26th July 2016

Where does it work?

No leaksNo leaks – A success story at major petrochemical processing plant in Taiwan where leak-free operations have been achieved.

The plant is now using measurement technology on a variety of applications following a dramatic success story on one of its combined feed exchangers at an aroma production plant at the site. The exchanger had leaked during hydro testing, on start up and then again during production. It was fitted out with 56 RotaBolt fasteners and the leaks stopped.

This was described simply as a “miracle” by the operators who promptly initiated plans to use the technology on a variety of reactors and heat exchangers throughout the plant. Since then thousands of RotaBolt fasteners have been fitted to heat exchangers, pressure vessels, pipelines, reactors and steam generators on various plants across the site.

The company has now decided to feature the science of RotaBolt measurement technology in its training regimes and has been successful in securing support for the training from the Taiwanese government. News of the success has also quickly spread to 60 other plants operating in the area.

No slippage – RotaBolts are being used on one of the most advanced tactical military bridging systems in the world

No slippageThe latest version of the Dry Support Bridge (DSB) from WFEL uses over 1,000 RotaBolt fasteners to help assure its structural integrity. The DSB has a special lightweight construction featuring a series of aluminium modules which are pinned together using steel jaws. The design of the jaw system relies on a guaranteed clamping force across the bolted joints.

The technology is being used by the company on each of the critical friction joints because they can be relied upon to achieve and maintain the necessary clamping force and assure structural integrity.

The new DSB can be deployed in under 90 minutes by just 8 soldiers using a single launch vehicle. It can span a gap of 46 metres and carry up to 120 tonnes of load. An added benefit is that during the assembly process in the field, the RotaCap on top of each RotaBolt can be very quickly and easily ‘finger checked’ to see that the correct tension or load has been achieved.

The American Army has been using the original DSB system since 2003 and the latest version from WFEL has seen an increase in its load capacity and span.

No loosening – Caterpillar are using RotaBolt measurement technology on special versions of their Cat® EL 2000 and 3000 Longwall Mining Shearers which are used in very challenging underground environments where vibration is a constant factor

No loosening The shearers have a reputation for maximum structural integrity and service life and the performance of RotaBolt fasteners has been helping Caterpillar to not only assure integrity but also improve maintenance checking.

The shearers can cut and load more than 5,000 tonnes an hour and feature a one-piece mainframe design. Special versions of the shearers with split mainframes are available wherever there are underground conditions that limit transportation. The mainframe is split into three separate units and RotaBolts up to 6 metres in length are being used to join the sections together.

The technical team at James Walker RotaBolt have worked closely with Caterpillar over the last five years evolving mainly M64 and M80 fasteners which have ranged from 1 metre in length to over 6 metres. In joining sections of the mainframes together, the bolts are being tightened by mechanical jack tensioners, with RotaBolts providing control and measurement of correct tension up to 250 tonnes.

Feedback from operational teams in mines across Asia and Europe has been very positive, reporting enhanced underground assembly and disassembly as well as ongoing assured structural integrity.

No fatigueNo fatigue – Vergnet are now fitting Rotabolt measurement technology on their unique GEV HP wind turbines

Vergnet’s design allows the main turbine to be quickly disassembled into two halves so that the upwind nacelle section, complete with rotors, can be lowered to the ground and easily secured. This can be either as a protective measure in extreme weather conditions, or for much quicker service and maintenance checking.

Each turbine uses thirty M90 RotaBolts on the main nacelle structural joint to hold the two halves together. This brings a number of complementary benefits to Vergnet’s design. The fasteners assure the integrity of this critical joint achieving and accurately maintaining the correct joint tension through the precise measurement technology built into each bolt.

In addition the RotaBolt fasteners can be instantly checked to see if any tension has been lost. During fast re-assemblies of the turbines, the RotaCap on the head of each bolt can be finger-tip checked to see if it has locked off at the correct level of installed tension. This not only dramatically speeds up the assembly process, but also makes routine maintenance much more cost effective.