Custom Hydraulic Tensioning Solution Enhances Reliability at LG Chem Daesan Complex
LG Chem Daesan Complex is an active petrochemical complex located in Gyeonggi Province, South Korea. A petrochemical complex processes crude oil and natural gas into petrochemicals. Key products produced in this complex include Low-Density Polyethylene (LDPE), Vinyl Chloride Monomer (VCM), and Polyolefin Elastomer (POE).
As an industry leader, operational efficiency and continuous production are imperative to the success of the facility. However, this plant faced recurring leaks in their essential high-pressure gasket joints. While these leaks caused unexpected shutdowns, they also compromised safety and increased maintenance costs. Addressing this issue requires precise preload management and a reliable, advanced tensioning solution to ensure leak-free performance.
To tackle this challenge, Boltight® engineers created a hydraulic tensioning package tailored to LG Chem’s specific requirements. For accurate preload application, our expert team of engineers designed custom M36 and M52 hydraulic tensioners. Additionally, the team recommended the Echometer ultrasonic measuring tools for swift and accurate bolt load measurements. To ensure smooth implementation and long-term reliability, Boltight offered comprehensive technical support, including on-site training programs, supervision, and repair services.
An In-Depth Look at the Solution
Boltight standard hydraulic tensioners (T-Series) are a quick, easy and safe method for tightening large diameter bolts to high and accurate preloads. They feature high wear and corrosion-resistant surface treatment as well as internal pieces that compensate for joint misalignment.
Key product benefits:
- Easy to install and remove
- Extremely durable due to surface coating of components (nitride)
- Tools can be connected in sequence to improve operation speed and ensuring even joint compression
The Echometer is a portable tool that uses ultrasonics to measure the elongation, stress, and load in fasteners. It offers quick and accurate measurements.
Key product benefits:
- Easy to operate
- Compact and durable
- Minimal operator training required
- Provides elongation, load, stress, and strain measurements
- Accurate and reliable
- Simple data recording and reporting
To ensure successful implementation of its tensioning solutions, Nord-Lock Group provided a comprehensive five-hour training session led by Boltight engineers, combining theoretical instruction with hands-on practice. Operators gained a solid understanding of preload principles and the mechanics of bolt tensioning before moving on to the practical installation and pressurization of the hydraulic tensioners. They learned to identify and troubleshoot potential issues during operation and were trained to use the Echometer tools to verify accurate bolt load measurements. This immersive training empowered the team to perform tensioning tasks with confidence, precision, and safety in the demanding environment of offshore wind turbine installation.
CONCLUSION
The LG Chem Daesan Complex in South Korea, a major petrochemical facility producing LDPE, VCM, and POE, faced recurring high-pressure gasket joint leaks that disrupted operations, compromised safety, and increased maintenance costs. To resolve this, Boltight engineers developed a customized hydraulic tensioning package featuring custom-designed M36 and M52 tensioners and the Echometer ultrasonic measurement tool for accurate preload management. The hydraulic tensioners deliver fast, safe, and precise bolt tightening with durability and ease of use, while the Echometer enables quick, reliable bolt load measurements. Through a combination of advanced tools, technical expertise, and hands-on training, Boltight supports LG Chem in achieving safer and more efficient operations.