Hydraulic Bolt Tensioning 10022-1817-C-0002-SC17-00027

DOCUMENT COVER PAGE
SRC CRU REVAMP PROJECT 1817

SUBCONTRACTOR: HIAP SENG ENGINEERING PTE LTD
EPC CONTRACTOR: JACOBS ENGINEERING SINGAPORE
OWNER / END USER: SINGAPORE REFINING COMPANY
PROJECT NO.: KC02
CONTRACT NO.: 10022-1817-C-0002
PACKAGE: M & P PACKAGE
HIAP SENG DOCUMENT NO. HSEL-CRU-QC-56
JACOBS DOCUMENT NO: 10022-1817-C-0002-SC17-00027
DOCUMENT TITLE: FLANGE BOLT TENSIONING PROCEDURE (PETRACARBON)
REV. NO. DATE BY

0 03-JAN-2019 KWEK BOON HIONG
By Narendra Kumar E at 4:45 pm, Jan 10, 2019

PETRACARBON PTE LTD
REV : C
ENGINEERING WORK INSTRUCTION
TITLE: CONVENTIONAL HYDRAULIC BOLT TENSIONING
DOCUMENT NUMBER: WI/PC/004
REVISION: C
Document No: WI/PC/004C Page: 1 of 13

IMPORTANT NOTICE
PETRACARBON PTE LTD has made every

effort to ensure that the information given in this
manual is correct and understandable. However,
it is acknowledged that there may be errors or
omissions in this publication.
The Company reserve the right to modify its products without notification and consequently
to supply machines that may not be in accordance with the descriptions and procedures in this
publication.
HEALTH & SAFETY AT WORK
To advise our customers on the safety and handling precautions to be observed when
installing, operating, maintaining and servicing their products. Accordingly, the following
points should be noted:
1. The relevant sections of these instructions should be carefully read before proceeding.
2. Installation, maintenance and servicing should only be carried out by suitably trained
and competent personnel.
3. Normal safety procedures must be taken into account the possibility of an accident
occurring.
4. Any safety equipment necessary for maintenance is responsibility of the customer.

1) PURPOSE
The objective of this procedure is to lay down the instruction for operating the
Conventional Hydraulic Bolt Tensioning System which is designed for installing and
removing threaded fasteners requiring precise high torque during bolt makeup and
maximum torque during bolt breakout at ambient condition.
2) SCOPE
This is applicable to Boltite Hydraulic Bolt Tensioners of Series BT-XX.
3) REFERENCE
PIM-SU-5209-A.2 & ASME-PCC-1.
4) GENERAL SAFETY
4.1 Use only the approved tools provided for the operation as list in the permitted
equipment list.
4.2 Carry out all operations according to these operating work instructions.
4.3 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.
5) PERMITTED EQUIPMENT
5.1 Boltite Bolt Tensioner Series BT-XX.
5.2 Hydraulic Feed Hoses and interconnecting hoses.
5.3 Hydraulic Pump Unit with calibrated pressure gauge and calibration certificate.

6) SAFETY EQUIPMENT
6.1 Approved Personal Protective Gear and equipment.
7) TECHNICAL SPECIFICATION
7.1 Input / Output Data

M39
M42
M45
M48

8) RESPONSIBILITIES
8.1 The Operations Manager, Workshop Supervisor and QA shall ensure that the
instrument, gauges and test equipment in use are calibrated and in good operating
condition.
9) INTRODUCTION
9.1 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.
9.2 This operator procedure given below details a 50% Bolt/Tool ratio.
Examples:
8 bolts flange requires 4 bolt tensioning tools.

12 bolts flange requires 6 bolt tensioning tools
10) BOLT SETUP
10.1 Ensure there is sufficient stud protruding from the top of the joint nuts. A minimum of
1 x stud diameter is essential. Note how each bolt is set up with the long stud
protrusion on every bolt. The long stud protrusion side is the side where the bolt
tensioning tool is fitted. In this case 4 bolt tensioner will be fitted on the topside of
the flange.

10.2 Example – For a Bolt size of 1” stud, the required stud protrusion is 1”.
10.3 Also ensure full engagement through the hexagon nut on the opposite end of the studs
being tensioned
11) BOLT TENSIONER SETUP PROCEDURE
11.1 Ensure the flanges are fully pulled together and that the bolts and nuts are tightened
down. Assembled 50% of the bolt tensioning tools over the bolt extension on one top
side of the flange. Screw down the reaction nut until it tightens against the tensioner
piston.
11.2 Ensure at least one thread protrudes above the top face of the reaction nut after fitting.
11.3 Ensure the flanges are fully pulled together and that the bolts and nuts are tightened
down. Assembled the other 50% of the bolt tensioning tools over the ‘long’ bolt
extension on the other side of the flange. Screw down the reaction nut until it tightens
against the tensioner piston.
11.4 Examine around the base circumference of the tensioner base to ensure it is sitting
fully flat against the tensioning surface.

11.5 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.
11.6 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 four setscrews, around the base of the Load Cell

11.7 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.
11.8 Assemble the Puller into each Bolt Tensioner screwing onto the threads protruding
above the hexagon nuts. Ensure the Pullers are threaded to the same diameter, thread
form and pitch as the bolts to be tensioned. Use the Tommy bars with the tensioning
equipment to fully screw down the Puller, until contact is made with the top face of
the Load Cells.
11.9 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 spring 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.

11.10 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.
11.11 Never pressurise an unconnected male.
12) TENSIONING PROCEDURE
12.1 The tensioning system is now ready to apply a bolt

load to the joint.
12.2 Before applying pressure to the system make sure

you understand the following points:
the correct operation of the pump unit.

the maximum working pressure of the
tensioner.
the maximum piston movement of the tensioner. An indicator line can be seen
emergining from the load cell.
the required working pressure that must be applied to the tensioner.
12.3 SAFETY NOTE - During pressurization procedure, continually monitor both piston
stroke and pressure. Never exceed either.
13) PRESSURIZATION OF THE TENSIONING SYSTEM
13.1 The tensioning system is now ready to apply a bolt load to the joint.
Step 1
Close stop valve on pump unit, then pressurize the system to the required pressure.
When the required pressure is reached, stop the pump. (Hold Pressure)
Step 2
At this stage, the bolts will be initially loaded with the load being held by the
tensioner. The tensioner piston ram will be extended and the flange hexagon nuts will
be lifted off the flange.
Step 3
Check the pump gauge to ensure the pressure is holding firm. When you are satisfied
that the pressure is stable, approach the tensioners and by using the Tommy bar, rotate
the hexagon nut through the bridge access window, 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
time to complete). It is not important in which order the nuts are tightened but to be
sure of not missing one, it is recommended that they are tightened in sequence.
Step 4
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 Puller to return the Piston to
their fully closed position (Note – If the desired pressure has not yet been reached,
continue from Section 10.8).
Step 5
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.

Note that the first pressurization was to ‘bed’ the flange bolt and nuts. This is useful
in order to maximize the amount of retained load we get from the second
pressurization.
14) DE-PRESSURIZATION OF THE TENSIONING SYSTEM
14.1 When de-tensioning, specific tool pressure is 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 pressure is available, the de-tensioning pressure is
usually marginally higher than the original tensioning pressure (but not always). The
tensioning system is now ready to apply a bolt load to the joint.
14.2 SAFETY NOTE - 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 authorized by the Engineer in-charge.
The joints / pipeline to be work 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 materials yield is not exceeded or the maximum tool pressure is
not exceeded, whichever is lower. Pump must be pre-set to achieve this.

Step 1
Assemble the tensioning tools to the bolts. With the Puller fully screwed down and
seated in the piston, unscrew the Puller through one and one half turns. This will
prevent the Puller becoming locked onto the piston when the bolt tension is released.
Step 2
Insert a Tommy 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 the system
pressure does not exceed that indicated in the safety notes above.
Step 3
Turn back each flange nut through one full turn. (6 holes on the nut rotating socket).
Step 4
De-pressurise the system and check to see that the flange nuts are still free to rotate.
Step 5
Remove the bolt tensioners. If the thread insert cannot be unscrewed and the flange
nut is also tight, then the Puller has locked onto the top face of the flange nut - see
Step 6. If the thread insert cannot be unscrewed but the flange nut is free, then the
Puller has locked onto the piston - see Step 7
Step 6
Puller locked onto top face of nut - If the flange nut is unscrewed further than that
indicated in Step 3, it can cause the nut to become locked onto the Puller when bolt
tension is released. To release the Puller / 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 Puller should be free to rotate
Step 7
Puller locked onto piston - This occurs if the Puller has not been unscrewed
sufficiently in Step 1 (half a turn may be insufficient for fine threaded bolts) causing
the Puller to become locked onto the piston as the tension is released in the bolt. To
release the Puller, re-apply the hydraulic pressure and turn down the flange nut. Upon
depressurisation, the Puller should freely rotate. Unscrew the Puller a further half turn
and repeat Step 2 to 5 as in Section 13.2.

A typical example of Bolt tensioning setup.
15) METHOD OF STATEMENT & CHECK SHEET FOR TENSIONING OF

STUBS (50%) -- AS SHOWN IN ATTACHMENTS

REV: B
TITLE: HYDRAULIC TORQUE WRENCH

(TX SERIES) – LOW PROFILE TYPE
DOCUMENT NUMBER: WI/PC/036
REVISION: B
Document No: WI/PC/036B Page: 1 of 24

Petracarbon Pte Ltd
TITLE: HYDRAULIC TORQUE WRENCH (TX SERIES)
IMPORTANT NOTICE
PETRACARBON PTE LTD has made every effort to ensure that the information given in this manual
is correct and understandable. However, it is acknowledged that there may be errors or omissions in
this publication.
The Company reserve the right to modify its products without notification and consequently to supply
machines that may not be in accordance with the descriptions and procedures in this publication.
HEALTH & SAFETY AT WORK
To advise our customers on the safety and handling precautions to be observed when installing,
operating, maintaining and servicing their products. Accordingly, the following points should be noted:
1. The relevant sections of these instructions should be carefully read before proceeding.
2. Installation, maintenance and servicing should only be carried out by suitably trained and
competent personnel.
3. Normal safety procedures must be taken into account the possibility of an accident occurring.
4. Any safety equipment necessary for maintenance is responsibility of the customer.

Petracarbon Pte Ltd
1) PURPOSE
The objective of this procedure is to lay down the instruction for operating the Hydraulic
Torque Wrench, TX Series which is designed for installing and removing threaded fasteners
requiring precise high torque during bolt makeup and maximum torque during bolt breakout.
2) SCOPE
This is applicable to Boltite Torque Wrench of Series TX-2, TX-4, TX-8, TX-16, & TX-32
Hydraulic Torque Wrenches and Hydraulic Pump Unit with calibrated pressure gauge and
calibration certificate.
3) REFERENCE
PIM-SU-5209-A.2 & ASME-PCC-1.
4) GENERAL SAFETY
4.1 Use only the approved tools provided for the operation as list in the permitted equipment list.
4.2 Carry out all operations according to these operating work instructions.
4.3 In case of emergency, press the emergency stop button of the machine / equipment to
discontinue operation.
4.4 Wear the appropriate safety equipment / clothing as recommended for this process.
4.5 Should any abnormality arise in this operation, stop operation immediately and report to your
chargehand or supervisor.
4.6 At all times, avoid bodily contact with moving parts of the machine.

Petracarbon Pte Ltd
HYDRAULIC BOLTING TOOLS
TX Series Torque Wrenches

Torque Wrench Series
Hydraulic Torque Wrenches
Operating and Maintenance Instructions

For TX Series Hydraulic Torque Wrenches
HYDRAULIC TORQUE WRENCHES
PETRACARBON PTE LTD

1001 REDHILL INDUSTRIAL ESTATE #04-01/06 JALAN BUKIT MERAH SINGAPORE 159455
TEL : (65) 62710800 FAX : (65) 62733121

Petracarbon Pte Ltd
OPERATION AND MAINTENANCE MANUAL

FOR BOLTITE TX-2, TX-4, TX-8, TX-16, AND TX-32
SQUARE DRIVE HYDRAULIC TORQUE WRENCHES
NOTICE
Series TX-2, TX-4, TX-8, TX-16, and TX-32 Low Profile Hydraulic Torque Wrenches are designed
for installing and removing large bolts having minimal wrench clearance at offshore platforms,
power plants, steel erection sites and other locations requiring precise high torque during bolt
makeup and maximum torque during bolt breakout.
BOLTITE is not responsible for customer modification of tools for applications on which
BOLTITE was not consulted.
WARNING
IMPORTANT SAFETY INFORMATION ENCLOSED.

READ THIS MANUAL BEFORE OPERATING TOOL.
IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PLACE THE INFORMATION IN
THIS MANUAL INTO THE HANDS OF THR OPERATOR. FAILURE TO OBSERVE THE
FOLLOWING WARNINGS COULD RESULT IN INJURY.
PLACING TOOL IN SERVICE

- Always operate, inspect and maintain this tool in accordance with American National
Standards Safety Code for Hydraulic Rams and Jacks (ANSI B301).
- This tool will function using an air or electric powered hydraulic pump. Adhere to the pump
safety requirements and follow instructions when connecting the pump to the tool.
- Use only equipment rated for the same pressure and torque.
- Use only a hydraulic pump capable of generating 10, 000 psi (681 bar) maximum
pressure with this tool.
- Use only twin line hydraulic hose for 10, 000 psi (681 bar) pressure with this tool.
- Do not interchange the male and female swivel inlets on the tool or the connections on
end of the hose. Reversing the inlets will reverse the power stroke cycle and may damage
the tool.
- Do not use damaged, frayed or deteriorated hoses and fittings. Make certain there are no
cracks, splits or leaks in the hoses.
- Use the quick connects system to attach the hoses to the tool and pump. Make certain the
spring – loaded retaining rings are fully engaged and the safety rings tightly treaded
against the spring – loaded retaining rings to prevent the connectors from disengaging
under pressure.
- When connecting hoses that have not been preloaded with hydraulic oil, make certain the
pump reservoir is not drained of oil during start – up.
- Do not remove any labels. Replace any damaged labels.

Petracarbon Pte Ltd
USING THE TOOL

- Do not handle pressurized hoses. Escaping oil under pressure can penetrate the skin, causing
serious injury. If oil is injected under the skin, see a doctor immediately.
- Never pressurize uncoupled couplers. Only use hydraulic equipment in a coupled system.
- Always wear eye protection when operating or performing on this tool.
- Always wear head and hand protection and protective clothing when operating this tool.
NOTICE
The use of other than genuine BOLTITE replacement parts may result in hazards,
decreased tool performance, and increased maintenance, and may invalidate all
warranties.
Repairs should be made only by authorized personnel. Consult your nearest BOLTITE
Authorized Service center.
Refer All Communications to the Nearest BOLTITE Office or Distributor.
For Technical Support and Information Contact:
PETRACARBON PTE LTD

1001 REDHILL INDUSTRIAL ESTATE #04-01/06 JALAN BUKIT MERAH SINGAPORE 159455
TEL : (65) 62710800 FAX : (65) 62733121

Petracarbon Pte Ltd
WARNING
FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY
USING THE TOOL

- Keep hands, loose clothing and long hair away from reaction arm and working area during
operation.
- This tool will exert a strong reaction force. Use proper mechanical support and correct
reaction arm positioning to control these forces. Do not position the reaction arm so that it tilts
the tool off the axis of the bolt and never use the swivel inlets as a reaction stop.
- Avoid sharp bends and kinks that will cause severe back-up pressure in hoses and lead to
premature hose failure.
- Use accessories recommended by BOLTITE.
- Use only impact sockets and accessories. Do not use hand (chrome) sockets or accessories.
- Use only sockets and accessories that correctly fit the bolt or nut and function without tilting
the tool off the axis of the bolt.
- This tool is not designed for working in explosive atmospheres.
- This tool is not insulated against electric shock. When using this tool with a pump having
an electrical power source or circuits, follow the pump instructions for proper grounding.

Petracarbon Pte Ltd
PLACING THE TOOL IN SERVICE
CONNECTING THE TOOL

1. Attach the twin line hose to the swivel inlets of the Square Drive Torque Wrench using the
spring – loaded quick connect ends. After making certain that they are fully engaged, thread
the safety rings tightly against the spring – loaded retainer rings.
2. Connect the opposite ends of the hose to the Pump in the same manner.
3. Push the Link Retaining Pin out of the Low Profile Drive Cylinder.
4. Mate the selected Ratchet Link to the Cylinder by inserting the end of the Cylinder opposite
the Swivel Inlet between the Side Plates of the Ratchet Link. (Refer to Dwg. 1)
5. Align the Holes for the Link Retaining Pin and insert the Pin through the side plates and
Cylinder to keep the units joined together.
ADJUSTMENTS
SETTING THE TOURQUE

After determining the desired torque, use the torque conversion chart on the Shroud or the torque
conversion charts on page 5 to determine that is necessary to achieve that torque.
1. Connect the tool to the power supply and turn the pump on.
2. Depress the remote control button causing the pressure to be shown on the gauge.
3. Adjust the pressure by loosening the wing nut that locks the pressure adjustment thumbscrew.
Rotate the thumbscrew clockwise to increase the pressure. When decreasing pressure,
always lower the pressure below the desired point and then bring the gauge back up to the
desired pressure.
4. When the desired pressure is reached, retighten the wing nut and cycle the tool again to
confirm that the desired pressure setting has been obtained.

Petracarbon Pte Ltd
OPERATING THE WRENCH

The position of the tool relative to the nut determines whether the action will tighten or loosen the nut.
(Refer to Drawing 02 for application examples). The power stroke of the Piston Assembly will always
turn the Ratchet Hex toward the Shroud.
1. Place the Ratchet Hex on nut. Make certain it is the correct size for the nut and that it fully
engages the nut.
2. Position the reaction surface against an adjacent nut, flange or solid system component. Make
certain that there is clearance for the hoses, swivels and inlets. DO NOT allow the tool to react
against the hoses, swivels or inlets.
3. After having turned the Pump on and presetting the pressure for the correct torque, depress
the remote control button to advance the Piston Assembly. If the notch in the piston rod did
not engage the Retract Pin in the Ratchet Link when the Link was joined to the Housing, it will
engage the Pin automatically during the first advance stroke.
4. When the Link is connected to the Housing and the wrench is started, the reaction surface of
the wrench will move against the contact point and the nut will begin to turn.
5. When the nut is no longer turning and the Pump Gauge reaches the preset pressure, release
the remote control button. The piston rod will retract when the button is released and under
normal conditions, an audible “click” will be heard as the tool resets itself.
6. Continue to cycle the tool until it “stalls” and the preset psi/torque has been attained.
7. Once the nut stops rotating, cycle the tool one last time to achieve total torque.

Petracarbon Pte Ltd
LUBRICATION
Mobil 1 Synthetic Grease
Lubrication frequency is dependent on factors known only to the user. The amount of contaminants in
the work area is one user. Tools used in a clean room environment will obviously require less service
than a tool out-doors and dropped in loose dirt or sand. Mobil 1 Synthetic Grease is formulated not to
wash out of the tool in areas where lubrication is critical. Whenever lubrication is required, lubricate as
follows:
1. Separate the Low Profile Cylinder from the Ratchet Link if they are joined.
2. After wiping of the old grease, apply a daub of Mobil 1 Synthetic Grease to the hooking notch
in the Piston rod and wipe a film of Mobil 1 onto the sides and faces of the two Sliders.
3. Disassemble the Ratchet Link as instructed in the Maintenance Section and wash the
components in a suitable cleaning solution in a well-ventilated area.
4. Dry the components, the wipe a film of Mobil 1 Synthetic Grease onto the wear surface of both
Side Plate Sleeves and the hubs of the Ratchet.
5. Spread a light film of Mobil 1 Synthetic Grease onto the inner faces of both Side Plates
covering the area where the Drive and Segment Pawl travel. DO NOT pack the teeth of the
Segment Pawl or Ratchet with lube. It can prevent the teeth from engaging properly.
6. Reassemble the Ratchet Link as instructed in the Maintenance Section.

Petracarbon Pte Ltd
BX
TX-2 TX-4 TX-8 TX-16 TX-32

Petracarbon Pte Ltd
TX-2, TX-4, TX-8 SERIES LINK
LINK PARTS TX-16, TX-32

TX-2
TX-4 SERIES CYLINDER
TX-8
TX-16, TX-32 SERIES LINK

LINK PARTS
TX-16
TX-32

Petracarbon Pte Ltd
Part Number for Ordering (Links)
Part TX-2 TX-4 TX-8 TX-16 TX-32

1 SIDE PLATE – L TX-2-L01 TX-4-L01 TX-8-L01 TX-16-L01 TX-32-L01
2 SIDE PLATE – R TX-2-L02 TX-4-L02 TX-8-L02 TX-16-L02 TX-32-L02
3 DRIVE PLATE TX-2-L03 TX-4-L03 TX-8-L03 TX-16-L03 TX-32-L03
4 DRIVE PIN TX-2-L05 TX-4-L05 TX-8-L05 TX-16-L05 TX-32-L05
5 DRIVE PIN SPRING TX-2-L07 TX-4-L07 TX-8-L07 TX-16-L07 TX-32-L07
6 RATCHET TX-2-L09 TX-4-L09 TX-8-L09 TX-16-L09 TX-32-L09
7 DRIVE SEGMENT TX-2-L11 TX-4-L11 TX-8-L11 TX-16-L11 TX-32-L11
8 UPPER SPACER TX-2-L13 TX-4-L13 TX-8-L13 TX-16-L13 TX-32-L13
9 MIDDLE SPACER N/A N/A N/A TX-16-L14 TX-32-L14
10 LOWER SPACER TX-2-L15 TX-4-L15 TX-8-L15 TX-16-L15 TX-32-L15
11 LOWER SPACER PIN TX-2-L17 TX-4-L17 TX-8-L17 TX-16-L17 TX-32-L17
12 SLEEVES - TX-2-L19 TX-4-L19 TX-8-L19 TX-16-L19 TX-32-L19
SIDEPLATE
13 SHROUD TX-2-L21 TX-4-L21 TX-8-L21 TX-16-L21 TX-32-L21
14 SEGMENT SPRING TX-2-L25 TX-4-L25 TX-8-L25 TX-16-L25 TX-32-L25
15 SCREWS – UPPER TX-2-L27 TX-4-L27 TX-8-L27 TX-16-L27 TX-32-L27
SPACER
16 SCREWS – LOWER TX-2-L29 TX-4-L29 TX-8-L29 TX-16-L29 TX-32-L29
SPACER
17 SHROUD SCREWS TX-2-L31 TX-4-L31 TX-8-L31 TX-16-L31 TX-32-L31
18 DRIVE PIN SPRING TX-2-L33 TX-4-L33 TX-8-L33 TX-16-L33 TX-32-L33
ROLL PIN

Petracarbon Pte Ltd
TX-2, TX-4, TX-8 SERIES CYLINDER

Petracarbon Pte Ltd
TX-16, TX-32 SERIES CYLINDER

Petracarbon Pte Ltd
Part Number for Ordering (Cylinders)
Part TX-2 TX-4 TX-8 TX-16 TX-32

1 HOUSING TX-2-C01 TX-4-C01 TX-8-C01 TX-16-C01 TX-32-C01
PISTON ROD TX-2-C03 TX-4-C03 TX-8-C03 TX-16-C03 TX-32-C03
ASSEMBLY
2 PISTON ROD N/A N/A N/A TX-16-C03-1 TX-32-C03-1
3 PISTON CAP N/A N/A N/A TX-16-C03-2 TX-32-C05-2
VALVE BALL N/A N/A N/A TX-16-C03-3 TX-32-C07-3
VALVE SPRING N/A N/A N/A TX-16-C03-4 TX-32-C09-4
VALVE HOLLOW N/A N/A N/A TX-16-C03-5 TX-32-C03-5
LOCK
4 PISTON SEAL PLATE TX-2-C05 TX-4-C05 TX-8-C05 N/A N/A
5 SEAL RING TX-2-C07 TX-4-C07 TX-8-C07 N/A N/A
6 SLIDER TX-2-C09 TX-4-C09 TX-8-C09 TX-16-C09 TX-32-C09
7 END CAP TX-2-C11 TX-4-C11 TX-8-C11 TX-16-C11 TX-32-C11
8 RETAINING RING TX-2-C13 TX-4-C13 TX-8-C13 N/A N/A
9 LINK PIN TX-2-C15 TX-4-C15 TX-8-C15 TX-16-C15 TX-32-C15
10 END COVER TX-2-C17 TX-4-C17 N/A N/A N/A
11 RETAINING SCREWS TX-2-C21 TX-4-C21 TX-8-C21 N/A N/A
12 END COVER TX-2-C23 TX-4-C23 N/A N/A N/A
SCREWS
13 BALL PLUNGER TX-2-C25 TX-4-C25 TX-8-C25 TX-16-C25 TX-32-C25
14 SLIDER PIN TX-2-C27 TX-4-C27 TX-8-C27 TX-16-C27 TX-32-C27
15 END PLUG SEAL TX-2-C29 TX-4-C29 TX-8-C29 TX-16-C29 TX-32-C29
16 ROD SEAL TX-2-C31 TX-4-C31 TX-8-C31 TX-16-C31 TX-32-C31
17 PISTON O-RING TX-2-C33 TX-4-C33 TX-8-C33 TX-16-C33 TX-32-C33
18 SWIVEL (2 N/A STX-4M-4M STX-4M-4M STX-4M-4M STX-4M-4M
REQUIRED)
19 SWIVEL (2 STX-4M-8M N/A N/A N/A N/A
REQUIRED)
20 COUPLER HC-S-100 HC-S-100 HC-S-100 HC-S-100 HC-S-100
ASSEMBLY
21 SEAL INSERTION ATX-2-ST ATX-4-ST ATX-8-ST N/A N/A
TOOL
22 END PLUG WRENCH N/A N/A N/A ATX-16-EPW ATX-32-EPW

Petracarbon Pte Ltd
TX-45 SERIES CYLINDER

Petracarbon Pte Ltd
Part Number for Ordering (Cylinders)
Part TX-45
1 HOUSING TX-45-C01
2 PISTON ROD ASSEMBLY TX-45-C03
3 PISTON ROD TX-45-C03-1
4 PISTON TX-45-C03-2
5 VALVE BALL TX-45-C03-3
6 VALVE SPRING TX-45-C03-4
7 VALVE HOLLOW LOCK TX-45-C03-5
8 WASHER TX-45-C03-6
9 SLIDER TX-45-C09
10 END CAP TX-45-C11
11 LINK PIN TX-45-C15
12 SPRING PLUNGER TX-45-C25
13 SLIDER PIN TX-45-C27
14 END PLUG SEAL TX-45-C29
15 ROD SEAL TX-45-C31
16 PISTON O-RING TX-45-C33
17 SWIVEL (2 REQUIRED) STX-4M-4M
18 COUPLER ASSEMBLY HC-S-100
19 PRESSURE PLUG TX-45-C39
20 ROD BUSHING TX-45-C51
MAINTENANCE SECTION
WARNING
Always turn off the power supply, bleed off hydraulic fluid from the hose connections on the
cylinder assembly and disconnect the hoses before attempting to repair maintenance on this
tool. Always wear eye protection when operating or performing maintenance on this tool.
DISASSEMBLY
GENERAL INSTRUCTIONS
1. Do not disassemble the tool any further than necessary to replace or repair damage parts.
2. Use extra care not to score, nick or damage surfaces that will contain hydraulic oil under
pressure.
3. Whenever grasping a tool in a vise, always use leather – covered or copper – covered vise
jaws to protect the surface of the part and help prevent distortion. This is particularly true of
threaded members and housings.
4. Do not remove any part that is a press fit in or on an assembly unless you have a complete
set of seals and o – rings for replacement.
5. Do not disassemble the hydraulic cylinder assembly unless you have a complete set of seals
and o – rings for replacement.
6. Use only British Standard Fractional size tools when disassembling.

Petracarbon Pte Ltd
DISASSEMBLY OF THE TOOL

1. Push the Link Pin (9) out of the Housing (1) and Side Plates (1&2).
2. Lift the Housing from between the Side Plates and separate the two units.
DISASSEMBLY OF THE TX-2, TX-4 AND TX-8 CYLINDER ASSEMBLIES

1. Grasp the Housing (1) in leather – covered or copper – covered vise jaws with the inlet end
upward and using a 3/4” wrench, unscrew and remove the two Swivel Inlets (18) with their
attached Couplers (19).
2. Remove the Housing Assembly from the vise jaws and over container to catch the oil, move
the Piston Rod (2) back and forth several times to purge the hydraulic oil from the Housing.
3. Grasp the Cylinder Housing in leather – covered or copper – covered vise jaws with the inlet
end upward.
4. For TX-2, use a Phillip’s Head screwdriver and TX-4 models, use a hex wrench to unscrew
and remove the End Cover Screw (12). Remove the End Cover (14).
5. Push the End Cap (7) inward approximately 1/2" and remove the two Retaining Rings (8) by
working them out of the groove in the Cylinder.
6. Install the Seal Insertion Tool (20) on the inlet end of the Housing.
NOTICE
The purpose of the Seal Insertion Tool in the following step is to prevent the End Plug Seal
from expanding into the Retaining Ring groove. If the Tool is not used, place two thin pieces of
flat stock at the midpoint of the opening against opposite walls to control the Seal expansion.
7. Thread one of the Swivel Inlets or a threaded pipe with a tee into the End Cap (7). Use the
Inlet or tee as a handle to pull the End Cap and End Plug Seal (15) out of the Housing through
the Seal Insertion Tool.
8. Push the Piston Rod toward the inlet end of the Housing and use a hex wrench, unscrew and
remove the two Retaining Screws (11).
9. Insert a hooked tool through each screw hole in the Piston Seal Plate (4) and work the Plate
upward out of the Housing.
10. Using an o-ring pick, pull the Seal Ring (5) and Piston O-ring (17) off the Piston Rod.
11. Pus the piston end of the Piston Rod forward in the Housing until the Slider Pin (14) aligns
with the cross holes in the Housing.
12. Using a small drift, tap the Slider Pin out of the Sliders (5) and position shaft and remove the
two Sliders.
13. Push the piston out of the Housing.
14. If the Rod Seal (16) needs replacement, use a hooked tool to pull it out of the Housing.
DISASSEMBLY OF THE TX-16, TX-32 AND TX-45 CYLINDER ASSEMBLIES

1. Grasp the Housing (1) in leather – covered or copper – covered vise jaws with the inlet end
upward and using a 3/4” wrench, unscrew and remove the two Swivel Inlets (18) with their
attached Couplers (19).
2. Remove the Housing Assembly from the vise jaws and over container to catch the oil, move
the Piston Rod (2 &3) back and forth several times to purge the hydraulic oil from the housing.
3. Grasp the Cylinder Housing in leather – covered or copper – covered vise jaws with the inlet
end upward.
4. Insert the pins of the End Plug Wrench (21) into the holes of the End Cap (7). Using a wrench
on the hex of the End Plug Wrench, unscrew and remove the End Cap with the End Plug Seal
(15).
5. Push the Piston Rod far enough into the Housing to expose the hex on the piston head.

Petracarbon Pte Ltd
NOTICE
During removal and after the piston shaft is removed; DO NOT grasp the round portion shaft
with any holding device that will damage the surface. Any nicks or scratches to the surface will
allow hydraulic oil to leak from the Cylinder when the tool is reassembled.
6. Using a socket on the hex of the piston head, unscrew and remove the piston head from the
shaft with the Piston O-ring (17).
7. Pull the Piston shaft out of the Housing.
8. If the Sliders (5) must be replaced, position the Slider Pin (14) over a clearance opening in a
soft block and use a small drift to tap the Pin out of the Sliders and shaft.
9. If the Rod Seal (16) needs replacement, use a hooked tool to pull it out of the Housing.
DISASSEMBLY OF THE RATCHET LINK

1. Lay the Ratchet Link flat on the workbench with the Left Side Plate (1) downward and using a
hex wrench, unscrew and remove the two Lower Spacer Screws (16).
2. Using a hex wrench, unscrew and remove the two Upper Spacer Screws (15).
3. For Series TX-16 and TX-32, use a roll pin punch to tap the Spacer Roll Pin (19) out of the
Right Side Plate (2).
4. While applying thumb pressure to the edge of the Ratchet (6), carefully lift the Side Plate off
the Assembly.
5. Grasp the Ratchet and Drive Plate (3) and, while maintaining their relationship, lift them both
off the Left Side Plate.
NOTICE
In the following step, when the Ratchet is removed from the Drive Plate, the Drive Segment and
Segment Spring will be free to fall from the Drive Plate recess. Do not allow the Drive Segment
to fall on a hard surface that might chip the teeth.
6. Push the Ratchet out of the Drive Plate and Remove the Drive Segment (7) and the Segment
Spring (14) from the Drive Plate Recess.
7. If the Drive Pin (4) or Drive Pin Spring (5) must be replaced, use a roll pin punch to push the
Drive Pin Spring Roll (18) out of the Drive Plate. Once the Pin Spring is removed, the Drive
Pin (4) will drop down to the large opening at the bottom of the slot for easy removal.
8. Lift the Lower Spacer (10) off the Lower Spacer Pins (11). If the Pins must be replaced, use a
hex wrench to remove the two Lower Spacer Screws from the Right Side Plate. Pull the Pins
out of the holes on the inner face of the Right Side Plate.
9. For Series TX-2, TX-4 and TX-8, unscrew the two Spacer Screws and remove the Upper
Spacer (8) from the Right Side Plate. For TX-16 and TX-32 use a roll pin punch to remove the
Spacer Roll Pin (19) from the Right Side Plate. Unscrew the two Spacer Screws and remove
the Middle Spacer (9) and Upper Spacer from the Right Side Plate.
10. If the Side Plate Sleeves out toward the inner face of the Side Plate.

Petracarbon Pte Ltd
GENERAL INSTRUCTIONS
1. Use extra care not to score, nick or damage surfaces that will contain hydraulic oil under
pressure.
2. Whenever grasping a tool in a vise, always use leather-covered or copper-covered vise jaws
to protect the surface of the part and help prevent distortion. This is particularly true if
threaded members and housings.
3. Apply o-ring lubrication to all o-rings before final assembly.
ASSEMBLY OF THE RATCHET LINK

1. If the Side Plate Sleeves (12) were removed, press new sleeves, shoulder end trailing, into the
Right and Left Side Plates (1 & 2) from the inner face of the side Plates. Make certain the
Sleeves are square with the side plate faces and the shoulder of the Sleeves enters the
recesses in the Side Plates and are pressed flush with the faces.
2. For Series TX-2, TX-4, and TX-8, position the Upper spacer (8) against the inside of the Right
Side Plate Apply a non-permanent thread-locking compound to the threads of the two Upper
Spacer Screws (15) and secure the Spacer with the Screws through the Side Plate. For series
TX-16 and TX-32 press the Spacer Roll Pin (19) into the Right Side Plate with one end of the
Pin flush with the external face of the Side Plate. Insert the Tab of the Upper Spacer (8) into
the slot in the Middle Spacer (9), and after aligning the holes in both pieces, install them on the
Spacer Roll Pin (19). When they are correctly positioned, apply to the threads of the two
Upper Spacer Screws (15) and secure the Spacer with the Screws through the side plate.
3. Insert the two Lower Spacer Pins (11) into the holes in the lower edge of the Right Side Plate.
Apply a non-permanent thread-locking compound to the threads of the Lower Spacer Screws
(16) and secure the Pins with the Screws through the Side Plate.
4. Place the Lower Spacer (10) over the Pins against the Side Plate. Make certain it is correctly
oriented so that no part of the Spacer extends beyond the edge of the Side Plate.
5. Insert the Drive Pin (4) into the Small cross-hole and slot in the Drive Plate (3). Invert the Plate
causing the ends of the Pin to enter the slot and make the Pin to the narrow end.
6. Position the Drive Pin Spring (5) in the drive plate slot with the two non-connected ends
between the Drive Pin and the large hole in the slot. Position the closed end of the Spring on
the opposite side of the Pin and then apply pressure on the Spring to align the hole through it
with the hole in the Drive Plate for the Drive Pin Spring Roll Pin (18). Insert the Spring Roll Pin
into the Drive Plate, through the Spring and into the far wall of the Drive Plate.
NOTICE
In the following step, an excessive amount of grease will prevent proper tooth engagement
between the Ratchet and the Drive Segment causing the tool to malfunction.
7. Wipe a thin film of Mobil Synthetic Grease onto the inner race of the opening in the Drive
Plate.
8. Position the Ratchet (6) in the central opening of the Drive Plate.
9. Insert the Drive Segment (7) into the opening adjacent to the Ratchet. Make certain the teeth
of the Ratchet correctly engage the teeth of the Drive Segment. Reverse the Ratchet if
they do not properly engage.
10. Slide the Drive Segment sideways to expose the spring hole. Install the Segment Spring (14)
into the hole. While compressing the Spring, slide the Drive Segment inward until the Drive
Plate captures the Segment Spring.
11. Apply a light coat of Mobil Synthetic Grease to both sides of the Drive Plate and Drive
Segment. Apply some of the Mobil Grease to the inner races of both side Plate Sleeves (12).
12. While keeping the assembly together, insert the hub of the Ratchet into the Side Plate Sleeve
of the assembled Side Plate.

Petracarbon Pte Ltd
13. Place the Left Side Plate Sleeve on the hub of the Ratchet and align the screw holes for the
Spacers.
14. After applying a non-permanent thread-locking compound to the threads and using wrenches,
install the two remaining Lower Spacer Screws.
ASSEMBLY OF THE TX-16, TX-32 AND TX-45 CYLINDER ASSEMBLIES

1. Grasp the link retaining pin lug in copper-covered, vise jaws with the Housing (1) horizontal.
2. If the Rod Seal (16) was removed from the Housing, apply a coat of o-ring lubricant to the
Seal and install it, lip end trailing, in the recess at the bottom of the piston bore.
3. Press the Slider Pin (14) into one of the Sliders (5) flush with one side. Install the Pin through
the hole in the piston shaft and press the remaining Slider onto the Pin.
4. Install the Piston O-ring (17) in the groove of the piston head.
5. Insert the piston rod, threaded end leading, into the small central opening from the non-piston
end of the Housing. The notch in the trailing end of the shaft should be toward the Ball Plunger
(13).
6. Insert the piston, hex end trailing, into the bore of the Housing, and use socket to thread and
tighten the piston onto the piston shaft.
7. Install the End Plug Seal (15) in the groove on the hub of the End Cap (7).
8. Using the End Plug Wrench (21), thread the assembled End Cap, o-ring end leading, into the
piston end of the Housing and tighten it.
9. Wrap the threads of the Swivel Sets (18) with Teflon tape and thread the swivel with the male
hose Coupler (19) into the center of the End Cap. Thread the Swivel with the female Coupler
into the hole in the Housing directly above the End Cap.
ASSEMBLY OF THE TX-2, TX-4 AND TX-8 CYLINDER ASSEMBLIES

1. Grasp the link retaining pin lug in copper-covered, vise jaws with the Housing (1) horizontal.
2. If the Rod Seal (16) was removed from the Housing, apply a coat of o-ring lubricant to the
Seal and install it, lip end trailing, in the recess at the bottom of the piston bore.
3. Insert the piston rod, notched end leading, into the Rod Seal and the small central opening
from the piston end of the Housing. The notch in the leading end shaft should be toward the
Ball Plunger (13).
4. Push the Piston Rod (2) inward until the hole for the Slider Pin (14) aligns with the holes in the
walls of the Housing.
5. Position one Slider (6) on each side of the piston shaft and insert the Slider Pin through the
hole in the Housing into both Sliders and the piston shaft. The fit between the Pin and Sliders
is an interference fit. Use a brass hammer and drift to set the Slider Pin below the outer edge
of both Sliders or deep enough to prevent the shaft ends from dragging on the Housing walls.
6. Install the Piston O-ring (17) in the internal groove of the Seal Ring (5).
7. Install the assembled Seal Ring and Piston O-ring on the hub at the large end of the Piston
Rod.
8. Install the Piston seal Plate (4) in the inlet end of the Housing with the side having the
countersunk screw holes trailing.
NOTICE
In the following step, DO NOT use thread-locking compound on the screw threads.
9. Using a hex wrench and an alternating tightening procedure, install the Retaining Screws (11).
Tighten each Screw a little at a time to obtain even compression and expansion of the Piston
O-ring and Seal Ring.
10. Place the Seal Insertion Tool (20) on the inlet end of the Housing.
11. Install the End Plug Seal (15) in the groove of the End Cap (7).

Petracarbon Pte Ltd
12. Insert the assembled End Cap into the Housing through the Tool with the O-ring end leading
and the threaded inlet hole upward. Push the Cap inward beyond the Retaining Ring groove
and approximately 1/2 “ into the Cylinder.
13. Remove the Seal Insertion Tool from the Housing.
14. Install the Retaining Rings (8) in the housing grooves at the inlet end of the Housing. Install
the Rings with the open ends of both rings at the middle of the opening and the beveled side
of the Rings towards the End Cap.
15. If an air hose is available, inject some air into the threaded opening of the End Cap to seat the
Retaining Rings. If air is not available, temporarily thread one of the Swivel Sets (18) into the
threaded opening and pull the End Cap back against the Retaining Rings to seat them.
16. For TX-2 and TX-4 models position the End Cover (10) against the Housing and after
applying a non-permanent thread-locking compound to the threads, install the End Cover
Screw (12).
17. Wrap the threads of the Swivel Sets (18) with Teflon tape and thread the swivel with the male
hose Coupler (19) into the threaded hole in the End Cap.
18. Apply some Mobil Synthetic Grease to the notch in the Piston Rod and the face of the Sliders.
ASSEMBLY OF THE TOOL

1. With the Cylinder Assembly in one hand and the Ratchet link in the other, hook the notch on
the shaft of the Piston Rod (2) onto the Drive Pin (4) and bring the two assemblies together.
2. Insert the Link Pin (9) into the hole in the Side Plate (1 or 2) until the Ball Plunger (13) snaps
into the annular groove around the center of the Link Pin.

Petracarbon Pte Ltd

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DOCUMENT COVER PAGE

SRC CRU REVAMP PROJECT 1817

DOCUMENT TITLE: FLANGE BOLT TENSIONING PROCEDURE (PETRACARBON)

REV. NO. DATE BY

By Narendra Kumar E at 4:45 pm, Jan 10, 2019

ENGINEERING WORK INSTRUCTION

TITLE: CONVENTIONAL HYDRAULIC BOLT TENSIONING

DOCUMENT NUMBER: WI/PC/004

Document No: WI/PC/004C Page: 1 of 13

PETRACARBON PTE LTD has made every

HEALTH & SAFETY AT WORK

4. Any safety equipment necessary for maintenance is responsibility of the customer.

Document No: WI/PC/004C Page: 2 of 13

This is applicable to Boltite Hydraulic Bolt Tensioners of Series BT-XX.

PIM-SU-5209-A.2 & ASME-PCC-1.

5.1 Boltite Bolt Tensioner Series BT-XX.

5.2 Hydraulic Feed Hoses and interconnecting hoses.

Document No: WI/PC/004C Page: 3 of 13

6.1 Approved Personal Protective Gear and equipment.

7.1 Input / Output Data

Document No: WI/PC/004C Page: 4 of 13

Document No: WI/PC/004C Page: 5 of 13

8 bolts flange requires 4 bolt tensioning tools.

10) BOLT SETUP

Document No: WI/PC/004C Page: 6 of 13

11) BOLT TENSIONER SETUP PROCEDURE

Document No: WI/PC/004C Page: 7 of 13

Document No: WI/PC/004C Page: 8 of 13

Document No: WI/PC/004C Page: 9 of 13

11.11 Never pressurise an unconnected male.

12) TENSIONING PROCEDURE

12.1 The tensioning system is now ready to apply a bolt

12.2 Before applying pressure to the system make sure

the correct operation of the pump unit.

13) PRESSURIZATION OF THE TENSIONING SYSTEM

Document No: WI/PC/004C Page: 11 of 13

14) DE-PRESSURIZATION OF THE TENSIONING SYSTEM

14.2 SAFETY NOTE - Prior to commencement of bolt de-tensioning ensure that:

All necessary safety precautions have been carried out.

Document No: WI/PC/004C Page: 12 of 13

Document No: WI/PC/004C Page: 13 of 13

A typical example of Bolt tensioning setup.

15) METHOD OF STATEMENT & CHECK SHEET FOR TENSIONING OF

Document No: WI/PC/004C Page: 14 of 13

ENGINEERING WORK INSTRUCTION

TITLE: HYDRAULIC TORQUE WRENCH

DOCUMENT NUMBER: WI/PC/036

Document No: WI/PC/036B Page: 1 of 24

HEALTH & SAFETY AT WORK

4. Any safety equipment necessary for maintenance is responsibility of the customer.

Document No: WI/PC/036B Page: 2 of 24

PIM-SU-5209-A.2 & ASME-PCC-1.

Document No: WI/PC/036B Page: 3 of 24

HYDRAULIC BOLTING TOOLS

TX Series Torque Wrenches

Operating and Maintenance Instructions

HYDRAULIC TORQUE WRENCHES

PETRACARBON PTE LTD