ABS BOLTSTRONG Product Brochure V11

www.absgroup.in

QUALITY WITH EXCELLENCE

Since 1998

BOLTING TOOLS & ACCESSORIES

BOLTSTRONG

Authorized Training Providers

With skilled human capital of over 250 employees, we serve major industries

including Oil & Gas, Wind, Power, Automobile Manufacturing & Assembly,

Railways, Construction, Heavy Engineering, Steel, Mining, Shipping, Defence, to

name a few.

We focus diligently on quality of deliverance through our quality management

system comprising of standard certifications like ISO 9001:2015, ISO 45001:2018

and ISO/IEC 17025.

Advanced Bolting Solutions Pvt Ltd (ABS) is the One Stop Solution to your

productivity needs when it comes to precision bolting and on-site machining.

Established in 1998, we are a leading multinational organisation in consultative

sales of torqueing systems, tensioning systems, and on-site machining systems ,

through technological leadership of international brands and unique customer

support initiatives. We are also a leading on-site mechanical services contractor

providing controlled bolting, machining and joint integrity services for Oil & Gas

sector.

We at ABS have the vision to be the leader in Industrial

bolting and machining systems committed to achieve

assurance of joint reliability.

VISION

MISSION

| | | Entrepreneurship

`

Expansion Ethics Excellence

9001:2015

ABOUT US

Boltstrong is the indigenous brand of ABS engaged in developing best-in-class hydraulic

tensioners & bolting accessories .

Decades of experience in providing bolting & flange management solutions to various

industrial domains has helped ABS develop these tools for optimal quality, durability and

economy of usage. Manufactured in accordance with ISO 9001: 2015 standards, these tools

are assisted with quality technical support from ABS and crafted using modern technology to

provide fast, accurate and safe solutions to tighten and loosen multiple bolts simultaneously.

www.absgroup.in

BOLTSTRONG

3

QUALITY MANAGEMENT SYSTEM

We believe an effective Quality Management System is the cornerstone of organisational effectiveness in delivering

value to our customers. In line with our motto of Continual Improvement, we work relentlessly to maintain our strong

quality management system.

With international standards certifications such as ISO 9001:2015 , ISO 45001:2018 and ISO/IEC 17025, we ensure

quality in our service delivery.

We are the Only Company in India to have:

§ NABL accreditation- torque tool calibration capacity up to 27000 Nm

§ ASME Authorised Training Provider

QUALITY POLICY

We at ABS have the vision to be the leader in,

Industrial bolting and machining systems committed to achieve assurance of joint stability;

through supply of high quality products and skilful service within the agreed time schedule, and

by adhering to environmental & legal regulations, thereby achieving customer satisfaction, and

work towards continual improvement of quality systems and process.

ISO 45001:2018

ISO 9001:2015

ISO/IEC 17025

Certificate of Testing and Calibration

Certificate of Quality Management System

Certificate of Occupational Health & Safety (OH&S) Management System

CERTIFICATIONS

Tool ReliabilityProcess QualitySafety at Work

4

The Boltstrong products are manufactured in an

infrastructure spread over 1500 sq ft area, housing

the best machinery and tooling.

Our facility ticks all the three categories of

manufacturing capability- technological processing

capability, physical size and weight, and production

capacity. The VMC machine can manufacture profile

jobs with excellent finish and unmatched accuracy

of upto .0005 microns. The CNC machine has low

cycle time for speedy production with accuracy.

The production is in the hands of qualified

experienced personnel, who are well trained to

deliver the product as per specifications. The team

of ITI people, programming experts and good

leadership ensure you get the best result.

MANUFACTURING CAPABILITY

Our technically strong and experienced team,

equipped with the tools and processes needed for

superior performance; is capable of working in

close synergy with the customer's personnel to

deliver efficiency, enhance productivity, and

optimize costs.

MANPOWER

Being ISO 45001:2018 certified, HSE excellence is

engrained as a key component of our

organizational DNA.

SAFETY

MANUFACTURING CAPABILITY

BAND SAW MACHINE Cutting Max Dia 380mm

LATHE MACHINE Max Dia Turning - 350mm

VMCXYZ AXIS - (4 AXIS)800 X 510 X 510

5

CNC Max Turning Dia 320mm X Length 700mm

STANDARD BOLT TENSIONERS

TENSIONERS

6

Puller

Socket

Load Cell

Bridge

The tensioning tool comprises of Hydraulic Cylinder, Socket, Bridge and Puller. The Adaptor Set comprises of socket, bridge and puller.

*Pictures shown are for illustration purpose only. Actual product may vary.

BOLTSTRONG standard tensioners operating

at maximum pressure of 1500 bar are

designed to fit most of ANSI B 16.5, 16.47, API

flanges. Custom built tensioners for

applications with space constraints or high

load requirements are also available. These

tools have suitable surface protection for long

term use in arduous conditions and have a

long operating life.

A comprehensive Health and Safety Operating

and Instruction Manual is provided free of

charge, which provides clear and concise

graphical illustrations of the equipment, its

correct use & maintenance, and operating

pressure data.

Additionally, we are available to provide quick

response to technical questions regarding the

equipment and the applications.

HYDRAULIC HOSE SYSTEM

The hoses have a safety factor of 2.5:1 on

maximum working pressure of 1500 bar. The

quick connectors are suitable for 1500 bar

operation.

OPTIONAL

¨ Automatic Piston Return for safe & fast

operation

¨ Gear Driven Nut Run Down for nut run down

ensuring firm and repeatable nut run down

torques.

Optimum technology composite material seals

that remain firm; do not dislodge; are low

maintenance; have an extended life and facilitate

easy piston retraction as compared to other seal

materials.

SEAL RELIABILITY

Clearly visible red warning indicator line to show

when the tool has reached its maximum piston

extension.

OVER-STROKE INDICATOR

TENSIONERS

TOOL NO. THREAD SIZE STROKE

mm HYDRAULIC

AREA SQ. mm MAX

LOAD KN TOOL OUTSIDE DIA

mm Inch mm

BST-11

- M16

12 1623 243 74

3/4 M20

7/8 M22

1 M24

1-1/8 M27

BST-12

1-1/8 M27

15 2939 440 104

- M30

1-1/4 M33

1-3/8 M36

1-1/2 M39

BST-13

1-1/2 M39

15 5378 806 134

1-5/8 M42

1-3/4 M45

1-7/8 M48

2 M52

BST-14

2 M52

15 8457 1268 164 2-1/4 M56

2-1/2 M64

BST-15

2-1/2 M64

15 12191 1828 194 - M68

2-3/4 M72

3 M76

BST-16

3 M76

15 17570 2635 235

3-1/4 M80

3-1/2 M90

3-1/2 M90

3-3/4 M95

4 M100

TECHNICAL DATA

GENERAL ARRANGEMENT OF TENSIONER

Data is subject to change with change in design.

Custom made tensioners to suit the application can be made available

7

TENSIONERS

Perfect for wind turbine

foundation bolts, these long

stroke spring assisted tensioners

come with optional cycle counter.

FOUNDATION TENSIONERS

Featuring a spring-assisted piston

function, the TSR fits all standard

oil and gas flanges and can be

used on most topside applications.

SPRING RETURN TENSIONER

Designed for subsea applications

this two piece tensioner focuses on

speed and ease of installation,

offering a choice of split or solid

reaction nuts. A plated surface

finish offers enhanced corrosion

resistance.

SUBSEA TENSIONER

A compact tensioner perfect for

high load and tight access

applications, typically on wind

turbines. Available as multi stage

or a single stage version, it is hard

wearing and ensures maximum

cyclic life.

MULTISTAGETENSIONER

The Xtra load range fits all Norsok,

Compact oil and gas flanges

catering to higher loads and

reduced space restrictions.

SPECIAL TENSIONER

Custom made tensioners to suit the application can be made available

8

NIPPLE COUPLING

We supply a range of fittings and connectors to suit different bolt tensioning applications including:

§ Two, four or five outlet manifolds, tee, elbow and cross blocks

§ Swivel adaptors (with nipple or coupling)

§ Blank nipples and couplings

§ Nuts and thread protection caps

All available in 700 bar, 1000 bar, 1500 bar and 2500 bar outputs (higher pressures available on request).

FITTINGS & CONNECTORS

ACCESSORIES

The hose configuration can be specified by the

part number using the following format:

BOLTSTRONG’s flexible hydraulic link pressure hoses

are manufactured from a multi-spiral steel reinforced

polymer with a clear PVC cover for additional

operator protection and resistance against abrasion

and corrosion.

The hoses, connectors and pumps are all colour

coded to ensure the correct hoses are used with the

correct tools.

HYDRAULIC HOSES

§ Hoses are filled with oil and pressure tested prior

to dispatch

§ Regardless of configuration all hoses come fitted

with quick connectors and dust caps

FEATURES

BST-AABB-CC

AA - REFERS TO THE MAXIMUM OPERATING PRESSURE

BB - REFERS TO THE END CONFIGURATION

CC - REFERS TO THE LENGTH

For example a 5 metre 1500 bar hose with a tee block and

coupling would be BST-1548-5.

See the following table for designation numbers:

1000 bar

1500 bar

1800 bar

2500 bar

STANDARD OPERATING PRESSURES

AA STANDARD END CONFIGURATION BB STANDARD LENGTHS CC

10

15

18

25

Coupling / Nipple

Coupling / Coupling

Nipple / Nipple

Coupling / Tee Block

40

41

42

48

1 metre

1.5 metre

2 metre

3 metre

4 metre

5 metre

6 metre

8 metre

10 metre

1

1.5

2

3

4

5

6

8

10

9

TEE BLOCK

PUMPS

Air powered hydraulic pumps have been optimised to be perfect for

pressurising hydraulic bolt tensioners. They are also suitable for use for

pressurizing all high pressure hydraulic systems such as hydraulic jacks,

pressure testing hydraulic systems and for hydro testing.

Our complete range covers other pressure ratings, and we also offer high

flow options for when there are many tools in operation simultaneously.

AIR POWERED HYDRAULIC PUMPS

This compact pump is well suited for the wind energy sector due to its

relatively low weight and small size.

The pump is mounted in a durable steel frame with rubber feet and comes

complete with a hydraulic quick connect fitting.

ELECTRICPUMP

§ The two stage pump is factory

set to provide high volume oil

flow to the tensioner.

§ The pump automatically

switches to high pressure

mode ensuring the desired

operating pressure is achieved

quickly.

§ To increase efficiency and

reduce maintenance the

pump is fitted with a

lightweight brushless motor

which allows the pump to

operate at a low noise level.

FEATURES

§ Compact design

§ Safe and Reliable

§ Reduced downtime

§ Pneumatic filter / regulator /

lubricator included

§ Calibrated gauge

§ 50° max operating

temperature

§ Air pressure safety relief valve

§ Outlet pressure regulator

FEATURES

10

The electric powered hydraulic pumps are robust, multi-purpose units

suitable for all types of bolt tensioning.

The pump is optimised to work with high reliability in adverse environmental

conditions and rough handling as found in workshops and other mobile and

industrial environments

§ CE marked

§ 1500 and 2500 bar options

§ Dual scale psi/bar 100mm

gauge

§ Single scale MPa gauge

option

§ Fitted with Quick Connector

outlet

§ Strong durable frame

§ <70 dBa quiet operation

§ 5L tank with level glass

§ Safety pressure release valve

§ Pressure setting valve

§ Full pendant control

§ Optional FMF secondary fine

mesh filter

FEATURES

ELECTRICPUMP

A hydraulic bolt tensioning tool provides a quick and

easy method for tightening large diameter bolts to

high and accurate pre-loads. Unlike conventional

methods it does not use torque and does not require

any forceful turning of the nut or bolt, like impact

wrenches, flogging spanners or hydraulic torque

wrenches. All of these methods have one common

enemy, FRICTION. Overcoming thread friction and

friction between the nut and the washer uses up over

80% of the torque energy applied to the nut or bolt,

leaving less than 20% of the energy to produce useful

tension in the shank of the bolt. Variations in this

friction loss, from bolt to bolt causes non uniform

tension in bolts that have been tightened to the same

torque or impact wrench setting.

INTRODUCTION TO HYDRAULIC TENSIONING

TENSIONING THEORY

Puller

Body &

Piston

Bridge

Tommy bar holes

Socket

The tensioning force is transferred

to the bolt via the puller

The hydraulic force is

transferred to the puller

Seal

Hydraulic Cylinder

Annular hydraulic jack

Oil inlet

Bolt 1 x ‘D’

protrusion over nut

Window for turning

the socket with

tommy bar

The nut can be turned with zero torque as the

oil pressure is increased

A hydraulic bolt tensioner is an annular jack which fits

over the bolt and nut to be tightened. The jack pushes

against the bolted joint and pulls on the end of the

bolt, which needs to be at least one diameter longer to

accommodate the bolt tensioning tool. Because the

force produced, by the jack, is applied directly to the

end of the bolt, a tension equal to the load generated

by the jack is developed in the shank of the bolt. With

the jack applying the tension, it is possible to turn the

nut with zero torque until it is tight. The load applied

by the jack is then relaxed and a high percentage,

depending on the length of the bolt and its diameter,

is retained in the shank of the bolt.

Bolt tensioning tools can be ganged together to

enable multiple bolts to be tightened simultaneously,

to the same high and accurate pre-load. This is

particularly useful when compressing gaskets in

pipeline or pressure vessel flanged connections. The

high load developed by the multiple bolt tensioning

tools, is evenly distributed around the joint causing

the gasket to fl ow into the surface irregularities of the

flange giving a much better seal.

Flexible hoses with self sealing quick connect

couplings are used to gang the bolt tensioning tools

together to form a hydraulic ring main. The ring main

and tensioning tools are normally pressurised using

an air driven pump working from a compressed air

supply.

11

TORQUE MULTIPLIER

12

RS = anti backlash device

TORQUE MULTIPLIERwith Angled Reaction Anchor

TECHNICAL SPECIFICATIONS

BTS8

BTS18

BTS28

BTS38

BTS50

BTS80

BTS120

BTS160

800

1800

2800

3800

5000

8000

12000

16000

12.5

20

12.5

20

20

20

20

20

20

25

25

25

40

40

40

63

-

-

X

X

X

X

X

X

65

90

95

95

120

132

156

215

105

150

200

200

215

268

272

292

132

188

240

240

272

344

348

370

130

132

132

132

150

200

200

225

1.06

2.46

4.26

4.26

5.74

9.43

11.48

21.32

FEATURES:

• Anti-backlash device

• Shear-off-system

• Overload protection

• Planetary gears

MODELNAME

TORQUE (Nm)

INPUTNUT SIZE

OUTPUTNUT SIZE

RS A B C DWEIGHT

(Kg)TORQUERATIO

1 : 3.5

1 : 3.6

1 : 13

1 : 13

1 : 17

1 : 49

1 : 58

1 : 75

1/2”

3/4”

1/2”

3/4”

3/4”

3/4”

3/4”

3/4”

3/4”

1

1

1

1-1/2”

1-1/2”

1-1/2”

2-1/2”

NUT SPLITTERS

13

HYDRAULIC NUT SPLITTER


FEATURES:

Ÿ Compact design used in confined space with enough force to split the rusted nuts.

Ÿ All models feature a rugged one-piece cutting frame coupled to heavy-duty hydraulic cylinder.

Ÿ Specially designed "tool steel" cutter blade cuts the nut to the precise point where it cracks.

Ÿ Unique angled head design to keep full contact with the nut being penetrated.

Ÿ Unique angled cutter blade with radius to have the greater resistance to cutting and breaking nuts.

Ÿ 5 popular models applicable to cover the most range of nuts.

BTS10

BTS15

BTS20

BTS35

BTS50

M12-M16

M16-M22

M22-M27

M27-M33

M33-M39

10

15

20

35

50

60

70

80

100

117

171.5

192

230

286

321

10

13

16

21

24

25

30

36

45

54.5

40

52

65

76

92

2.2

3.3

4.4

8.2

11.7

MODELNAME

BOLT RANGE(mm)

CAPACITY(TON)

OIL CAPACITY(c.c.)

A(mm)

B(mm)

C(mm)

D(mm)

E(mm)

WEIGHT(Kg)

HEXAGON NUT RANGE

(mm)

19-24

24-32

32-41

41-50

50-60

18

40

68

150

250

68

79

92

116

134

F(mm)


BTS-FS-25ES

BTS-FS-25EK

BTS-FS-25EMK

23

23

23

59

59

59

342

342

342

50.5

50.5

50.5

70

70

70

MODELNAME

SPREAD (mm) STROKE(mm)

C(mm)

D(mm)

E(mm)

F(mm)

G(mm)

WEIGHT(Kg)

CAPACITY(TONS)

25

25

25 X 2

42.5

42.5

42.5

65

65

65

7.8

7.8

7.8

H(mm)

7

7

7

Min - A Max - B

82

82

82

BTS-FS-25ES

BTS-FS-25EK

BTS-FS-25EMK

FLANGE SPREADER

14

HYDRAULIC FLANGE SPREADER

FEATURES:

Ÿ Ideal for numerous industrial maintenance repair jobs.

Ÿ Accurate height adjustments (for instance shaft alignment) can easily be executed by one person.

Ÿ Easy, light and very practical to use.

Ÿ Particularly suitable when available space is very limited from 5 - 40mm.

Ÿ Due to the reduced thickness of the jaws, made of high quality hardened steel, these multi-functional wedges can be used for jobs where working space is extremely limited.

Ÿ Package models are also available, please contact with the authorized distributors for details.


BFAH-6 240

MODELNAME

EXTENSION (mm) WEIGHT(Kg)

ALIGNING FORCE(TONS)

6 15.5106

Min Max

FLANGE ALIGNER

15

HYDRAULIC FLANGE ALIGNER

FEATURES:

Ÿ Compact lightweight design

Ÿ Safe, Simple, cost effective

BFAH-6

BOLTING ACCESSORIES

*Details available on request. Non-standard sizes can also be provided.

16

ALLEN KEY SOCKETS

½”, ¾”, 1”, 1 ½”

STACK SOCKETS

* As per requirement

IMPACT SOCKETS

*Bi-Hex Sockets also available in

imperial/metric sizes

½”, ¾”, 1”, 1 ½”, 2 ½”

IMPACT SOCKETS

LOW CLEARANCE HEX INSERT


SQUARE DRIVE HEX ADAPTER

½”, ¾”, 1”, 1 ½”, 2 ½”

REACTION ARMS


BACKUP WRENCHES


TRACK PADS


SPECIAL ACCESSORIES


ABS House, Plot No. W-116 (A)

T.T.C. Industrial Area, MIDC Khairane

Navi Mumbai - 400 708

Tel: +91 22 4171 4444

Email: [email protected]

Web: www.absgroup.inSince 1998

ABS BOLTSTRONG Product Brochure V11

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