titan case study hydraulic nuts aluminum mill · 9001 jameel road, suite 180 • houston, tx 77040...

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


• 12 High Tensile Hydraulic Nuts • 12 new studs provided by Titan Technologies • Existing nuts were used on the other side as the back-up nut

Time Study of the Titan Technologies Solution

• 15 minutes to install new studs

• 10 minutes to install Titan Technologies Hydraulic Nuts and back up-nut


• 10 min to set up hose & pump connections

• 8 minutes to simultaneously load all bolts on flange, properly tighten mechanical

locking collars. Procedure called for three passes. Sequencing eliminated.


• 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

during the next scheduled maintenance cycle.

Benefits:

• Ease of operation • Speed of operation


• No bolt damage • No coupling face damage • No coupling surface damage • Accuracy – Proper and EVEN load with an accuracy of +/-3* of DESIRED

RESIDUAL LOAD • Even Flange Closure • Less Down-Time • Estimated Cost reduction:

8 men x 8 hrs with SuperBolt (4 men each shift for two shifts) as apposed to 3 men for 48 MINUTES with Titan Technologies Hydraulic Nut

• Improved labor availability: 62-75 man-hours

titan case study hydraulic nuts aluminum mill · 9001 jameel road, suite 180 • houston, tx 77040...

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