9001 Jameel Road, Suite 180 • Houston, TX 77040 Toll Free: 866.345.8484 • Phone: 281.449.9994 • Fax: 281.449.9996 • Email: [email protected]Titan Case Study Hydraulic Nuts Aluminum Mill Customer: ALCOA Warwick Operations ,Evansville Indiana Application: Coupling on 5000 hp DC Motor Reversing Mill Original Equipment Manufacturer: Morgan Construction- Worcester Massachusetts, USA Bolt pattern: Twelve, 3-1/2” Diameter Studs Previous Methods: SuperBolt and previous to that, Hydraulic Wrenches Previous Time Taken: Minimum 12 hours per coupling – usually 16-20 hours. Issues with SuperBolt method: • Innumerable repetitive passes and sequencing • Improper and inaccurate loading of fasteners resulting in Scores in the flanges, which could only result in movement between the flanges • Extremely time consuming. A full two (2) shifts were required to assemble or disassemble • Labor intensity of previous method inevitably lead to errors which translated to improper bolt load. The result was that the proper load was never achieved • Inaccuracy – bolts can be over or under loaded due to frictional variances • This often leads to series coupling surface fretting and damage requiring repair work and longer maintenance periods with direct effect on production. Such was the case at ALCOA. Issues with Hydraulic Wrench method: • Safety – weight and trapping risks • Heavy Tools • Labor Intensive - Proper loading entailed multiple passes in sequential order • Nut and bolt and coupling surface damage due to galling and reaction • Inaccuracy – bolts can be over or under loaded due to frictional variances Titan Technologies SOLUTION
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Titan Case Study Hydraulic Nuts Aluminum Mill · 9001 Jameel Road, Suite 180 • Houston, TX 77040 ... SuperBolt and previous to that, ... 9001 Jameel Road, Suite 180 • Houston,
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Customer: ALCOA Warwick Operations ,Evansville Indiana Application: Coupling on 5000 hp DC Motor Reversing Mill Original Equipment Manufacturer: Morgan Construction- Worcester Massachusetts, USA Bolt pattern: Twelve, 3-1/2” Diameter Studs Previous Methods: SuperBolt and previous to that, Hydraulic Wrenches Previous Time Taken: Minimum 12 hours per coupling – usually 16-20 hours. Issues with SuperBolt method:
• Innumerable repetitive passes and sequencing • Improper and inaccurate loading of fasteners resulting in Scores in the flanges, which could only
result in movement between the flanges • Extremely time consuming. A full two (2) shifts were required to assemble or disassemble • Labor intensity of previous method inevitably lead to errors which translated to improper bolt
load. The result was that the proper load was never achieved • Inaccuracy – bolts can be over or under loaded due to frictional variances • This often leads to series coupling surface fretting and damage requiring repair work and longer
maintenance periods with direct effect on production. Such was the case at ALCOA.
Issues with Hydraulic Wrench method: • Safety – weight and trapping risks • Heavy Tools • Labor Intensive - Proper loading entailed multiple passes in sequential order • Nut and bolt and coupling surface damage due to galling and reaction • Inaccuracy – bolts can be over or under loaded due to frictional variances
• 5 minutes to remove hoses, connects and pack up.
Result: All studs were evenly loaded to 250kps, residual load. The customer was ecstatic with the accuracy, simplicity and end result. Titan will be installing Hydraulic Nuts on their other coupling