Case Study: Powering Next-Gen Infrastructure with HYTORC

One of the largest state-owned public power companies in the United States was undertaking an ambitious $1B power plant modernization initiative.

Project Scope and Challenges

The project focused on upgrading the plant’s 10+ power-generating units, many of which still had original mechanical components dating back to the plant’s opening in the 1960’s. Modernization included both structural and technological advancements. This extensive overhaul required tools capable of generating high torque output to manage the physical demands of the project, such as removing and installing massive bolts on generator shafts and turbine components. This called for powerful safe bolting solutions to meet these requirements.

Solution: HYTORC’s Advanced Bolting Tools

To address the power company‘s needs, HYTORC of NY provided a tailored suite of hydraulic and pneumatic bolting tools, including the AVANTI hydraulic torque wrench as a centerpiece of the toolset. The AVANTI is recognized in the industry for its broad torque range, reaching over 130,000 foot-pounds in its largest model, making it ideal for tasks involving large, heavy-duty components. Here they were used to fasten and release main generator shaft coupling bolts, which required torque values exceeding 50,000 foot-pounds.

HYTORC Advantages:

• AVANTI Hydraulic Torque Wrenches: Equipped with a patented reaction drive, they eliminate harmful twisting forces, enabling precise, reliable torque application. (They’re also compatible with our specialized fasteners, including the HYTORC Washer and Nut, which increase worker safety and reduce operating time.)
• Custom Sockets: These custom components were designed specifically for this project’s requirements and enable efficient handling of the large bolts used throughout the power plant.
• On-Site Service and Delivery: HYTORC of New York’s Territory Manager, Anthony Knighten, personally managed the delivery, hand-delivering the tools to ensure timely and direct service.

Execution and Customer Impact

Thanks to HYTORC’s tools, contractors could efficiently perform essential upgrades and maintenance, while helping to prevent unscheduled downtimes. The AVANTI’s precision and high torque output meant they could safely manage heavy-duty bolting tasks, supporting the timely completion of overhaul processes. Additionally, Knighten’s hands-on support made a significant impact on the project. The customers expressed appreciation for HYTORC’s direct, responsive service, highlighting the value of our “one-stop-shop” model that simplified procurement and sourcing for their bolting needs. Knighten’s commitment extended beyond product delivery, creating a foundation for a lasting partnership.

This order was just the tip of the iceberg as they plan on adding multiple battery guns, impact guns and clickers to their fleet before the next outage begins. They love and appreciate our ‘one stop shop’ model that simplifies their procurement and sourcing for all of their bolting needs. – Anthony Knighten, Bolting Specialist and Territory Manager, HYTORC of New York

Outcomes and Future Potential

HYTORC’s tools were essential in executing the project’s modernization goals, with immediate benefits in both safety and efficiency. The customer is planning to add HYTORC’s battery-powered torque guns, impact guns, and other bolting solutions. This ongoing partnership is expected to grow as other contractors working on this turn to HYTORC’s high-quality bolting solutions.

This project represented a landmark effort to sustain and enhance one of the nation’s largest hydroelectric plants. HYTORC’s bolting tools, particularly the AVANTI, met the customer’s demanding requirements, enabling safe, high-powered torque applications essential for its success. This case study demonstrates HYTORC’s ability to support large-scale infrastructure upgrades with advanced technology, dedicated service, and long-term partnership potential.