPARE PART ORDERING INFORMATION
The following information should be quoted when ordering spare parts.
a) The assembly name and Serial No (obtained from GA and Parts list/actual assembly respectively).
b) The component name and part number (obtained from GA and parts list).
c) The contract number or approximate date the equipment was purchased.

26 PS/OP/1095/Iss. 4
11 – APPROVED DISTRIBUTORS
Contact Hydratight (UK) direct, who will inform of the nearest approved distributor/agent.
27 PS/OP/1095/Iss. 4
Issue 2
Section 11.0 changed to approved distributors. Appendix ‘A’ added to include general arrangements and
parts lists – July 1998
Issue 3
Table in Section 2.1 Technical Specifications, updated to include metric bolts.
Section 6.1, Hydraulic Reservoir, tank capacity was 9 litres.
Fig 5 Updated.
Section 7, revised.
Back-up ring added to Section 10.2.
Issue 4
General Arrangement Section Removed
Section 4: Section added referring to use of banjo fittings
Section 7.2: Instructions added for the changing of quick disconnect coupling seals on 1/8” BSP fittings
and for the assembly of banjo fittings – 23 March 2005
28 PS/OP/1095/Iss. 4

CS 5200 SC01 Ope PRC 253007 - A - C2

Uploaded by

Copyright:

Available Formats

You might also like

CS 5200 SC01 Ope PRC 253007 - A - C2

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

CS 5200 SC01 Ope PRC 253007 - A - C2

Uploaded by

Copyright:

Available Formats

Find the CTR comment enclosed.

The comment sheet is available separately.

PROJECT: JUBILEE SOUTH EAST

DOCUMENT NUMBER: CS-5200-SC01-OPE-PRC-253007

DOCUMENT TITLE: JSE - ORSAM - IN-COUNTRY LARGE FABRICATION -

A 28/01/2022 Issued for Review Arsene TSAGUE Emre EDİZER

SCTR Document Number Revision Rev. Date: 28/01/2022

CS-5200-SC01-OPE-PRC-253007 A Page 2 / 78.

SCTR Document Number Revision Rev. Date: 28/01/2022

CS-5200-SC01-OPE-PRC-253007 A Page 3 / 78.

Figure 1 – Jubilee field schematic

SCTR Document Number Revision Rev. Date: 28/01/2022

CS-5200-SC01-OPE-PRC-253007 A Page 4 / 78.

3 6" Production Gooseneck insulated

Quality Management Systems - Requirements ISO 9001- Edition 2015

SCTR Document Number Revision Rev. Date: 28/01/2022

CS-5200-SC01-OPE-PRC-253007 A Page 5 / 78.

4.2. Reference Company Documents

QUALITY REQUIREMENTS Section 3(G) _Rev1

Handling Procedure for TQ, DR and CR TGJSU002-PM-PRO-0001 _Rev0

4.3. Reference Contractor Documents

Exhibit I - HSE Requirements 300032C-000-CSI-5200-0001_rev1

4.4. Reference Supplier Documents

SCTR Document Number Revision Rev. Date: 28/01/2022

CS-5200-SC01-OPE-PRC-253007 A Page 6 / 78.

JSE - ORSAM - In-country large fabrication - Factory Acceptance

5. DEFINITIONS AND ABBREVIATIONS

SCTR Document Number Revision Rev. Date: 28/01/2022

CS-5200-SC01-OPE-PRC-253007 A Page 7 / 78.

6. RULES and RESPONSABILITIES

6.2. QUALITY CONTROLLER

6.3. SITE SUPERVISOR

6.4. HSE SUPERVISOR

SCTR Document Number Revision Rev. Date: 28/01/2022

CS-5200-SC01-OPE-PRC-253007 A Page 8 / 78.

Description of the bolt tensioning

Figure 1 – Bolt tensioner & Air driven Hydraulic Pump

Refer to Attachment 3 for Hydraulic Pump calibration certificate.

SCTR Document Number Revision Rev. Date: 28/01/2022

CS-5200-SC01-OPE-PRC-253007 A Page 9 / 78.

Figure 2 - Hydraulic pressure for bolt tensioning

8.1. 50% Tensioning Coverage

SCTR Document Number Revision Rev. Date: 28/01/2022

CS-5200-SC01-OPE-PRC-253007 A Page 10 / 78.

Figure 3 - Typical Hydraulic Tensioner Arrangement (50% coverage)

9. BOLTS TENSIONING DATA

SCTR Document Number Revision Rev. Date: 28/01/2022

CS-5200-SC01-OPE-PRC-253007 A Page 11 / 78.

SCTR Document Number Revision Rev. Date: 28/01/2022

CS-5200-SC01-OPE-PRC-253007 A Page 12 / 78.

ATTACHMENT 1 – BOLTS TENSIONING TASK PLAN

SCTR Document Number Revision Rev. Date: 28/01/2022

CS-5200-SC01-OPE-PRC-253007 A Page 13 / 78.

SCTR Document Number Revision Rev. Date: 28/01/2022

CS-5200-SC01-OPE-PRC-253007 A Page 14 / 78.

SCTR Document Number Revision Rev. Date: 28/01/2022

CS-5200-SC01-OPE-PRC-253007 A Page 15 / 78.