WASHER SYSTEM

STARTING ANINDUSTRIAL REVOLUTION

IN BOLTING

NO MATTER IF YOU ARE A:Safety Manager

Engineer

Productivity Manage

Plant Manager

Bolting Contractor

Asset Owner

Procedure Manager

Reliability Manager

Purchaser

FIND OUT THE BENEFITS FOR YOU.

JUST IMPLEMENT IT IN YOUR BOLTINGPROCEDURE.

TESTED, RECOMMENDED AND MILLIONSINSTALLED OVER THE LAST 10 YEARS!

3

THE HYTORC WASHER SYSTEM

In the bolting industry there are several methods for tightening and loosening bolted connections. Since1968 HYTORC has been active on a global scale in finding solutions and developing tools for theseindustrial bolted connections. HYTORC has introduced ground-breaking innovative solutions to make thebolting process safer, more accurate and faster.

In 2014 HYTORC introduced the latest development in bolting technology: the HYTORC WASHER SYTEM.The system characterises itself by a smartly designed throughly hardened reaction and back-up washer whichreplaces commonly used throughly hardened washers. Sizes ranging from M16 – M150. The HYTORCWASHER SYSTEM eliminates several commonly accepted dangers and reduces costs significantly.

THE BOLTING REVOLUTION

UNTIL 1968STANDARD BOLTING

METHOD

VANAF 1969TOOL

MECHANISATION

2014INTRODUCTION

HYTORC WASHERSYSTEM

TIMELINE OF DEVELOPMENT

4

THE HYTORC WASHER SYSTEMINTRODUCTION

The HYTORC WASHER SYSTEM consists of the HYTORC WASHERcombined with the BACK UP WASHER. Both washers can beused independently. Bolting has never been this safe!

HYTORC WASHER SYSTEM

ACTIVE SIDE

The HYTORC WASHER starts its revolution at the side on which the torquewrench is being used. All hydraulically, electrically and air driven torque toolsneed a reaction arm to abut against a fixed point. The HYTORC WASHERbecomes the reaction point and eliminates all risks of hand injuries.

The HYTORC WASHER is simple and easy to use. Like every other throughlyhardened steel washer the HYTORC WASHER prevents from damaging theflange surface and makes the coefficient of friction of the flange surface agiven constant.

REACTIVE SIDE

At the reactive side of the flange there is often an opposite nut. This nut rotatesand needs to be kept stationary by a back-up wrench that abuts against asolid object. HYTORC continues the revolution with the BACK UP WASHER,which eliminates the use of a back-up wrench.

Back-up wrenches are potentially dangerous tools; inconvenient and timeconsuming. The BACK UP WASHER is cheap and has a return on investmentafter the first use by cutting the bolting time in half.

5

THE HYTORC WASHER SYSTEMGROUND BREAKING DIFFERENCE

LINE OF FORCES

BACK UP WRENCH

REACTION FIXTURE

TORQUE WRENCH

BACKUP WASHER

DOUBLESOCKET DRIVE

HYTORC WASHER

ACTIEVE FLENSZIJDE

PASSIEVE FLENSZIJDE

BOLT CENTRE AXIS

TORQUE WRENCH

2000kg

2000Nm

A reaction fixture induces enormous shearing andbending forces, causing the bolt to stand askew.

The HYTORC WASHER enables coaxial torqueing using a double drive socket. Both action and reaction happen around the bolt centre axis.

USING A CLASSICREACTION FIXTURE

HYTORC WASHERWITH BACK UP WASHER

Ra

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THE HYTORC WASHER SYSTEMCONVENTIONAL METHOD

CONVENTIONAL

REACTION FIXTURE

BACKUP WRENCH

TORQUEWRENCH

FLANGE SURFACEDAMAGED BY

TURNING

DAMAGED THREAD

WHEN ABBUTTING NEARBY THE REACTIONFORCES EXCEED 30.000 LB. CAUSING

UNWANTED SHEAR AND BENDING FORCESTHAT INFLUENCE THE RESIDUAL BOLT LOAD.

HIGH SURFACEPRESSURE

NEEDS TO BEHAMMERED

LOOSE

DAMAGE TO PAINTAND COATING

THERE ARE THOUSANDS OF REACTIONFIXTURES PROVED NECESSARY

PINCH HAZARD

CONVENTIONAL METHOD USING A REACTION FIXTURE

PINCH HAZARD

TILT

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BACKUP WASHER

M16TO

M150

HY TORC WASHER(BOTTOM SIDE)

M16TO

M150

OUTER SOCKET = REACTION SOCKET

NO CHANCE OFPINCH HAZARD

STANDARD SOCKET

OUTER SOCKET PROFILEREACTS ONTO WASHER

PROFILE

HY TORC WASHER(TOP SIDE)

M16TO

M150

RIDGES APPLIED TO THE BOTTOM SIDEPREVENT THE WASHER AND THE TOOL

FROM TURNING

RIDGES APPLIED TO BOTH SIDES PREVENTTHE COUNTER NUT FROM TURNING

REACTIONPOINTS AND (SPECIAL)REACTION FIXTURES ARE

SUPERFLUOUS!

TORQUEWRENCH

THE HYTORC WASHER SYSTEMTHE REVOLUTION

CO AXIAL DUAL SOCKET DRIVE

90O TO THEFLANGE SURFACE

REUSABLE

THROUGHLY HARDENED

SMOOTH SURFACE GUARANTEES ACONSTANT BOLT LOAD

SCRATCH RESISTANT

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THE HYTORC WASHER SYSTEMTHE ADVANTAGES

SAFETY

Less personnel.No pinch hazard.

EQUAL BOLT LOAD

The coefficient of frictionand thus the bolt load,

depends on many factors.With the WASHER

SYSTEM the scatter in boltload is cut in half.

DURABILITY

Through hardened washerswill reduce the surfacepressure. Relaxation &settings will decrease.

The bolting forces remainupright.

REUSE OF BOLTS ANDNUTS

Shear and bendingforces lead to galling at

loosening, especially whenloosening corroded bolts.

By loosening themcoaxially, bolts can be

reused more often.

NUMBER OF BOLTS >

BOLT

LOA

D (L

BS) >

BOLT

LOA

D (L

BS) >

TIJD >

HALF OF THE SCATTER

LESS RELAXATION

NUMBER OF BOLTS >

BOLT

LOA

D (L

BS) >

STANDARD SCATTER

BOLT

LOA

D (L

BS) >

TIJD >

MORE RELAXATION

CONVENTIONAL METHOD HYTORC WASHER SYSTEEM

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CONVENTIONAL METHOD HYTORC WASHER SYSTEEM

LEAKAGE

Equal bolt load leads toeven gasket pressure.

Leakage and diffuse losseswill be reduced and TA Luft

standards will be met.

WASHER

Choose for the bestoption; the washers ofthe HYTORC WASHER

SYSTEM.

SPEED

Setting up reaction fixtures and removing the back-upwrench by hammer are nolonger necessary. Boltingtime will reduce by 50%.

FLANGE SURFACECONDITION

By using a washer theflange surface will remainas new. Costly mechanical

re-machining treatmentsare no longer needed.

HYTORC WASHER BACKUP WASHERSTANDARD WASHER

FLANGE

RE-MACHINED FLANGESURFACE

FLANGE

UNDAMAGED FLANGE SURFACE

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The HYTORC WASHER can be used with every modern HYTORC tool. The only accessory needed iseither a double socket drive or an extra holding plate. Below you can see a cut-out of the double socketdrive which can be used on all modern HYTORC tools.

JGUNDIGITAL JGUN

LITHIUMFLASH

ICEAVANTI

ELECTRICHYDRAULIC PNEUMATIC

SQUARE DRIVE TOOLS

DUAL SOCKET DRIVE

DUAL SOCKET DRIVEBOTTOM SIDE

DUAL SOCKET DRIVETOP SIDE

THE HYTORC WASHER SYSTEMTOOL MODELS

The HYTORC WASHER can be used with every modern HYTORC tool. The limited clearance tools areperfect for situations with limited clearance above the nut or in case of long stud protrusion. A graphicalpresentation of this is shown below.

HIGHEST STANDARDSThe HYTORC WASHER SYSTEM meets ISO7090, ISO4759, ANSI-B18.22.1 and DIN267.The use of a throughly hardened washer is generally recommended by ASME PCC-1-2013 and VDI2230..

CERTIFICATIONAvailable with a 3.1 or a 3.2 certificate.

WANT TO KNOW MORE?For technical specifications, dimensions, and norms please contact us or ask for a free demonstration.

OFFSET LINKWITH INTEGRATED PROFILE

STEALTH

LIMITED CLEARANCE TOOLS

HOLDING PLATE

HYDRAULICHYDRAULICPNEUMATIC

ELECTRIC

“IT’S NOT THE ONE BIG THING, IT’S THE MANY LITTLE THINGS WE DO,THAT MAKE HYTORC THE BEST.” MATHIEU VAN KORTENHOF, CEO HYTORC® BENELUX.

HYTORC® Nederland BVPlatinawerf 86641 TL BeuningenThe NetherlandsT: +31 24 3660 660

HYTORC® Benelux BVBAYsselaarlaan 65B2630 AartselaarBelgiumT: +32 38 705 220

HYTORC is globally active in solutions and tools for industrial bolting. For over 45

years we are taking bolting to a higher level. We strongly believe in specialism

combined with innovation and 24/7 service.

www.hytorc.nlwww.hytorc.be2016 HYTORC®, Division UNEX Corporation. All rights reserved.