Enerpac AquaJack EAJ1 Series Instruction Sheet

Enerpac AquaJack EAJ1 Series Instruction Sheet

Bolt tensioners

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L4374 Rev. C 03/22
CONTENTS
1.0 INTRODUCTION .......................................1
2.0 SAFETY ....................................................2
3.0 SPECIFICATIONS .....................................4
5.0 SETTING UP .............................................5
6.0 INSTALLATION .........................................5
10.0 STORAGE .............................................23
11.0 TROUBLESHOOTING ..........................24
12.0 TECHNICAL DATA ................................26

1.0 INTRODUCTION

Overview
The aim of the AquaJack Bolt Tensioning
System is to quickly and accurately apply a pre-
determined load to a nut and bolt assembly.
It has been primarily developed for use in the
underwater environment where speed, ease of
operation and reliability are paramount.
In use, AquaJack Bolt Tensioners are attached
to every stud bolt in the joint assembly allowing
simultaneous and uniform bolt tightening.
AquaJack Bolt Tensioners are to be used as
part of a complete hydraulic system, alongside
a pump, hose arrangement and reaction nuts.
The AquaJack series can used on a wide range
of bolt size and pressure requirements.
Delivery Instructions
Upon delivery all components must be
inspected for damage incurred during shipping.
If damage is found the carrier should be notified
at once. Shipping damage is not covered by
the Enerpac warranty.
© 2022 Enerpac, All Rights Reserved.
Instruction Sheet
AquaJack ® Bolt Tensioners
Warranty
• Enerpac guarantees the product only for the
purpose for which is intended.
• Refer to the Enerpac Global Warranty
document for terms and conditions of the
product warranty.
Any misuse or alteration invalidates the
warranty.
• Observe all instructions as communicated in
this manual.
• When replacement parts are needed, use only
genuine Enerpac replacement parts.
Modification to any part of the equipment
outlined in this manual should not be attempted,
nor any component part be replaced without
first consulting Enerpac. Modifications may
render the equipment dangerous. Component
parts are each rated to suit the demands of
the overall equipment design and replacement
with similar items without provenance may
lead to unexpected and dangerous accidental
features.
If any equipment abuse is evident, the warranty
will be invalidated and Enerpac will not be
made responsible for an injury due to misuse or
failure to comply with the above safety notes.
1

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Summary of Contents for Enerpac AquaJack EAJ1 Series

  • Page 1: Table Of Contents

    10.0 STORAGE ..........23 11.0 TROUBLESHOOTING ......24 12.0 TECHNICAL DATA ........26 1.0 INTRODUCTION Warranty • Enerpac guarantees the product only for the Overview purpose for which is intended. The aim of the AquaJack Bolt Tensioning • Refer to the Enerpac Global Warranty...
  • Page 2: Safety

    WARNING, CAUTION, and the requirements for CE NOTICE. and UKCA. DANGER Indicates hazardous Enerpac declares that the product(s) have been tested and conforms to applicable standards situation that, avoided, will and the product(s) are compatible to all EU and result in death or serious personal injury.
  • Page 3 Non-Enerpac parts may break or cause the product to malfunction. • Never set a relief valve to a higher pressure • Use hydraulic tensioners only in a coupled than the maximum rated pressure of the pump and tensioner.
  • Page 4: Specifications

    3 - Grip Tape 4 - Body 5 - Coupler (2) Maximum 6 - Lifting Eye Stroke Bolts (2) Indicator 7 - Tommy Bar FIGURE 3, MAXIMUM STROKE INDICATOR FIGURE 2, TENSIONER MAJOR COMPONENTS © 2022 Enerpac, All Rights Reserved.
  • Page 5: Setting Up

    Enerpac HF oil ISO32. Table 1 - Tensioner Oil Volumes Enerpac HF oil is available at your local Enerpac Distributor or Authorized Service Centre. Maximum Oil Volume at Maximum Stroke (each tensioner)
  • Page 6 FIGURE 4, DRILLED NUT Table 1 - Hexagon Nut Drilling Metric Heavy Series TOMMY Ø A Ø B Ø C NUT A/F BOLT DIA. DIAMETER 10.2 10.2 10.2 10.2 12.4 12.4 14.4 14.4 16.4 16.4 16.4 © 2022 Enerpac, All Rights Reserved.
  • Page 7 2.3/4" 1.7/8" 10.2 2.15/16" 2” 12.4 3.1/8" 2.1/4" 12.4 3.1/2" 2.1/2” 14.4 3.7/8” 2.3/4" 14.4 4.1/4" 3” 16.4 4.5/8” 3.1/4" 16.4 5" 3.1/2" 16.4 5.3/8" 3 3/4" 16.4 5 3/4" 4” 16.4 6 1/8” © 2022 Enerpac, All Rights Reserved.
  • Page 8 2 3/4” EAJ7 easily engages. 3” Alternatively, if solid reaction nuts are used, 3 1/4” ensure free running over bolt protrusion, EAJ8 3 1/2” length C. FIGURE 5, BOLT PREPARATION © 2022 Enerpac, All Rights Reserved.
  • Page 9 Prior to installation of the flange bolts, it is recommended that the flange is squared and brought into close contact using methods such as the Enerpac flange puller. Once the flange faces are square and in close proximity the bolts and gasket may then be installed.
  • Page 10 REACTION NUT INTO PLACE could lead to stripping of the bolt threads. 5. The AquaJack Tensioners assembled, ready for hose connection. FIGURE 10, COMPLETE QUICK-FASTENING FIGURE 7, FULLY RETRACT PISTON REACTION NUT INSTALLATION © 2022 Enerpac, All Rights Reserved.
  • Page 11 45 lb-ft • Coupling locking collars not fully screwed (61 Nm). back (on down-line hoses only). © 2022 Enerpac, All Rights Reserved.
  • Page 12 FIGURE 11, COMPLETE QUICK-FASTENING REACTION INSTALLATION FIGURE 12, DOWN-LINE ADAPTER COUPLING FIGURE 13, 100% TENSIONING HYDRAULIC CIRCUIT WITH A BANJO FITTING © 2022 Enerpac, All Rights Reserved.
  • Page 13 7. Pressure Gauge Made up in 30 metre lengths, used to A Budenberg 0-25000 psi hydraulic oil connect the AquaJack hydraulic circuit to pressure gauge positioned behind the topsides pump unit. protective wire guard. © 2022 Enerpac, All Rights Reserved.
  • Page 14 The pump is now ready to be operated by using the pump start/stop valve. When the pre- determined required hydraulic oil pressure is reached then the pump will automatically stall. FIGURE 15 , PUMP ANCILLARY EQUIPMENT ARRANGEMENT © 2022 Enerpac, All Rights Reserved.
  • Page 15: Tensioning And De-Tensioning

    Should the operator wish to adopt their own Bolt Tensioning Data Sheet’ will be provided by ‘tried and tested’ subsea tensioning procedures Enerpac (see appendix C for a sample sheet). with the AquaJack equipment then Enerpac will This data sheet will show relevant flange and be pleased to advise accordingly.
  • Page 16 Apply Pressure “B” (At all studs marked “1”) (At two diametrically opposite studs marked “1”) FIGURE 18, RECHECKING FIRST PASS TENSION FIGURE 16, TENSIONER ARRANGEMENT, FIRST (50% TENSIONER COVERAGE) PASS - TYPICAL (50% TENSIONER COVERAGE) © 2022 Enerpac, All Rights Reserved.
  • Page 17 7. De-pressurise the system and remove the Should the operator wish to adopt their own AquaJack. ‘tried and tested’ subsea tensioning procedures with the AquaJack equipment then Enerpac will 7.4 AquaJack Retraction be pleased to advise accordingly. The AquaJack tensioner piston must be 7.3 De-tensioning Instructions...
  • Page 18 The AquaJack tensioner has been purposely designed with a long piston stroke to ensure that the majority of tensioning operations can be completed without the fear of the piston over-stroking. © 2022 Enerpac, All Rights Reserved.
  • Page 19 It is recommended that repairs and servicing the secondary over-stroke elimination device be carried out by Enerpac at intervals agreed will operate, should the piston exceed it’s by Enerpac and customer. All parts will be maximum stroke.
  • Page 20 Enerpac for seal replacement, however if this in Section 9.4. is not possible then the enclosed procedure If tensioners are subject to a lot of use it is should be followed.
  • Page 21 1. Seal inspected and tested in accordance with 2. Ram Enerpac’s stringent requirements. Any parts failing in use that are found upon Enerpac’s 3. Anti-Extrusion Ring (AER) inspection found not to be Enerpac’s genuine 4. Pliers spare parts will invalidate any operative 5.
  • Page 22 Follow the procedure below if the adaptor has separated from the coupler. FIGURE 23A - INCORRECT AER ASSEMBLY a. Clean the coupler thread and adaptor, removing all traces of debris. © 2022 Enerpac, All Rights Reserved.
  • Page 23: Storage

    Remove surplus ‘Loctite’. should return it to Enerpac where the pump d. Leave the assembly for a minimum of 30 can be serviced and repaired by qualified minutes curing time before proceeding with technicians.
  • Page 24: Troubleshooting

    2. Replace hose 2. Leaking/burst hose 3. Replace coupler/seals 3. Leaking coupler/seals 4. Replace seals 4. Leaking tensioner seals 5. Check pump for oil 5. Defective pump unit delivery © 2022 Enerpac, All Rights Reserved.
  • Page 25 Hydraulic fluid visible at top/ 1. Maximum stroke achieved 1. Tighten nut and repeat bottom of tensioner – Relief valve activated procedure Oil is leaking from the tension- 2. Leaking tensioner seals 2. Replace seals er body. © 2022 Enerpac, All Rights Reserved.
  • Page 26: Technical Data

    12.0 TECHNICAL DATA 12.1 AquaJack Tensioner Specifications E = Nearest obstruction G = Measured across tool ø D centerline H = Extra stud length required FIGURE 24 © 2022 Enerpac, All Rights Reserved.
  • Page 27 12.2 AquaJack Tensioner Specifications Metric Table (see Fig 24a, 24b for locations of dimensions A, B, C, D, E, F, and G) © 2022 Enerpac, All Rights Reserved.
  • Page 28 © 2022 Enerpac, All Rights Reserved.
  • Page 29 NOTES _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________...
  • Page 30 NOTES _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________...
  • Page 31 NOTES _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________...
  • Page 32 www.enerpac.com...

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