BOLT TENSIONERS

Tools for every conceivable need..... www.torcup.ae

BOLT TENSIONER
BOLT TENSIONER

Bolt tensioning is now the preferred method of tightening bolts & stud on all critical applications.
PST range of bolt tensioners by Torcup provides optimum solutions to bolt tensioning requirements.

PST Series, Bolt Tensioners are designed for operation in a wide variety of applications including pipeline
flanges, heat exchangers, pressure vessels, compressor covers, boilers feed pumps, anchors bolts and many
others.

PST Bolt Tensioner is very simple to use consisting of four parts i.e. Puller, Load Cell , Bridge & Nut Driver.

Part of Tensioner :

PULLER LOAD CELL BRIDGE NUT DRIVER

Operational Sequence :
Fig. 1 Fig. 2 Fig. 3 Fig. 4
T O R C U P

To use bolt tensioner the nut-driver is placed over the nut (fig. 1). The bridge and load cell is then placed
over the bolt (fig. 2). The Puller is then screwed over the stud protruding above the nut face. (fig. 3).
Desired hydraulic pressure is then applied to load cell, which stretches the bolt. (fig. 4). The nut is then
turned down using nut-driver & tommy bar. The Pressure in then released leaving the stud loaded
to desired value.
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 BOLT TENSIONER FEATURES
FEATURES

THE PST SERIES BOLT TENSIONERS ARE LIGHT, COMPACT & VERSATILE LINE OF
TENSIONERS WITH SOME OF THE FOLLOWING FEATURES:-

Standard Features :
(A) Versatile Design :- PST Series standard variable tensioners are designed to provide a wide range of
flexibility, covering stud sizes 3/4” to 5.3/4”. Different stud sizes are accommodated by simply
changing adaptor kit consisting of Puller, Bridge & Nut Driver, while utilizing the same Load cell.

(B) High Strength Alloy Steel :- The PST Series tensioner operate at a maximum pressure of 1500 Bar
& utilizes high strength AISI 4340 steel parst for long lasting performance.

(C) Stroke Indicator: - The PST Series tensioner has an excerption stroke of 15 mm. Integral stroke
indicator allows piston stroke to be viewed & measured indication of stroke is provisioned with
over stroke limit indication.

(D) Safe Design :- The PST series tensioners are designed so that in event of over-stroke the high
pressure fluid will be released from inner side of the load cell & thus saving the operator
from exposure.

(E) Multi Tensioning :- The PST Series load cell is provisioned with two connections & this acts as
manifold for multi tensioning applications. By using Torcup high pressure link hoses any
number of bolt tensioners can be connected & tightened simultaneously. This ensures equal tightening
of all bolts in the assy. & reduce the work time.

(F) Anti Roll Seals :- Low frictions, anti roll seals & rigid backup rings incorporated for improved
life & reliability.

(G) Floating Piston :- The unique piston design allows 2º tilt without any loss of load, preventing piston
seizure or damage of piston bore.

w w w . t o r c u p . a e
Optional Features :
(A) Auto Retraction :- For additional ease of use the PST series tensioner can be supplied with auto
spring retraction system.

(B) Special Fitting :- Optional fitting like bi-hex nut driver. Special bridges, puller etc can be
supplied to customer requirement.

(C) Customized Solutions :- Torcup can supply not only customized fittings but complete tool customized
to customer requirement.
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BOLT TENSIONER SPECIFICATIONS
‘PST SERIES’ SPECIFICATIONS

B PITCH

Specifications :
Model No. Max Load Hyd Area Min Relief Height Clearance
Bolt Size O.D. Pitch A
C B
Cell Adaptor inch mm Ton kN in2 mm mm mm mm mm
PST-01 A1-0.12 3/4 38.1 339 3.50 84 46 26 92 156
A1-M20 20 47 26 92 156
A1-0.14 7/8 53 30 100 164
A1-M24 24 54 30 100 164
A1-1.00 1 55 30 100 164
PST-02 A2-M27 27 44.7 397 4.11 98 58 29 104 172
A2-1.02 1.1/8 61 32 104 172
A2-M30 30 64 32 105 177
A2-1.04 1.1/4 69 35 105 180
A2-M33 33 70 35 107 183
A2-1.06 1.3/8 72 36 109 188
A2-M36 36 73 36 109 189
PST-03 A3-1.04 1.1/4 71.8 639 6.60 115 73 37 106 176
A3-M33 33 74 37 108 178
A3-1.06 1.3/8 76 38 110 182
A3-M36 36 77 38 110 183
A3-1.08 1.1/2 84 43 114 191
A3-M39 39 84 43 114 191
PST-04 A4-1.06 1.3/8 81.1 721 7.45 128 79 39 110 183
A4-M36 36 80 39 110 183
A4-1.08 1.1/2 87 43 114 188
A4-M39 39 87 43 114 188
A4-1.10 1.5/8 92 46 116 192
A4-M42 42 92 46 116 193
A4-1.12 1.3/4 97 49 120 200
A4-M45 45 98 49 120 200
PST-05 A5-1.10 1.5/8 105.9 942 9.73 145 95 47 118 193
A5-M42 42 95 47 118 195
A5-1.12 1.3/4 100 50 122 200
A5-M45 45 100 50 122 201
A5-1.14 1.7/8 106 53 125 207
A5-M48 48 106 53 125 207
A5-2.00 2 111 55 128 215
A5-M52 52 112 55 128 215
T O R C U P

PST-06 A6-1.14 1.7/8 152.2 1354 13.99 165 107 54 125 205
A6-M48 48 107 54 125 205
A6-2.00 2 112 56 128 210
A6-M52 52 112 56 128 210
A6-M56 56 113 60 132 219
A6-2.04 2.1/4 123 62 134 222
A6-M60 60 126 62 137 229

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 BOLT TENSIONER SPECIFICATIONS
‘PST SERIES’ SPECIFICATIONS

Model No. Max Load Hyd Area Min Relief Height Clearance
Bolt Size O.D. Pitch A
C B
Cell Adaptor inch mm Ton kN in2 mm mm mm mm mm
PST-07 A7-M56 56 178.3 1587 17.06 180 119 58 135 221
A7-2.04 2.1/4 122 61 137 225
A7-M60 60 125 61 140 230
A7-2.08 2.1/2 133 66 143 237
A7-M64 64 133 66 143 237
A7-M68 68 137 67 148 247
A7-2.12 2.3/4 142 69 151 253
A7-M72 72 143 69 151 255
PST-08 A8-M68 68 222.4 1978 20.4 198 140 70 148 244
A8-2.12 2.3/4 140 72 151 249
A8-M72 72 141 72 151 251
A8-M76 76 146 77 154 260
A8-3.00 3 150 77 154 260
PST-09 A9-2.12 2.3/4 253.7 2257 23.3 215 144 72 153 254
A9-M72 72 144 72 153 254
A9-M76 76 152 77 156 261
A9-3.00 3 155 77 156 267
A9-M80 80 160 85 161 272
A9-M85 85 163 85 161 275
A9-3.04 3.1/4 166 85 161 275
PST-10 A10-M80 80 342.5 3047 31.5 244 162 87 165 271
A10-3.04 3.1/4 165 87 165 274
A10-M85 85 170 89 170 280
A10-3.08 3.1/2 175 91 174 284
A10-M90 90 178 91 174 285
A10-M95 95 178 95 180 296
A10-3.12 3.3/4 184 95 180 296
A10-M100 100 185 99 185 307
A10-4.00 4 189 99 185 307
PST-11 A11-3.12 3.3/4 423.5 3768 38.9 280 185 96 183 298
A11-M100 100 186 100 188 303
A11-4.00 4 190 100 188 305
A11-4.04 4.1/4 199 105 197 320
A11-M110 110 199 105 197 321
A11-4.08 4.1/2 218 117 202 332 w w w . t o r c u p . a e
A11-M120 120 218 118 209 344
A11-4.12 4.3/4 227 118 209 346
A11-M125 125 227 121 213 354
PST-12 A12-M125 125 534.4 4754 49.1 325 225 123 215 362
A12-5.00 5 232 123 215 367
A12-M130 130 232 126 218 370
A12-5.04 5.1/4 254 126 221 373
A12-5.08 5.1/2 254 135 227 387
A12-M140 140 254 135 228 388
A12-5.3/4 5.3/4 255 138 229 397
A12-M150 150 265 141 232 404

Bolt Load = Bolt Stress x Area of Stud.

= (Bolt Stretch x Modulus of Elasticity x Area of Stud)/ Effective Length.
Hydraulic Pressure = (Bolt Load x Relaxation Factor)/ Load Cell Area.
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BOLT TENSIONER PUMPS & ACCESSORIES
BOLT TENSIONER PUMPS & ACCESSORIES

PU-HP-1500
PU-AH-1500
A choice of manual or air driven hydraulic pump units both compatible for use with standard
PST stud bolt tensioners is available. Both models are easy to operate and are supplied complete with
A calibrated pressure gauge and quick release outlet coupling. The air driven PUAH1500 model also
incorporates an integral inlet air filter regulator & lubricator.
Usable Oil Outlet Length Dimensions Height Net
Model No. Description Capacity Coupler Weight
(Liters) mm mm mm Kg.
PU-AH-1500 1500 bar (21750 psi) Air/Hydraulic Pump 0.7 HNCP-002 610 170 180 7.00
PU-HP-1500 1500 bar Hand Pump c/w 200 bar gauge 2.0 HNCP-002 450 390 390 22.0

HNCP002 HNCP011
PU-HG500
Torcup ultra-high pressure hoses are compatible for use with all Torcup bolt tensioning products
up to a maximum of 1500 bar working pressure. Each hose is supplied complete with quick connect coupling
and has a safety factor of 3:1 on maximum working pressure. Four standard length are available with special
lengths available on request. Spare coupling, nipples and washers are also available.
T O R C U P

Part No. Description Weight Part No. Description Weight

Hose-22000 psi (c/w female couplers each end) HNCP001 Std Male Snap Coupler 0.05
PU-HG150 1.5 meter Hose 1.1 HNCP002 Std Female Snap Coupler 0.2
PU-HG300 3 meter Hose 2.5 HNCP011 Nipple Extension Adaptor 0.05
PU-HG500 5 meter Hose 4.5

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 APPLICATION CHECKLIST
APPLICATION CHECKLIST

Dimensional Details
A) H)

B) I)

C) J)

D) K)

E) L)

F) M)

G1) N)

G2) O)

H
N O
C
B L
J
D M
A

K
G2
G1 E
F

Number of stud threads per inch. ____________________ Stud material. _________________________

Stud strength. _________________________ Desired retained stress in stud. ____________________ w w w . t o r c u p . a e

Desired installation pressure. _______________________

Internal diameter if nut fits in a counterbore (or spot face diameter). _______________________________

Depth if nut fits in a counterbore (or spot face depth). __________________________________________

Chemicals in contact with studs. ____________________ Actuation temperature. __________________

Service temperature. ____________________ Desired stroke or amount of flange compression. ______

Will studs be loaded individually or several at a time? __________________________________________

If several, how far will studs be apart? _______________ How many studs? ______________________
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 BOLTEN(TOR)/10071

TORCUP MIDDLE EAST FZE.

A4-80, Saif Zone, P. O. Box 8911, Sharjah, UAE.
Phone: +971.6.5573478 Fax: +971.6.5573479 email: [email protected]