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Variable Tensioners

Variable Model Hydraulic Tensioners

Hydraulic tensioning is the ideal method for tightening bolted connections. Hydraulic tensioning eliminates inaccuracies and helps achieve correct bolt loading in critical connections. At HTI, we’ve been building hydraulic tensioners and nuts since 1986. 

What are Variable Hydraulic Tensioners?

Variable stud tensioner models allow the tensioning of different bolt/stud sizes or thread forms, while utilizing a common load cell. All of this is necessary to change out the pullers and bridges to accommodate a different size. The versatility of the variable hydraulic tensioner keeps tool inventory to a minimum.

Like fixed model stud tensioners, HTI’s variable models are simple to operate and maintain, designed and built using Total Quality Assurance, and provide extremely dependable operation. Variable model tensioners offer the additional cost-effectiveness and flexibility of working on a variety of studs. 

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Variable tensioner kit

Applications of Variable Hydraulic Tensioners

Variable Stud Tensioners can be used in a wide variety of applications, wherever accurate bolt loading is required. 

  • Pipeline Flanges
  • Pressure Vessels
  • Valves and Pumps
  • Manways
  • Heat Exchangers
  • Diesel Engines
  • Cranes
  • Presses
  • Steam & Gas Turbines
  • Shaft Couplings
  • Coal and Rock Grinders
  • Catalyst Reactors
  • Wind Turbines
  • Electric & Steam Generators
  • And more

Variable Tensioner Features:

HTI tensioners offer some key features:

  • Trouble–free, No–Leak, Lo–Friction Seals
  • Overstroke Indicator – fail-safe design if accidentally over-extended
  • Extra–Long Working Stroke
  • Compact and Lightweight Design
  • Twin Hydraulic Ports (on standard models) – for tool chaining
  • Available in a variety of finishes

Variable Stud Tensioner Options

Variable model tensioners are available in:

  • Single-stage for vertically limited spaces
  • Multi-stage for diametrically limited spaces
  • Standard or spring return

If a standard catalog size won’t work, we can design a customer variable tensioning system for any application, for imperial or metric sized studs.

HTI can provide a wide variety of pullers, bridges, and nut rotating sockets including many standard stud and nut sizes, or any custom size you may need.

Variable Stud Tensioners - Inch Tool Model

V2A075

V2A088

V2A100

-

V2A112

V2B125

V2B138

V2B150

V2C150

V2C162

V2C150

V2C162

V2C175

V2C188

V2C200

V2D188

V2D200

V2D225

V2D250

V2E250

V2E275

V2E300

V2F325

-

V2F350

V2F375

V2F400

-

Please contact us to get started desining a variable tensioner kit for your applications. 

How to operate a variable model stud tensioner

The operator selects the Puller Bar, Bridge and Nut Rotating Socket for the stud and nut size to be tensioned. After placing the Bridge and Load Cell Housing over the nut, the operator threads the Puller Bar onto the stud. They then connect the Stud Tensioner to the Hydraulic Pump using Hydraulic Hoses with with Quick–Disconnect (QD) fittings.

The Hydraulic Pump supplies high–pressure hydraulic oil to the Tensioner Load Cell, producing an accurate axial tension that stretches the stud. When the pump reaches a pre–set pressure, the operator uses a small bar to tighten the nut by hand. He then removes the Stud Tensioner and the process is completed.

The illustration above shows the Tensioner with an optional drilled nut. Drilled nuts can be hex or round. A Nut Rotating Socket (NRS), that fits inside of the Bridge, and turns a hex nut, is furnished standard.

Custom Engineered Tensioners Since 1986

HTI has been designing engineered solutions to your toughest bolt tensioning problems since 1986! You can choose from one of our standard catalog sizes above, or we can design a custom fixed tensioner for any application when a standard model won’t work. HTI tensioners can be designed for imperial or metric-sized studs, high loads, high temperatures, large stud sizes or corrosive environments. Our multi-unit tensioning systems can make easy work of large bolted systems, and our automated tensioning systems can reduce labor and increase throughput in high-volume manufacturing applications. 

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If you have questions, comments, would like more information about our products, or want to get started designing your custom tensioning solution, please contact us and we will respond promptly.