riverhawk IM-116 User manual

Repairs – Rentals
Field Service
215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]
RevisionH
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INSTRUCTIONMANUALIM‐116
ForGasTurbineTensionedStudsandNuts
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Fr.9ETurbineto9A3ELINGeneratorGE358A7202P022
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GEPower&Water
GENERALELECTRICCOMPANY
MLI: ____ OF ____
DATE
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CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL
ISSUED:
THISDOCUMENTSHALLBEREVISEDINITSENTIRETY.ALLSHEETSOFTHISDOCUMENTARE
THESAMEREVISIONLEVELASINDICATEDINTHISVENDORSUPPLIEDDRAWINGAPPLIQUE.
REV
373A4028
GEDRAWINGNUMBER
VENDORSUPPLIED
THISDOCUMENTISFILEDUNDERTHEGEDRAWINGNUMBER.
GENOTTOREVISE.GEREVISIONLEVELISSHOWNONTHISAPPLIQUE.
GESIGNATURES
CHECKED:
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TheRiverhawkCompanyreservestherighttoupdatethisdocumentwithoutdisseminationornotice.The
latestrevisionmaybeobtainedbycontactingRiverhawkCompanyorthruwww.riverhawk.com.
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InstructionManualIM‐116
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]
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REV
373A4028
GEDRAWINGNUMBER
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TableofContents
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Section Description PageNumber
1.0 CautionsandSafetyWarnings 3
2.0 Scope 4
3.0 QuickCheck‐List 4
4.0 GeneralPreparations 7
5.0 HardwareSetPreparations 8
6.0 StudandNutAssembly 10
7.0 AssemblyofHydraulicTensionerEquipment 10
8.0 AssemblyofTensioneronStud 12
9.0 StudPullingandTensioning 13
10.0 ThreadLocking 15
11.0 Stud/NutRemoval 15
12.0 FrequentAskedQuestions 16
13.0 RevisionHistory 18
AppendixA1 ECDeclarationofConformity 19
AppendixA2 UKCADeclarationofConformity 20
AppendixB 16‐BoltTensioningPatternRecordSheet 29
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InstructionManualIM‐116
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]
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GEDRAWINGNUMBER
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1.0CautionsandSafetyWarnings
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WARNING
Impropertooluseandthefailuretofollowthecorrectproceduresaretheprimaryrootcauses
oftoolfailuresandpersonalinjuries.Alackoftrainingorexperiencecanleadtoincorrect
hardwareinstallationorincorrecttooluse,onlytrainedoperatorswithcareful,deliberate
actionshouldusehydraulictensioners.ContactRiverhawkCompanywithanytrainingneeds.
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CAUTION
Personalinjuryandequipmentdamagecanoccurifthepullerscrewisnotsecurelyengaged
withthetaperedthreadofthestud.Properengagementisachievedwhenthepullerscrewis
tightinthestudandtheTensionerAssemblyisfreetorotate.
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WARNING
Riskofhighpressurehydraulicfluidinjection.Riverhawktoolsoperateunderhighpressure.
Thoroughlyinspectallhosesandconnectionsfordamageorleakspriortousingthisequipment.
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WARNING
Theproperpersonalprotectiveequipmentmustbewornatalltimes.Riverhawkrecommends
ataminimum,safetyglasses,longsleeveshirt,hardhat,heavyworkgloves,andsteeltoe
shoes.
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WARNING
ThesafetycageMUSTbeinplaceandhandskeptoutofdesignatedareasatalltimeswhenthe
tensionerispressurizedotherwisepersonalinjurycanoccur.
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CAUTION
DONOTEXCEEDTHEMAXIMUMPRESSUREVIBROSCRIBEDONTHEPULLERBODY.Excessive
pressurecandamagethestudandthepullerscrew.
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WARNING
FireHazard!DONOTheatwhenthepullerassemblyisinplace.Personalinjuryorequipment
damagemayoccur.UseofanOxy‐Acetylenetorchisnotrecommended.
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NOTICE
DonotusemorethreadlockingcompoundthanspecifiedorthenutmaybeVERYdifficultto
removeatdisassembly.
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CAUTION
DONOTEXCEEDTHEMAXIMUMPRESSUREVIBROSCRIBEDONTHEPULLERBODY.Excessive
pressurecandamagethestudandpullerscrew

InstructionManualIM‐116
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]
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GEDRAWINGNUMBER
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Note:Beforethreadingthepullerscrewintothestud,carefullycheckthecleanlinessofboth
thestud'sandthepullerscrew'sconicalthreads.Applyalightcoatofcleanturbineoilora
spraylubricanttothepullerscrew.Donotuse“NeverSeize”ontheconicalthreads.This
procedurewilleaseassemblyandassurepositivematingofthethreadsbeforetightening.
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2.0 Scope
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Thisdocumentdescribestheproceduretobeusedtoinstallstudsandnutssuppliedby
RiverhawkCompanyintheflangesattheturbine/couplingandcoupling/generatorconnections.
ThishardwareisdepictedonthefollowingdrawingsThesedrawingsaswellasthetooling
drawingsformapartofthismanual.
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 HF‐0813
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3.0QuickChecklist
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ThefollowingchecklistisintendedasasummaryofthestepsneededtousetheRiverhawk‐
suppliedequipment.Newpersonnelorthoseexperiencedpersonnelwhohavenotusedthe
Riverhawkequipmentrecentlyareencouragedtoreadtheentiremanual.
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EQUIPMENTINSPECTION
□Checkoillevelinhydraulicpump.
□Checkairpressureat80psi[5.5bar]minimum.(Forair‐drivenpumps)
□Checkhydraulichosefordamage.
□Testpump.
□Inspecttensionerforanydamage.
NUTANDSTUDPREPARATION
□Inspectstudandnutsforanydamage.

InstructionManualIM‐116
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]
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□Measurestudlength.
□Cleanthestudsandnuts.
□Installstudsandnuts(off‐center)intotheflange.
□Setstick‐outdimensiononthecouplingsideoftheflange.
□Handtightenallstuds.
□Verifystick‐outmeasurement(VERYIMPORTANT)

Tensioning(Boltinstallation)
□Matchthetensionersetuptotheflangejoint.
□Applyalightcoatofcleanturbineoilorspraylubricanttothepullerscrew.DONOTUSE
“NEVERSEIZE”ONTHECONICALTHREADS.
□Slidespannerringoverthepullerscrew.
□Mountthetensioneronthestudinflange.
□Installspannerringontonut.
□Insert1/2”hexAllenwrenchintothebacksideofthestud.
□Tightenthepullerscrew.
□Backoffpullerscrew1/2turn.
□Retightenthepullerscrewandleavetight.DONOTBACKOFFPULLERSCREW.
□Bleedthetensioner.DoNOTbleedtensioneroffofastud!Damagetothetoolwill
result!
□Tensionto50%.Consultmanualforcorrectpressure.

InstructionManualIM‐116
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]
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REV
373A4028
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□Usethepinwrenchinspannerringtotightennut.
□Releasepressure,movetonextstudinpattern.
□Repeatabovestepsatfinalpressure.
□Measurefinalstudlengthandrecordonstretchdatasheets.Calculatestretch.
□Torquenuts'setscrews.

Detensioning(Studremoval)
□Loosennuts'setscrews
□Inspectandcleanstuds'conicalthreads.DonotcontinueuntilALLdebrisisremoved
fromthethreads!Donottrytousethetensionertoremoveadamagedstud!
□Applyalightcoatofcleanturbineoilorspraylubricanttothepullerscrew.DONOTUSE
“NEVERSEIZE”ONTHECONICALTHREADS.
□Slidespannerringoverthepullerscrew.
□Mountthetensioneronthestud.
□Installspannerringintonut.
□Tightenthepullerscrew.
□Backoffpullerscrew1/2aturn.
□Retightenthepullerscrewandleavetight.DONOTBACKOFFPULLERSCREW.
□Bleedthetensioner.DoNOTbleedtensioneroffofastud!Damagetothetoolwill
result!
□Applyfinalpressure.

InstructionManualIM‐116
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]
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□Loosennutwiththespannerringandpinwrench.
□Movetonextstudinpattern
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4.0GeneralPreparations
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Readandunderstandallinstructionsbeforeinstallingstuds.

Thisequipmentproducesveryhighhydraulicpressuresandveryhighforces.Operatorsmust
exercisecaution,wearsafetyglassesandhardhatswhenusingthisequipment.

HighpressurefluidfromtheHydraulicPressureKitsystempressurizesthetensionerwhich
generatesastretchingforcethatactuallystretchesthestud.Asthestudisstretchedthenut
liftsofftheflange.Thenutisthenreseatedintopositionontheflangebyturninganutdriver
byhand.Whenthenutistightagainsttheflange,thepressureinthetensionerisreleased
leavingthestudloadedtoitspredeterminedvalue.

4.1MachinePreparation

Theflangetobetensionedmustbefullyclosedpriortopositioningofstudsintheflanges.
Theremustbeprovisiontoturntheshaftsoftheturbineandthegenerator.Also,itwillbe
advantageoustoremoveasmanyobstructionsaspossiblefromtheflangearea,suchasspeed
probesandconduit.

4.2Hardware–Balance

 Hardwareissuppliedasweightbalancedsets
 StudsandNutsareinterchangeablewithinsets
 Donotmixwithothersets
 Saveweightcertificationforthepurchaseofspares

4.3Tensioner–CareandHandling

 Whennotinuse,thetensionershallbemaintainedinacleanenvironmentandallcapsand
plugsforhydraulicopeningsandfittingsmustbeinplace.
 UseISO32gradeoil.
 Wheninuse,thetensionershallbeprotectedfromsandandgrit

InstructionManualIM‐116
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]


REV
373A4028
GEDRAWINGNUMBER

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
 Longtermstorage–coattensionerwithoil,returntooriginalcontainer,sealcontainerand
protectfrommoisture
 Shipment–coattensionerwithoilandshipinoriginalcontainer

4.4 HandTools

Severalhandwrenchesandmicrometerswillberequiredtoperforminstallationand
measurementofthestuds:

5/8”wrench
1"wrench
1”socketandimpactwrench
AsetofAllenWrenches
3’–4’BreakerBar
9”to10”micrometerorcaliper
10”to11”micrometerorcaliper


4.5SpecialTools

HydraulicTensionerKit: HT‐0814HydraulicTensioner

HydraulicPumpKit: AP‐0532Air‐OperatedHydraulicPump
(recommended)
(referenceGE359B2502)
 MP‐0130ManualHand‐Operated
HydraulicPump
(referenceGE359B2506)


5.0HardwareSetPreparations

5.1NutPreparation

Fornewinstallations,thenutsshouldcomesealedfromthefactoryandwillneednocleaning.

Previouslyinstallednutsrequirecleaningasfollows:Wirebrushusingapetroleum‐based
solventtoremoveanyforeignmaterialontheexternalsurfacesandthreads.

Ifpreviousinstallationsemployedathreadlockingcompound,whichwillbevisibleasagrayish‐
greenresidue,removeasmuchofthiscompoundaspossible.


InstructionManualIM‐116
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]


REV
373A4028
GEDRAWINGNUMBER
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
Donotapplythreadlubricantstothethreads.

Finishthecleaningprocessbyrinsinginavolatilesolventsuchasacetoneandallowtodry.

5.2StudPreparation

Fornewinstallations,thestudsshouldcomesealedfromthefactoryandwillneednocleaning.

5.2.1StudCleaning‐OldInstallations

Previouslyinstalledstudsmayrequirecleaning.Cleanconicalthreadsshouldhaveabrightand
shinyappearance.

Ifcleaningisrequired,followthesesteps:

1. Blowoutthethreadswithcompressedairtoremoveloosedebrisanddryconical
threads.Donotapplyasolventorothercleaningsolutiontothethreadsasthismay
chemicallyattackthestud.

2. UseStudCleaningKit,GT‐4253orasimilar1"diameterBrasspowerbrush.


PictureofBrassPowerBrush

3. Insertthebrushintoanelectricdrillandsetdrilltoruninacounterclockwisedirection
athighspeed.

4. Workthedrillinacircularmotionwhilemovingthebrushinandouttocleanallofthe
threads.Trynottoholdthebrushinoneplacetoolong,soasnottoremovethestud's
protectivecoating.

5. Blowoutthethreadswithcompressedairtoremovelooseneddebris.

6. Visuallyinspectthreadsforcleanliness.Threadsshouldbebrightandshiny.

7. Repeatifanydirtcanbeseeninthethreads.

8. Inspectthreadsforanydamagethatmayhavebeencausedbypreviousinstallation.


InstructionManualIM‐116
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]


REV
373A4028
GEDRAWINGNUMBER

RevisionH
Page10of29

Donotapplythreadlubricantstothethreads.

Finishthecleaningprocessbyrinsinginavolatilesolventsuchasacetoneandallowtodry.

5.3StudLengthMeasurement

Measureandrecordtheinitiallengthsofthestuds.Thefollowingrecommendationswill
improveyourresults.

 Plantostartandfinishanyflangeinthesameday.
 Studsandflangemustbeatthesametemperature.
 Numbereachstudwithamarker.
 Markthelocationofmeasurementonstudendwithapermanentmarker.
 Measureeachstudtonearest0.001inch.
 Recordeachmeasurementonthesuppliedcharts.
 Donotallowthemeasuringinstrumentstosetinthesun.


6.0StudandNutAssembly

Refertohardwareassemblydrawing(HF‐0813)listedinSection2.0ofthismanual.
1. Assemblecylindricalnuttothetaperedthreadend(PullEnd)ofthestud.
2. SlidethestudandcylindricalnutassemblyintotheflangeasshowninFigures1&2and
installtheothernutonthebackside.
3. Adjustthenut/studassemblysothatthestudprotrudesfromthefaceofthe
cylindricalnuttheamountasdepictedonthehardwaredrawing(HF‐0813).SETTING
THISPROTRUSIONOFSTUDTONUTISCRITICALFORPROPERTENSIONEROPERATION.
4. Hand‐tightentheassemblytoasnugfit.Seephotos1&2forviewofstudsinflange
priortotensioning.


7.0AssemblyofHydraulicTensionerEquipment

7.1KitAssembly

Assemblethehydraulicpumpwithitshosetothepullertoolandbleedthesystemofairper
followinginstructions.Photo4showshoseconnectedtomanifoldoftensioner.

Cleanpullerscrewandcheckforanydebrisanddents.


InstructionManualIM‐116
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]
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REV
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GEDRAWINGNUMBER
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
Pullerscrewshouldbefreetorotateandmovebackandforth.

Seambetweencylindersclosedtightly.

Inspecttensionerguardforanysignsofdamage.Bentguardsshouldbereplaced.Also,besure
therubberpadisinplaceontheendoftheguard,ifmissing,replace.

7.1.1Fittings

Makesurebothmaleandfemalepartsarecleanandfreeofdebris,seeFigure3forfitting
configuration.Holdfemalepartsecurelywhentighteningsoastopreventdamagetoadjacent
tubing.Iffittingleaksfirsttryretighteningasneeded.Ifleakingcontinuesthendisassemble
andcheckforscratchesordebrisontheseatingconicalsurfaces.Cleanasrequired.Replace
plasticcapswhenfinishedwithtooling.

7.2Pump

Thepumpkitisshippedfullofhydraulicoil.Thepumpreservoircapissealedforshipment.To
useturncaptotheventposition.Topreventoilspillageclosecapwhennotinuse,during
storageandshipment.LostoilshouldbereplacedwithEnerpacHydraulicOil.ISO32.Mineral
Oilmaybesubstituted,ifnecessary.

7.3BleedingHydraulicSystem

FollowthetensionerassemblyinstructionsofSection8.0.

TOAVOIDFAILURE,ENSURESAFETYANDPROPEROPERATIONTHETENSIONERASSEMBLY
MUSTBEMOUNTEDONTHESTUDBEFOREBLEEDINGTHESYSTEMANDTENSIONINGBEGINS.

ThetensionerhasfourportsseeFig.5,oneforpressurizing,twoforbleedingthesystemanda
fourthpressurereliefport.

Tofacilitatebleeding,startbyfirstmountingthetensionerateitherthe30’clockor9o’clock
studpositiondependingonwhichwillcriticallyplacethebleedportsintheiruppermost
position.Inaddition,makesurethatthepumpisalwayssituatedbelowthetensionerassembly.

Thepullertoolisequippedwith5/8in.[16mm]Hexconedstembleederfittingsinstalledinthe
bleederports.Withthesestwofittingsloosenedsimultaneously,strokethepumprepeatedly
untilthestreamsofoilexitingthetoolfromeachportarefreeofair,thenretightenthefittings.


InstructionManualIM‐116
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]


REV
373A4028
GEDRAWINGNUMBER

RevisionH
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
Providingthatthehoseisnotdisconnectedorloosenedintheprocessoftensioningallthe
studs,bleedingtheassemblyonceatthefirstpositionshouldsufficetofilltheassemblyand
precludetheneedtorepeatthebleedingprocess.

Note:Thehoseisstiff,useofthistoolingcanbesimplifiedbytemporarilymountingthepuller
toolononestudpriortofinaltighteningoffittings.Thiswillreducethetendencyforthe
fittingstoloosen.


8.0AssemblyofTensioneronStud

Alltensioningwillbeperformedfromthetaperedthreadendofthestudwithorientationof
thestudtotheflangeasshowninFigures1&2.RefertoTensionerassemblydrawingand
Figure5fortensionertoflangemounting.

Thisassemblyhasthefollowingfeatureswhichshouldmakestudtensioningsafeandeasy.

 Thesafetycageisintegral(bolted)tothepullertool
 Thehydraulicpistonisspringloadedtoretract.
 Thepullerscrewisa2‐piecedesignwhichrequiresthattheoperatortightenthepuller
screwintothestud.

Assemblysequenceisasfollows:

1. Openthehydraulicreturnvalveonthehandpumptoallowhydraulicfluidtobepushed
backfromthepullertoolintothepumpreservoir.(Thisisautomaticwiththeair‐operated
hydraulicpump)
2. Placethespannerringonthepullersidecylindricalnut
3. Applyalightcoatofcleanturbineoiloraspraylubricanttothepullerscrew.Donotuse
“NeverSeize”ontheconicalthreads.
4. Placeandholdthetensionerassemblyovertheendofthestudtobetightened.See
photos3,4&5.
5. Slidethepullerscrewintothetaperedthreadofthestudandhandtighten.Besurenotto
crossthreadassembly.
6. TightenthepullerscrewusingAllenwrenchesonthepullerscrewandthestud.DONOT
wrenchonthenutoppositethepullertool.
7. AtthispointtheTensionerAssemblyMUSTBEFREETOROTATE,thepullerscrewmustbe
tightinthestudandthepullernuthasbeenbacked‐off2flats.

InstructionManualIM‐116
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CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

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Tel:+13157684855
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

Ifthepullertoolisnotfreetorotatewhenthepullerscrewistight,theneither.(1)The
tensionerisdamaged,or.(2)Thestudisnotproperlypositionedintheflangeandthenuts
mustrepositioned.Thiscanbedoneasfollows.

1. Slightlyloosenthepullerscrew
2. Backthenutoppositethepullertooloffabout1/2turn
3. Tightenthepullerscrewsidenuttotakeuptheslack.
4. Retightenthepullerscrewperaboveandcheckforloosenessoftool

CAUTION
Personalinjuryandequipmentdamagecanoccurifthepullerscrewisnotsecurelyengaged
withthetaperedthreadofthestud.Properengagementisachievedwhenthepullerscrewis
tightinthestudandtheTensionerAssemblyisfreetorotate.


9.0StudPullingandTensioning

Thestudswillbetensionedintwosteps,atapproximately50%pressureandatfinalpressure.
Followthetensioningsequenceforeachflangejointasdefinedonthedatasheetsfoundatthe
endofthismanual

Note:Beforethreadingthepullerscrewintothestud,carefullycheckthecleanlinessofboth
thestud'sandthepullerscrew'sconicalthreads.Applyalightcoatofcleanturbineoilora
spraylubricanttothepullerscrew.Donotuse“NeverSeize”ontheconicalthreads.This
procedurewilleaseassemblyandassurepositivematingofthethreadsbeforetightening.

WARNING
ThesafetycageMUSTbeinplaceandhandskeptoutofdesignatedareasatalltimeswhenthe
pullertoolispressurizedotherwisepersonalinjurycanoccur.

9.1Tensioningat50%pressure

Afterthetensionerisproperlyinstalledapplyhydraulicpressuretothetool.Bringthepressure
tothe50%levelinaccordancewiththefollowingtable.



InstructionManualIM‐116
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
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Tel:+13157684855
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
FlangePosition StudSize 50%Pressure 50%Stretch
TurbinetoCoupling 2.784"
[71mm]
9000psi
[620bar]
Donotmeasure
Donotuse
CouplingtoGenerator 2.283"
[58mm]
10000psi
[690bar]
Donotmeasure
Donotuse

9.1.1TighteningtheTurbine/CouplingandCoupling/GeneratorNuts

TurnthecylindricalnutusingthespannerringandpinwrenchasdepictedinFigure5untilit
bottomsontheflange.

9.2RemovingtheTensionerfromanInstalledStud

Pullertoolremovalistoaccomplishedasfollows:

1. Releasethepullertoolpressurebyopeningthevalveonthepump.Leavethevalve
open.Thisisautomaticontheair‐operatedhydraulicpump.
2. Unscrewthepullerscrewusingawrench
3. Tappingthewrenchwithahammermaybenecessarytoloosenthepullerscrew.
4. Movethetooltothenextstud/nutassemblytobetensioned,followingthe
sequence/patternasdefinedonthesupplieddatasheets.

9.3TensioningatFinalPressure

Repeatthepullingandtighteningprocedurestatedaboveatfullpressure.Measuresthelength
ofthestudsafterallhavebeentensioned.Thefinalpressureandrequiredstretchvaluesare
listedinthefollowingtable

FlangePosition StudSize FinalPressure FinalStretch
TurbinetoCoupling 2.784"
[71mm]
18000psi
[1170bar]
0.011"‐0.014"
[0.28mm‐0.36mm]
CouplingtoGenerator 2.283"
[58mm]
20500psi
[1240bar]
0.019"‐0.023"
[0.48mm‐0.58mm]



InstructionManualIM‐116
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
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Tel:+13157684855
Fax:+13157684941
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
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
CAUTION
DONOTEXCEEDTHEMAXIMUMPRESSUREVIBROSCRIBEDONTHEPULLERBODY.Excessive
pressurecandamagethestudandthepullerscrew

FortheproceduresofSection9.3excessivestretchvariationorlowstretchvaluescanbe
correctedbyretensioningallorselectedstudstothepressurevaluesstatedintheabovetable.
Havefinalstretchvaluesapprovedbythesupervisorresponsiblefortheinstallation.


10.0ThreadLocking

Oncepullingandtensioningiscompleteallstudsandnutsmustbelockedinposition.Thelock
nutsusedintheturbine/couplingandcoupling/generatorconnectionsemployamechanical
lockingfeature.Thesemechanicallocknutshavetwosetscrewslocatedonthetopface,see
Figure4.

Beforethreadingthenutontothestudchecktobecertainthatthesetscrewsarefreetoturn.
Oncethenutisseatedtorquethesetscrewstothevaluesspecifiedinthefollowingtable.
Whenseatedandtorquedtothevaluesspecifiedtheloadcreatedbythesetscrewdisplaces
thethreadofthenutintheareaofthewebcreatingthedesiredlockingaction.


StudSize SetScrewSize Torque
2.784"
[71mm] 3/8"‐24UN 200in∙lbs‐250in∙lbs
[22.6N∙m–28.2N∙m]
2.283"
[58mm] 1/4"‐28UN 80in∙lbs‐90in∙lbs
[9.0N∙m–10.2N∙m]


11.0Stud/Nutremoval

Removalisaccomplishedasfollows:

1. Usingawirebrushandshopaircleantheinternaltaperedthreadofthestudtoremove
anydebris/depositswhichmayhaveaccumulatedduringservice.(seesection5.2.1)
2. WithanAllen‐wrenchloosenthetwolockingsetscrewsbutdonotremovefromthenut
seeFigure4.
3. InstalltheappropriatepullertooltothestudasdescribedinSection8.0.

InstructionManualIM‐116
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
215ClintonRoad
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Tel:+13157684855
Fax:+13157684941
Email:[email protected]
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
4. ApplytheappropriatehydraulicpressureperthefollowingTableandusingthespanner
ringandspanner/pinwrenchesshowninFigure5loosenthenut,thenreleasethe
pressureandremovethepullertool.

FlangePosition StudSize RemovalPressure
TurbinetoCoupling 2.784"
[71mm]
18000psi
[1170bar]
CouplingtoGenerator 2.283"
[58mm]
20500psi
[1240bar]


12.0FrequentlyAskedQuestions

Thissectioncontainssomefrequentlyaskedquestionsandproblems.Ifthestepslistedheredo
notsolveyourproblem,contacttheRiverhawkCompanythruourwebsite,email,orphonecall.

Q: Atensionerhaspulleditselfoutofthestud'sconicalthreads.CanIcontinueusinga
tensioneronthisstud?

A: No.Boththetensionerandthestudmayhavebeendamaged.Ifthestudistensioned,a
NutBusterrepairkit,fromRiverhawk,mustbeusedtoremovethedamagedstudby
drillingoutthenut.Riverhawkcansupplyareplacementstudandnutbasedonthe
initialweightcertificationsuppliedwiththehardwareset(seesection4.2).The
damagedtensionershouldalsobereturnedtoRiverhawkforinspectionandrepair.


Q: Thehydraulictensionerhasbeentakenuptoitsfinalpressure.Thefinalstretchlength
isshortofthefinalstretchtarget.Whatisthenextstep?

A: Donotincreasethehydraulicpressure.Checkifthehydraulicpumpissettotheright
pressure.Installthetensionerandre‐pressurizethetensionertothefinalpressurethen
recheckthestretchmeasurement.Ifthestretchvalueisstillshort,removethestud
fromtheholeandre‐measurethestud'sinitiallengththentrytoinstallthestudagain.




InstructionManualIM‐116
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL
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NewHartford,NY13413
Tel:+13157684855
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
Q: Thehydraulictensionerhasbeentakenuptoitsfinalpressure.Thefinalstretchlength
islargerthanthefinalstretchtarget.Whatisthenextstep?

A: Removethestudfromthebolthole.Checkifthehydraulicpumpissettotheright
pressure.Re‐measurethestud'sinitiallengththentrytoinstallthestudagain.


Q: Isthereaneasierwaytosupportormovethetensioneraroundthecouplingshaft?

A: Usetwostraps.Onearoundthecouplingshaftandtheotherattachtoanyoverhead
support.Strapsmustbeslackduringmountingtensionertostudandduringtensioning.


Q: Thetensionerisatitsfinalpressure,butthenutcannotbeloosen.

A: Ifthenutscannotbeloosenedatthefinalpressure,continuallyincreasingthepressure
willnothelpandcanbedangerousandinsomecasesmakeithardertoremovethenut.
Checkthenuttoseeifitssetscrewshavebeenloosened.Checkforandremoveany
corrosionaroundthenut'sthreads.


Q: HowdoIcleantheconicalthreadsonastud?

A: Theconicalthreadsarebestcleanedusingaspiralwoundbrassbrushinadrillas
describedinsection5.2.1


Q: Duringtheinitialstepsofremovingatensionedstud,thestick‐outlengthisfoundtobe
wrong.

A: Donotproceed.ContactRiverhawkforassistance.Withthewrongstick‐outlength,the
hydraulictensionerhasalimitedstrokeandmaynotworkproperlyandcanbe
damaged.


Q: Thehydraulicpumpappearstobeleaking.

A: Checkthehoseconnectiontothehydraulicpump.Ifthe1/4"highpressurefittingisnot
assembledcorrectly,itmaylooklikethepumpisleaking.Iftheproblemcontinues,it
maybenecessarytoopenthepumpkit.ContactRiverhawkforguidance.


InstructionManualIM‐116
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]


REV
373A4028
GEDRAWINGNUMBER

RevisionH
Page18of29


Q: Thehydraulichosehasacollaronitthatcan'tbemovedbyhand

A: Thecollarissometimesheldinplacewithathreadlockingcompound.Thispreventsthe
collarfrommovingtooeasily.Itmaybenecessarytoadjustthiscollarwithasetofvise‐
grippliers.Becarefultonotstripthethreadsoffthetubeorhoseend.


13.0RevisionHistory

Revision
Letter
EffectiveDate Description
H May19,2022 UpdatedECDeclarationofConformity;AddedUKCA
DeclarationofConformity
G Jan16,2015 Updatedsections1.0,4.3and14.0
F Jun13,2014 AddedECDeclarationofConformity
E Jun10,2009 Addedturbineoilandremoved“NeverSeize”from
sections1.0,3.0,8.0,and9.0
D Mar25,2009 Addedsections3and13,AddedGETitleblocktoall
pages
C Jun23,2000 Page2para2.0,Page4para4.0,Page5para5.3,page7
para7.3
B Jan11,2000 Page1
A Jul20,1999 
‐ Mar19,1999 Released




InstructionManualIM‐116
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]


REV
373A4028
GEDRAWINGNUMBER

RevisionH
Page19of29

AppendixA1

ECDeclarationofConformity


Manufacturer: RiverhawkCompany
Address: 215ClintonRoad
NewHartford,NY13413,USA


Thehydraulicpumpandbolttensioningtooldescribedinthismanualareusedforinstallingand
applyingtensiontolargeboltsthatarespecificallydesignedbyRiverhawkCompanytobe
tensionedhydraulically.

AllapplicablesectionsofEuropeanDirective2006/42/ECformachineryhavebeenappliedand
fulfilledinthedesignandmanufactureofthehydraulicpumpandbolttensioningtool
describedinthismanual.ReferencealsoISO12100:2010,ISO4413:2010,andISO4414:2010.

Furthermore,thisequipmenthasbeenmanufacturedundertheRiverhawkqualitysystemper
ENISO9001:2015

ConsulttheDeclarationofConformanceincludedwiththeshipmentofthisequipmentthat
identifiestheauthorizedRiverhawkrepresentative,applicableserialnumbers,andappropriate
signature.


InstructionManualIM‐116
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]


REV
373A4028
GEDRAWINGNUMBER

RevisionH
Page20of29

AppendixA2

UKCADeclarationofConformity


Manufacturer: RiverhawkCompany
Address: 215ClintonRoad
NewHartford,NY13413,USA


Thehydraulicpumpandbolttensioningtooldescribedinthismanualareusedforinstallingand
applyingtensiontolargeboltsthatarespecificallydesignedbyRiverhawkCompanytobe
tensionedhydraulically.

AllapplicablesectionsofSupplyofMachinery(Safety)2008havebeenappliedandfulfilledin
thedesignandmanufactureofthehydraulicpumpandbolttensioningtooldescribedinthis
manual.ReferencealsoISO12100:2010,ISO4413:2010,andISO4414:2010.

Furthermore,thisequipmenthasbeenmanufacturedundertheRiverhawkqualitysystemper
ENISO9001:2015

ConsulttheDeclarationofConformanceincludedwiththeshipmentofthisequipmentthat
identifiestheauthorizedRiverhawkrepresentative,applicableserialnumbers,andappropriate
signature.


