hytorc power generation

THE NEW STANDARD IN BOLTING FOR POWER GENERATION

SAFETY QUALITY SCHEDULE

HYTORC was formed in 1968 by John Junkers. At that time tight was when the nut could not be turned any further. Today, 43 years later, HYTORC guarantees Joint Integrity with unmatched Bolt Load Precision, Speed and Safety. HYTORC’s first hydraulic ratcheting wrench was developed in 1972 in cooperation with the Westinghouse field service division. Since then, HYTORC literally invented every single major improvement in torque and tension tools. Realizing in the early nineties that further developments of hydraulic torque and tension tools are limited by the fact that, in the field, torque has unknown friction and tension has unknown bolt relaxation, HYTORC formed a Research & Development company called JETYD in 1993. It’s challenge: to eliminate the unknown friction of torque and the unknown bolt relaxation of tension. Existing bolting tools were already capable of accurate torque so JETYD focused on the fastener in order to achieve accurate bolt load through accurate torque, a previously unaccomplished feat. In 1995, JETYD engineered the world’s first fastener that can be operated with a standard HYTORC torque tool. Its field use assures a torsion- and side load-free calibrated bolt load accuracy of + 5% as well as a frictional turning resistance from nut to nut within 3%. Bolt and surface galling and nut loosening are eliminated, joint failures and lengthy bolt elongation measurements are no longer necessary, bolting time is literally cut in half over any other method including heat induction and best of all, our new technology is the safest in the world market. Additionally, HYTORC sets the standard in its industry with 4 hydraulic tool lines: the economical solution for basic maintenance, the most frequently used torque tool in the world, the patented and universal Stretch-to-Load torque/tension machine and the fastest hydraulic tool in the market. With the largest worldwide sales and service network of Bolting Experts in its field, an alliance with ASME and OSHA for world-wide industrial bolting and safety courses and the certification of its technology by TUV, ISO and Lloyd, HYTORC reached the first plateau in its endeavor for perfection. The following is a presentation of the HYTORC Technology for your kind consideration. _______________________________________ John K. Junkers, CEO HYTORC, Division UNEX Corporation 333 Route 17, Mahwah, NJ 07430, USA + 1 201 512-9500 1 800 FOR HYTORC

An Introduction to HYTORC

Presentation Contents

Hytorc Nut Applications

Hytorc Nut Technology

Hytorc Washer Applications

Hytorc Washer Technology

Installation Supervision

Accreditations

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Pages 6-37

Why HYTORC? Pages 3-5

Pages 40-47

Pages 38-39

Pages 48-49

Pages 50-51

Pages 52-59

Hytorc Torque Technology Pages 50-51

Why HYTORC? 3

•  HYTORC is the oldest and largest company in its field.

•  Accredited by ASME and OSHA for bolting procedures and safety

•  Worldwide 24/7 service by trained bolting experts

•  The most experienced job supervision teams in the industry

•  The only company in its field to provide free Safety Trainings on request

RELIABILITY

•  HYTORC invented every single major improvement in Torque and Tension since 1972

•  The only technology in the industry that can reach the desired bolt load within 5% without requiring measurements

•  Our newest technology works with your standard HYTORC Torque Tool

•  The first torque wrench that can stretch bolts without side load, torsion, or bolt relaxation

•  The only torque wrench that can be remote operated even on inverted applications for hands-free safety

•  The first company to do the job in half the time of any other method

INNOVATIONS

The only company in its field with 4 unique product lines:

PRODUCTS

The economical basic maintenance Torque Wrench line

The world’s most trusted, field proven Torque Wrench line

The largest selling universal Torque & Tension Tool line

The world’s fastest universal Torque & Tension Tool line

OUR GLOBAL SERVICE POLICY COVERS ALL HYTORC TOOL USERS

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Why HYTORC?

•  FREE User safety training upon receipt of merchandise •  FREE Semi-annual user safety training on request •  FREE Annual safety seminar on appointment •  FREE Loaner tools in case of product failure within 24 hours •  FREE Torque/Tension consultation/seminar •  FREE Half day, first use supervision •  FREE Annual product inspection on request •  FREE Product demonstration •  FREE 12 Month No-Questions-Asked Warranty •  FREE Lifetime safety/durability/function upgrades (Above services are NOT subject to travel expense charges)

FREE SERVICES

•  All Repairs are guaranteed for 6 months from date of repair

•  Repairs are subject to labor and part cost, as outlined in the official HYTORC Price List

•  All Warranty Repairs are free of all charges including return-freight

•  All Repairs will be tested and calibrated to ensure the highest quality repairs

REPAIRS

•  50% of all rentals will be applied as a discount toward new purchases for 12 month after rental period

•  100% of all rental fees will be applied if purchasing the same equipment

•  User training for first time rentals is FREE of all cost •  Return freight charges are FREE •  Rental tools are guaranteed to perform and are subject to the

FREE loaner tool policy of HYTORC

TOOL RENTALS   Money-Back Guarantee for

leak-free/failure-free startup using new technology

  100% Satisfaction Guaranteed

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Why HYTORC? BECAUSE HYTORC SUPPORT IS WORLDWIDE

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THE HYTORC NUT TM

Applications and Case Studies from Various Industries

(18) Alstom-‐LP Upgrade Turbines in the Exelon System

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STEAM TURBINES HYTORC Nut Installation

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3-‐1/2” Bolts-‐Inner casing horizontal joint 2-‐1/4” Inner casing manways 2 Blade carriers/Exhaust diffuser 1-‐3/4” Diaphrams

Horizontal Joint

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Safe BolOng: Exposure to high pressure bolOng equipment is a thing of the past. Hands-‐Free Remote OperaOon on horizontal, verOcal and inverted applicaOons.

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Exhaust Diffuser bolts Quad CiOes Nuclear Plant Upgrade Unit #1

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Blade Carriers/Exhaust diffuser

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Precision cold stretch Tensioning 100% to Load in one Bolt Pass.

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Blade Carriers

Limited radius is never a problem for the HYTORC-‐Nut.

GE TURBINE-‐INNER CYLINDER BOLTS

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OLD METHOD – PREVIOUS INSTALL: 14 HOURS W/INJURIES NEW METHOD: HYTORC-‐NUT/COLD STRETCH (40) 2” BOLTS -‐ HIGH TEMP: 3-‐1/2 HOURS, FREE OF INJURY! OVER 10 HOURS OF TIME SAVED!

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EXELON LIMIRICK -‐ 08 IN SERVICE FOR 14 YEARS WITH THE HYTORC-‐NUT DISASSEMBLY TIME, FREE OF INJURY: 4 HRS 26 MIN. ASSEMBLY TIME WITHOUT A SINGLE NUT REPLACEMENT: 3 HRS.

LP-‐STATIONARY-‐BLADE RINGS

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(16) 2-‐1/2” -‐8 BOLTS OLD METHOD: 5 HOURS, 45 MIN NEW METHOD: 30 MINUTES OVER 5 HOURS OF TIME SAVED!

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COMPLETE LP TURBINE

(82) INTERNAL/EXTERNAL BOLTS OLD METHOD: 21 HOURS 50 MINUTES NEW METHOD: 3 HOURS NEARLY 20 HOURS OF TIME SAVED!

LP-‐GUIDE BLADE CARRIERS

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(16) 2-‐3/4”-‐8 BOLTS OLD METHOD: 6 HOURS NEW METHOD: 30 MINUTES OVER 5 HOURS OF TIME SAVED!

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ALSTOM LOW PRESSURE TURBINE UPGRADES (44) 2-‐1/4 Internal HYTORC-‐NUTS (40) 3-‐1/2 Horizontal HYTORC-‐NUTS

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Installa<on Time 1 Tool/1 Operator per side: 1 Hr 43 Min 2 Tools/2 Operators per side: 25 Min

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COMPLETE -‐HP TURBINE (52) INTERNAL BOLTS OLD METHOD: 15 HOURS 10 MINUTES NEW METHOD: 2 HOURS 30 MINUTES

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LP POCKET BOLTS AND TURBINE CASING

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OLD METHOD: 10 HOURS 10 MINUTES NEW METHOD: 2 HOURS 30 MINUTES OVER 7 HOURS OF TIME SAVED!

LP TURBINE INTERNAL BOLTS HANDS-‐FREE REMOTE CONTROLLED TURBINE ASSEMBLY WITH EXTENSION

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VerScal Joint Turbine Shell to CDC – Tightened Hands-‐Free

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GAS TURBINES HYTORC Nut Installation

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COMPLETE – HORIZONTAL SHELL Average Time to stretch each bolt to the desired Load Compression: 2 min. 54 sec.

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GAS TURBINES HYTORC Nut Installation

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INVERTED INTERNAL BOLTS HANDS-‐FREE REMOTE CONTROLLED STEAM LINE ASSEMBLY

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STEAM LINES HYTORC Nut Installation

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CROSS-‐OVER FLANGES NEW METHOD: HYTORC NUT/COLD STRETCH (60) 2” BOLTS – NEW TIME: 2 HOURS 15 MINUTES OLD METHOD-‐PREVIOUS TIME: 5 HOURS NEARLY 3 HOURS OF TIME SAVED!

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GE – LOAD COUPLING NEW METHOD: HYTORC NUT/COLD STRETCH (20) 2-‐1/4” BOLTS – NEW TIME: 55 MINUTES OLD METHOD-‐PREVIOUS TIME: 4 HOURS 20 MINUTES OVER 3 HOURS OF TIME SAVED!

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COUPLING HYTORC Nut Installation

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GE – MAIN STOP VALVES NEW METHOD: HYTORC NUT/COLD STRETCH (16) 2-‐3/4” BOLTS -‐ NEW TIME: 35 MINUTES OLD METHOD-‐PREVIOUS TIME: 4 HOURS 30 MINUTES NEARLY 4 HOURS OF TIME SAVED!

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GE – REHEAT VALVES-‐PRODUCTION HYDRO NEW METHOD: HYTORC NUT/COLD STRETCH (14) 2-‐3/4” BOLTS -‐ NEW TIME: 35 MINUTES OLD METHOD-‐PREVIOUS TIME: 4 HOURS 30 MINUTES NEARLY 4 HOURS OF TIME SAVED!

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REHEAT VALVE HYTORC Nut Installation

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STEAM CHEST VALVES NEW METHOD: PARALLEL JOINT CLOSURE (16) 1-‐3/4” BOLTS – NEW TIME: 35 MINUTES OLD METHOD-‐PREVIOUS TIME: 6 HOURS 10 MINUTES OVER 5 HOURS OF TIME SAVED!

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MAIN STOP VALVES NEW METHOD: PARALLEL JOINT CLOSURE (14) 1-‐1/2” BOLTS – NEW TIME: 25 MINUTES OLD METHOD-‐PREVIOUS TIME: 3 HOURS 10 MINUTES NEARLY 3 HOURS OF TIME SAVED!

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STOP VALVE HYTORC Nut Installation

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BOILER CIRCULATING PUMPS NEW METHOD: HYTORC NUT/COLD STRETCH (8) 2-‐1/2” BOLTS -‐ NEW TIME: 22 MINUTES OLD METHOD-‐PREVIOUS TIME: 6 HOURS 45 MINUTES OVER 6 HOURS OF TIME SAVED!

PUMP HYTORC Nut Installation

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BOILER FEED PUMP -‐STUFFING BOX NEW METHOD: HYTORC-‐NUT/COLD STRETCH (16) 1-‐1/2” BOLTS -‐NEW TIME: 1 HOUR OLD METHOD-‐PREVIOUS TIME: 6 HOURS 15 MINUTES OVER 5 HOURS OF TIME SAVED!

PUMP HYTORC Nut Installation

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BOILER FEED PUMP-‐MAIN HEAD NEW METHOD: HYTORC-‐NUT/COLD STRETCH (16) 2-‐1/2” BOLTS -‐ NEW TIME: 1 HOUR 20 MINUTES OLD METHOD-‐PREVIOUS TIME: 8 HOURS 10 MINUTES NEARLY 7 HOURS OF TIME SAVED!

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•  Turbine Casing Horizontal Joints: 2-1/2”, 3”, 3-1/2” (Avanti-20/Clamp Drivers) •  Turbine Blade Carriers: M56, M60 (Avanti-5/Clamp Drivers) •  Turbine Inner Casing: Bolt sizes 1-3/4”, 2”, 2-1/4” (Avanti-5/Clamp Drivers) •  Throttle Valves: Bolt Size 2-1/4” (Avanti-10/Clamp Drivers/Pump) •  Governor Valves: Bolt Size 2” (Avanti-5/Clamp Drivers/Pump) •  Control Valves: Bolt Size 2-1/4” (Avanti-5/Clamp Drivers/Pump) •  Combined Intermediate Valves: Bolt Size 2” (Avanti-5/Drivers/Pump) •  Turbine Bypass Valves: Bolt Size 1-1/2” (Avanti-5/Clamp Drivers/Pump) •  Main Stop Valves: Bolt Size 2-3/4” (Avanti-10/Clamp Drivers/Pump) •  Boiler Feed Pumps: Bolt Size 2-1/2” (Avanti-l0/Clamp Driver/Pump)

•  Cross Around Relief Valves: Bolt Size 1-1/4” (Avanti-1/Drivers/Pump) • Boiler Circ Pumps: Bolt Size 2-3/4” (Avanti-20/Clamp Driver/Pump) • Cross Over Flanges: Bolt Size 2” (Avanti-5/Clamp Driver/Pump)

•  Load Couplings: Bolt Size 2-1/4” (Avanti-10/Clamp Drivers/Pump) •  HP Nozzle Plates: Bolt Size 1-3/4” (Stealth-4/Pump) •  Feed Water Heaters: Bolt Size 1-1/2” (Avanti-3/Clamp Drivers/Pump) •  Generator Belly Bands: Bolt Size 1” (Avanti-1/Drivers/Pump) •  Main Steam Safety Valves: Bolt Size 1-1/2” (Avanti-3/Drivers) •  Steam Chest: Bolt Size 1-3/4” (Stealth-1 Low Clearance Tools)

Nuclear-Steam Turbines/Valves/Pumps HYTORC Nut Installations

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THE HYTORC NUT TM

HOW DOES IT WORK?

THE HYTORC NUT® has an Inner Sleeve, an Outer Sleeve and a Washer, which is spline-connected with the Inner Sleeve. Inner Sleeve and Washer have a higher turning friction than Outer Sleeve. When a Precision HYTORC reacts on the Inner Sleeve or the Washer and acts on the Outer Sleeve, only the Outer Sleeve turns. This raises the Inner Sleeve. As the Outer Sleeve turns at a known coefficient of friction, the bolt is stretched without side-load or torsion to the desired calibrated bolt load within 5%.

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THE HYTORC NUT HOW DOES IT WORK?

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THE HYTORC WASHER TM

Applications and Case Studies from Various Industries

www.HYTORC.com

GE – GENERATOR – BELLY BANDS NEW METHOD: LOADISC (6) 1”-‐8 BOLTS – NEW TIME: 2 HOURS 10 MINUTES OLD METHOD-‐PREVIOUS TIME: 8 HOURS 10 MINUTES TIME SAVINGS OF 6 HOURS!

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GENERATOR HYTORC Washer Installations

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REHEAT VALVE (20) 2-‐1/2”-‐8 BOLTS-‐PARALLEL JOINT CLOSURE NEW METHOD: 35 MINUTES OLD METHOD: 3 HOURS 10 MINUTES NEARLY 3 HOURS OF TIME SAVED!

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HEATER HYTORC Washer Installations

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FEEDWATER -‐ HEATERS (20) 1-‐5/8” BODY BOUND BOLTS NEW METHOD: 45 MINUTES OLD METHOD: 2 HOURS 35 MINUTES NEARLY 2 HOURS OF TIME SAVED

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HEATER HYTORC Washer Installations

CROSS AROUND RELIEF VALVE (20) 1-‐1/4” BODY BOUND BOLTS NEW METHOD: 35 MINUTES OLD METHOD: 2 HOURS 25 MINUTES NEARLY 2 HOURS OF TIME SAVED!

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STEAM VALVE HYTORC Washer Installations

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INVERTED REACTOR APPLICATION (32)  1-‐1/2” BOLTS (4-‐Tool Parallel Joint Closure) NEW METHOD: 27 MINUTES OLD METHOD: 2 HOURS 54 MINUTES OVER 2 HOURS OF TIME SAVED!

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REACTOR HYTORC Washer Installations

REACTOR COVER (28) 1-‐3/4” BOLTS (50% Coverage, Parallel Joint Closure) NEW METHOD: 19 MINUTES OLD METHOD: 2 HOURS 36 MINUTES OVER 2 HOURS OF TIME SAVED

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REACTOR HYTORC Washer Installations

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CRITICAL PATH JOINT (28) 1-‐3/8” TENSION BOLTS (4-‐Tool Parallel Joint Closure) NEW METHOD: 43 MINUTES OLD METHOD: 3 HOURS 17 MINUTES OVER 2 HOURS OF TIME SAVED!

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CRITICAL PATH HYTORC Washer Installations

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THE HYTORC WASHER TM

HOW DOES IT WORK?

The HYTORC Torque Machine can be equipped with an inner and an outer socket. The nut is dry-lubed to reduce the usual frictional scatter. The inner socket turns the nut and the outer socket locks on to the economical HYTORC washer underneath the nut. Hands-free operation in any position and a reliable facial friction of the nut is assured.

Action and reaction become coaxial. The usual friction-causing side load is eliminated.

A threaded segment in the inside of the HYTORC washer creates a counter-nut effect with the nut thread. It stops the bolt from turning with the nut. Further turning of the nut creates an axial bolt elongation, which pulls along the thread segment in the inside of the washer.

The counter-nut effect remains intact throughout the assembled state of the fastener, so that despite the use of a low-friction, dry lubricant, inadvertent nut-loosening is eliminated.

An inexpensive ASTM compliant washer perfects bolting by providing even bolt load within 10% without affect ing the integrity of your fastener.

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THE HYTORC WASHER HOW DOES IT WORK?

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HYTORC TORQUE TECHNOLOGY

Examples of Custom Fixtures Developed by HYTORC

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GLOBE / CHECK VALVE DOSE AND MANPOWER REDUCED BY 50% HANDS FREE REMOTE CONTROLLED VALVE BOLTING

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KEROTEST VALVE HYTORC Custom Installation

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MAIN STOP VALVE-‐PRESSURE SEAL HEADS DOSE AND MANPOWER REDUCED BY 50% HANDS FREE REMOTE CONTROLLED VALVE BOLTING

© Copyright UNEX Corp. 09

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PRESSURE VALVES Dose, Time and Manpower reducOon by 50% Hands-‐free remote controlled Valve Assembly

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PRESSURE VALVE HYTORC Custom Installation

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GE – CONTROL VALVES NEW METHOD: PARALLEL JOINT CLOSURE (8) 2-‐3/4” BOLTS – NEW TIME: 35 MINUTES OLD METHOD-‐PREVIOUS TIME: 4 HOURS 10 MINUTES OVER 3 HOURS OF TIME SAVED!

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CONTROL VALVE HYTORC Custom Installation

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GE – SHAFT COUPLINGS NEW METHOD: SIMULTORC (12) 2-‐3/4” BOLTS – NEW TIME: 35 MINUTES OLD METHOD-‐PREVIOUS TIME: 8 HOURS 10 MINUTES OVER 7 HOURS OF TIME SAVED!

COUPLING HYTORC Custom Installation

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HYTORC JOB SUPERVISION

The Installation Process from Start to Finish

From Cri<cal Path to On-‐Time Startup!

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SURVEY PROCEDURES / SOLUTION HARDWARE INSPECTION

1 2 3

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JOINT PREPARATION INSTALLATION START UP GUARANTEE

SUPERVISION OF STAFF OR CONTRACTORS

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HYTORC ACCREDITATIONS

CERTIFICATES AND RECOMMENDATIONS

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CERTIFICATES & ACCREDITATIONS

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AVANTI, STEALTH, XXI: Contact HYTORC, Division UNEX Corporation

333 Route 17N, Mahwah, NJ 07430. USA Tel.: +1 201 512-9500 Fax: +1 201 512-9615

Email: [email protected] Web: www.HYTORC.com

HYDRAULIC, 10,000 PSI PUMPS Contact HYTORC, Division UNEX Corporation

333 Route 17N, Mahwah, NJ 07430. USA Tel.: +1 201 512-9500 Fax: +1 201 512-9615

Email: [email protected] Web: www.HYTORC.com

HYTORC NUT & HYTORC WASHER Contact: JETYD Corporation

120 Wesley Street, South Hackensack, NJ 07606 Tel.: +1 201 343-4570 Fax: +1 201 828-5224

Email: [email protected] Web: www.JETYD.com

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