Ammonia Reactor

Problem: This large ammonia reactor required the use of two very expensive, very large hydraulic tensioners. Prior to the use of Superbolt, tensioning or detensioning required 3 days, working around the clock. The 6,500 lb. tensioners had to be manipulated by two cranes, and each stud required several passes. Work was reportedly very strenuous in addition to being time consuming.

Solution: Not only was the initial cost for the Superbolt Tensioners only a fraction of the cost of the hydraulic tensioners, but the installation time was much faster. Total tightening time with two laborers was only 5 hours! Only 169 ft-lbs per jackbolt was required to tension the studs to 2,000,000 lbs! Two laborers worked at 180º apart for even gasket compression, as shown in the above photo.

The plant saved several times the cost of the tensioners in labor and downtime as the reactor had to be closed and opened several times due to problems with internal components.

Ammonia Reactor close up
Air impacts were used for the majority of the work. Torque wrenches were used for final step.