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PIONEERING COUPLING TECHNOLOGYThe world’s most advanced coupling concepts
POWERPower
Pilgrim International LimitedSouthlink, Oldham OL4 1DE, UK
Tel: +44 (0) 161 785 7700 Fax: +44 (0) 161 785 7777
Email: [email protected]
COMPANY HISTORY
A TRACK RECORD OF INNOVATION
AND DEVELOPMENT
A TRACK RECORD OF INNOVATION
AND DEVELOPMENT
Pilgrim was established over sixty yearsago in the UK. In the proceeding years ithas developed into an innovative andworldwide leading supplier of boltingsolutions primarily to the Power and Marineindustries, as well as a number of otherindustries such as Oil, Steel and Mining.
The company has expanded rapidly during thelast ten years as these industries haverecognised the time and cost savingsassociated with the use of the Radial Fit Bolt.It has also provided a safe installation andremoval procedure, which meets everincreasing health and safety requirements.
In the Power Industry, Pilgrim is a majorsupplier to all the turbine OEM’s and leadingUtilities with the concept of the hydraulicRadial Fit Bolt now being truly acceptedworldwide. The product is now installed in all five continents.
The company continues both to develop theproduct and the manufacturing process. Thisdevelopment has further cemented thecompany’s worldwide reputation foroutstanding quality and performance. This isrecognised by the company gaining ISO 9001,14001 and 18001 accreditation as well astechnology agreements with a number ofTurbine OEM’s.
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With a track record of more than sixty yearsof innovation, Pilgrim is a world leader in thedesign, manufacture and supply of specialisthydraulically-tensioned fastener products foruse in all major industries worldwide.
Through a combination of the latest technology,proven manufacturing techniques andexceptional quality we consistently exceed theexpectations of both our OEM partners andcustomers. Underpinning everything we do is atotal commitment to on-time delivery, customercare and after-sales support.
Accredited with both ISO 9001 OHSAS No.18001 and ISO 14001 Environmental Systems,we are focused on building upon our success inglobal markets by challenging conventionalbolting systems and advancing innovative new coupling concepts.
Challenging traditionwith innovativecoupling concepts
HYDRAULIC RADIAL FIT BOLTS
Hydraulic Radial Fit Bolts
Coupling Hole Alignment Tools
Pilgrim Nut
Datum Plugs
High Pressure Pumps
Tensioning Equipment
Training Kits
Full range of support servicesincluding site supervision,refurbishment, training, on-sitemachining and installation
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Clamp Bolts
Closure Bolts
With a strong engineering bias Pilgrimdesigns its products to meet the specificapplication, taking into account theoperating parameters and environment. All materials subsequently used are fullytested and certified according to the design requirements.
> Carbon alloy steels> Stainless steel> High nickel alloys> Customer specified material
ENGINEERING
4 For data sheets please visit: www.pilgrim-international.co.uk
MANUFACTURING CAPABILITYWe have a wide range of machinesspecifically available to manufacture ourproduct range. These cover turning, milling,boring, drilling and grinding.
Main equipment includes:
CNC lathes
CMM machine
UDDM machine
Deep hole boring machine
Grinding machines
Milling machines
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BENEFITS THATCONVENTIONAL BOLTINGSYSTEMS CAN’T MATCH
An innovative alternative to conventional fitted bolts
Faster and easier to install and remove
No more costly outage delays caused by bolts getting stuck in-situ
Reduced turbine vibration
Coupling slippage eliminated
Significantly lower life cycle costs
Direct retrofit
Reliability means more effective planning
No re-machining
Concentricity re-established
OEM approval
Safe and reliable
6 For data sheets please visit: www.pilgrim-international.co.uk 7
LIFE CYCLE COST COMPARISON
Offering faster installation than conventionalbolts, faster removal, longer product life andreduced maintenance downtime, HydraulicRadial Fit Bolts give Power Plants asignificant return on their investment.
Moreover, it is a return that becomes evengreater when electricity generating prices aretaken into account. As the following exampleshows, the time gained during overhauls byHydraulic Radial Fit Bolts translates into majorpotential monetary savings in generating costs.
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CONVENTIONALHYDRAULICRADIAL FIT BOLT
A re-occuring problem in many power plants isthe damage to coupling holes using standardconventional bolts as shown opposite. Thisdamage may be caused due to poor installationor coupling movement whereas by installing aHydraulic Radial Fit Bolt the problem iseliminated as the Hydraulic Radial Fit Bolt isassembled to an interference condition. With full contact achieved between the sleeve ODand the coupling ID coupling movement is prevented.
Example: 500MW/16 hole Coupling
Type Hydraulic Radial Fit Bolt Conventional fitted boltInstallation 10 mins/assembly 20 mins/assemblyRemoval 10 mins/assembly 45 mins/assemblyTotal number of hours per coupling 5.33 17.33
The Hydraulic Radial Fit Bolt is made up of atapered body, a matching tapered boredsleeve and two round nuts. The bolts are re-usable, reduce maintenance downtimes and are a direct retrofit replacement forconventional coupling bolts.
Specially designed to suit specific couplinggeometry, the Hydraulic Radial Fit Bolt offersturbine operators a number of significant benefits.
Because they are installed and removed fasterthan conventional bolts, less time is required tosplit and re-build turbine couplings, bringingdown outage time and costs.
Thanks to their precise and repeatable location,the bolts can potentially reduce the turbinevibration and coupling slippage often associatedwith conventional systems.
Moreover, the problems of bolt seizure andsurface pick-up are avoided, concentricity isestablished and maintained even under extremeoperating conditions and once fitted there is noneed for re-machining.
And finally, the reliability of the Pilgrim HydraulicRadial Fit Bolt installation and removal meansthat outage planning can be based on extremelypredictable outcomes – a major factor as allsectors seek to minimise downtime schedules.
If we assume a kw/hr tariff rate of six cents, the potential saving in generation costs based on a 10-hour working day would beapproximately $800,000.
This figure will vary of course depending on the number of couplings, added timeshould a conventional fitted bolt be stuckduring installation/removal, variations inregional tariffs and differences in plantmaintenance downtimes.
PILGRIM RADIAL FIT BOLTS
8 For data sheets please visit: www.pilgrim-international.co.uk 9
REMOVAL SUMMARYINSTALLATION SUMMARY
INSERTION OF THE BOLTThe Pilgrim Hydraulic Radial Fit Bolt assembly iscomposed of a tapered bolt, an internally taperedsleeve, and two securing nuts. When the sleeve isplaced over the tapered bolt, the resulting OD isless than that of the coupling hole (clearancecondition). For a coupling hole dia 100.00mmhole, a typical clearance condition would be0.12mm making the Hydraulic Radial Fit Bolt veryeasy to insert into the coupling hole.
SETTING THE SLEEVEThe setting bridge is placed over the end of thebolt and is firstly used to locate the position of thesleeve within the coupling hole. The setting bridgethen holds the sleeve in position whilst thehydraulic head ‘draws/pulls’ the bolt into thesleeve. As the bolt is drawn into the sleeve, theOD of the sleeve is forced to increase. Firstlyoccupying the clearance condition within the holeand then exerting a pressure inside the couplinghole along the entire contact area between thesleeve and the hole.
TENSIONING THE BOLTAfter setting the sleeve, the securing nuts arefitted to both ends of the Hydraulic Radial Fit Boltassembly, and tightened firmly by hand. Atensioning bridge is then used to bridge over thenut, from the same end at which the sleeve wasset. Applying pressure through using a hydraulichead whilst under load the nut under thetensioning bridge is tightened using a tommy bar.Once tightened, the pressure can be released andboth the tensioning bridge and hydraulic head areremoved, and the Hydraulic Radial Fit Boltassembly is now fully installed.
The interference fit of the bolt assembly ensuresthat the coupling concentricity is easily achieved,maintained and that all bolts transmit effectively theapplied torque. The coupling halves are securelyheld together and coupling slippage is eliminated.
DE-TENSIONING THE BOLTThe axial load is released by reversing thetensioning procedure.The tensioning bridge is fittedover the same nut, which was tightened during thetensioning of the bolt. Reapplying pressure throughusing a hydraulic head and whilst under load, thenut under the tensioning bridge is released 2 fullturns using the tommy bar. After which, thepressure can be released and both the tensioningbridge and hydraulic head can be removed.
SLEEVE REMOVALTwo methods are available:
First preference
Oil injection adaptorThe oil injection adaptor is screwed into the oilinjection port of the Hydraulic Radial Fit Bolt andtightened. The hose is directly attached to theadaptor and pressure is applied until release ofthe sleeve occurs. Following release the hose,adaptor and nuts can be removed and cleaned.
Alternatively
Removal bridgeWe must first remove the nut at the slotted end ofthe bolt before the removal bridge can be fitted,At no time should the opposite nut be removed itshould however be two turns back from thecoupling face as stated. With the removal bridgeand hydraulic head fitted apply pressure. As youcontinue to pump, the pressure will drop until youreach zero to ensure release of the sleeve fromthe bolt, Once completed remove the bridge,hydraulic head and nuts.
Both methods allow the sleeve to return to itsoriginal clearance condition.
Depending upon the coupling geometry, spacerestrictions etc Pilgrim will design the hydraulicbolt assembly and tensioning equipment to fit thespecific coupling geometry.
Helical oil groovesTo facilitate easy removal by oil injection, the body ofthe Pilgrim Hydraulic Radial Fit Bolt is machined withtwin helical grooves. These allow the oil to distributefreely and quickly between the mating surfaces of thebolt and the sleeve to achieve efficient separation – themost effective way of producing an even interfacepressure that ensures the bolts can be taken outsmoothly and quickly.
Hardened taper sleeveThe tapered sleeves are surface hardened to provide apredictable coefficient of friction between bothcomponents, improving resistance to corrosion andallowing the sleeve to be removed from the bolt more efficiently.
The non-metallic nature of the compound zone formedon the surface of the sleeve eliminates pick-up andprevents bolt seizure. When oil is introduced during theremoval process, the coefficient of friction is reduced toensure fast and efficient separation of bolt and sleeve.
Bolt tensioning kitThese can be single or dual operated. They include all ofthe necessary components for fast installation andremoval. The dual kit allows two bolts to be pressurisedsimultaneously, further reducing the assembly andremoval time.
Internal taper threadThe internal taper threads at each end of the bolt arenecessary to facilitate the use of hydraulic tensioningequipment without increasing the bolt length. A speciallyheat treated taper threaded puller is assembled into thebolt end during bolt installation and removal.
Bolt removal by oil injectionThis entails injecting oil under pressure between theinterface of the bolt and the sleeve by means of anadaptor that locates into the bolt end. The oil injectionadaptor is supplied with a lens ring, hardened formaximum life, ensuring the high pressure connection issealed effectively and with the minimum physical effort.The lens also eliminates the possibility of damage toboth the adaptor and injection port.
Mechanical removalAn alternative mechanical removal facility isprovided for all bolts. Its design is such that it providesthe option for both the oil injection and the mechanicalremoval to be performed simultaneously or individually.
Robust ancillary equipmentAll Pilgrim equipment is designed for ease of use androbustness in the on-site environment. Pilgrim havemany years experience of product design to suit theharsh needs of turbine maintenance.
Material specificationAll standard components of Pilgrim Hydraulic Radial FitBolts and bolt tensioning kits are manufactured from NiCr Mo alloy steels.
Weight ToleranceThe Hydraulic Radial Fit Bolts are supplied as completeassemblies to a specific weight tolerance. Allcomponents are supplied as a matched set.
SizesAll Hydraulic Radial Fit Bolts are on a ‘made to order’basis, designed to the exact bespoke requirements ofthe coupling flanges into which they will be installed.
QualityPilgrim International Limited operates a quality controlsystem that conforms to BS-EN-ISO 9001:2008. Thesystem is regularly audited by an approved accreditation company.
Inspection and testingThe design, materials and finished product arecomprehensively tested and proven by our engineers.Indepedent witnessing can be undertaken on requestbefore despatch.
SafetyAll Pilgrim Hydraulic Radial Fit Bolts and ancillaryequipment are designed for safe and simple use. Theease of bolt installation and removal eliminates many ofthe traditional, unsafe working practices oftenundertaken when using conventional bolts.
Technical supportPilgrim will undertake bolting, loading and torquecalculations and liaise with turbine manufacturers onbehalf of our customers. Service engineers can beprovided to assist in the installation and removal of thePilgrim Hydraulic Radial Fit Bolts and to provide on-sitetraining in the correct use of Pilgrim equipment.
10 11For data sheets please visit: www.pilgrim-international.co.uk
GENERAL TECHNICAL INFORMATION
Saves time
Reduces cost
Aligns and closes couplings
Accurate and reliable
Quick and efficient
Versatile
Powerful and safe
Easy to handle
Spigotted or plain couplings
The Coupling Hole Alignment Tool (CHAT) is afurther development from the Pilgrim productportfolio, designed in response to OEMmaintenance and end user companies’requirements. It achieves coupling hole alignmentquickly and to a tolerance that permits effectivebolt installation or removal.
The CHAT system is simple, accurate and reliable inoperation and can greatly improve the effectivenessof outage planning. The system is based on the samebasic principles as the Pilgrim Hydraulic Radial FitBolts, utilising hydraulic equipment throughspecifically designed tools to expand or remove the sleeve.
COUPLING HOLE ALIGNMENT TOOLING
12 For data sheets please visit: www.pilgrim-international.co.uk
(CHAT)
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The sleeve itself is segmented into four pieces,allowing a considerable range of expansion.This in turn allows the tool to rotate thecoupling flanges with several millimetresmisalignment, close and hold turbinecouplings aligned whilst the Pilgrim HydraulicRadial Fit Bolts are either installed or removed.
Should the conventional coupling boltsbecome seized in the holes due to couplingslippage, the CHAT system can re-establishcoupling alignment once the bolts have been removed.
Depending upon the complexity, sizeand design of the coupling, Pilgrim willsupply a sufficient number of CHAT toolsto effect safe and accurate alignment.
Each tool is located loosely into the boltholes and coupling hole alignmentachieved as the units are expandedsimultaneously. The coupling faces arethen closed using the CHAT inpreparation for installing the bolts.Once sufficient Radial Fit Bolts havebeen fitted to hold the coupling aligned,the CHAT tools can be removedand the remaining bolts installed.
Lightweight, efficient, compact and easy tooperate, the Morpress 10 provides instantand totally reliable hydraulic power.
The Morpress utilises a low pressure air input togenerate a high pressure output. This isachieved by means of a simple differential areasystem in which a large area piston at lowpressure produces high hydraulic pressure on asmall area piston. The standard Morpresscomprises an air pressure regulator, air pressuregauge, air filter, air lubricator, on/off controlvalve, oil reservoir, SC Air/Oil intensifier unit, oilreturn to tank valve, pressure relief safety valveand oil pressure gauge with damping facility.The Morpress can also be built to customerspecifications. Lower or higher pressuremodels, special outlet arrangement andcustomised gauges can all be accommodated.
Both oil and air are filtered prior to entering thesystems. The Morpress requires only twoconnections, one to the air supply and one to the hydraulic output. Simple and safe self-sealing quick release couplings are usedto connect the equipment being pressurised.
HYDRAULIC PUMPS
MK10 MORPRESS AIRDRIVEN PUMP
TECHNICAL SPECIFICATION:
Model 525 Model 535 Model 620 Model 640
Hydraulic 0-1700 bar 0-3000 bar 0-1700 bar 0-3500 barOutput Pressure 0-25000psi 0-40000 psi 0-25000 psi 0-50000 psi
Pressure gauge rating will vary according to customer requirements.
Approx weight with 21.0 kg 21.25 kg 25.2 kg 27.0 kgempty oil tank
Overall dimensions 380mm x 360mm x 440mm 15ins x 14.2 ins x 17.3 ins
Reservoir capacity 8 litres 1.8 gallons (imp)
14 For data sheets please visit: www.pilgrim-international.co.ukFor data sheets please visit: www.pilgrim-international.co.uk
BOLT TENSIONING KIT
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Customised for the application, the PilgrimTensioning Kit can be supplied in differentconfigurations to meet the specific needsof the customer.
The kits are supplied with all components toensure that the engineer can fully operate thesystem. They are designed to be user friendlyand can be either of the single or dual type.The latter enables two bolt assemblies to be
pressurised simultaneously, thus reducingfurther the maintenance downtime duringmajor or minor shutdowns. The hydraulicheads supplied as part of the bolt tensioningkit meet the requirements of the EuropeanPressure Equipment Directive and are thereforeCE marked thus providing further confidencethat the Pilgrim product meets the requiredInternational safety standards.
BENEFITS
Lightweight
Easy operation
Robust construction
Safe and reliable
Well proven for use in all major industries
DATUM PLUGS
Pilgrim’s Datum Plug provides a simpleaid in measuring the length of the HydraulicRadial Fit Bolt.
The Datum Plug provides an accurate andconsistent reference point for your measuringsystem. The bolt length measurement can betaken before and after hydraulic tensioning toverify that the installation and loading has beenundertaken correctly.
BENEFITS
Accuracy
Operator confidence
Repeatability
Improve QA records
Confirm bolt extension
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TECHNICAL SUPPORT
Pilgrim provide a complete range of technical andtraining services. These include on-site installationsupport, line-boring, comprehensive operation andmaintenance manuals and spare parts either fromstock or on an emergency basis with extremely fastlead times.
Our reputation for safety and reliability, built up overmany years, is the result of the integrity of our bolts andcomponents and the thoroughness of the assistanceand guidance we offer to both managers and installers.At every stage of a project we ensure that you have allof the help you need.
Pilgrim’s technical and commercial personnel can becontacted by telephone, facsimile or e-mail to discussany issue relating to the Hydraulic Radial Fit Bolt.
To maintain the smooth and continuous operation ofessential equipment, we recommend and undertake in-house refurbishment of all tooling including completebolt tensioning kits, hydraulic heads and air-operatedpump units.
The training kit is lightweight, safe and easy tohandle and can be used in either a workshop ortraining facility without the need to access theturbine itself.
The kit is both visual and practical in its use inproviding engineers the ability to develop theirunderstanding in both installation and removaltechniques. By providing engineers such a trainingopportunity time savings during turbine overhauls arefully maximised.
The kit comprises of a Hydraulic Radial Fit Boltassembly, steel block that is used to simulate thecoupling hole and comprehensive bolt tensioning kit.
High pressure Hand pump can be supplied on request.
TRAINING KIT
For data sheets please visit: www.pilgrim-international.co.uk 17
QUALITY ASSURANCEPilgrim International are fully accredited toISO 9001 standard. Over many years wehave developed different Quality AssuranceProgrammes to meet the stringent demandsof the turbine manufacturers by way ofproviding comprehensive documentationpackages that can fully detail the completetraceability of all materials used during manufacturing.
Services available:
> Ultrasonic inspection> Hardness testing > Mechanical tests> Material identification> MPI inspection> Visual & dimensional checks> Pressure tests > Functional Testing
Prior to despatch all products are etched,suitably packed and sprayed with ananti-corrosive fluid for transportation purposes.
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INSTALLATION REFERENCESPilgrims safety and reliability have been proven
over many years in countless nuclear, hydroelectric and fossil plants throughout the world
being supplied on steam and gas turbines
T: +44 (0) 161 785 7700F: +44 (0) 161 785 7777
Pilgrim Hydraulic Radial Fit Bolts have beensupplied for 50HZ and 60HZ rated machines in the nuclear, hydro electric and fossil plantsthroughout the world.
Typical turbine arrangements:
> Alstom> Ansaldo> Fuji> GE> Hitachi> MAN> MHI> Siemens> Toshiba
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DIVERSE APPLICATIONSThe Pilgrim Hydraulic Radial Fit Bolt and thecompany’s related products are usedextensively by the power industry worldwide.
Our innovative coupling technology is alsoused in many other industrial applicationsincluding steel production, mining, aluminiumsmelting, shipping and onshore/offshore oil production.
The ability of Pilgrim to provide customers withsolutions to engineering problems has furtherenhanced its reputation to supply bespoke specialistproducts. Our engineering and sales teams areavailable should you require assistance with anyspecific enquiry.
Examples of the specialist products and solutionssupplied to industry include:
> Pilgrim Hydraulic Nuts> Hydraulic Bolt Tensioning> Rotor Bore Plugs> Pilgrim Bolts> Mini Fit Bolts> Generator Through Bolt Nuts> Morgrip Bolts> Dowel Pins> Studs and Nuts> High Pressure Oil Injection> Hydraulic Pumps
CONTACT
Pilgrim are represented in anumber of countries byterritorial agent/distributors.Please refer to the Pilgrimwebsite for the releventlocal contact details.
