riverhawk IM-125 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]
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INSTRUCTIONMANUALIM‐125
ForGasTurbineandSteamTurbine
TensionedStudsandNuts


ApplicableBoltingConnections
Fr.7FAGasTurbineto7FH2Generator
Fr.7FAGasTurbinetoLoadCoupling
Fr.7FBGasTurbineto7FH2Generator
Fr.7FBGasTurbinetoLoadCoupling
LoadCouplingorSteamTurbineto7FH2Gen

ApplicableGEOrderingSheetPartNumbers
358A7202P001
358A7202P002
358A7202P012
358A7202P018
358A7202P020
358A7202P031
358A7202P032
361A5218P001

377A9477P001
377A9477P002
377A9477P003
377A9477P004
377A9477P005
377A9477P006
382A6121P003
382A6121P004
382A6121P006

 
GEPower&Water
GENERALELECTRICCOMPANY
MLI: ____ OF ____
DATE

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
373A4000
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:




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.

InstructionManualIM‐125
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
373A4000
GEDRAWINGNUMBER
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RevisionW
Page2of38
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TableofContents

Section Description PageNumber
1.0 CautionsandSafetyWarnings 3
2.0 ScopeandGEPartNumberCross‐Reference 4
3.0 QuickChecklist 6
4.0 GeneralPreparations 9
5.0 HardwareSetPreparations 11
6.0 StudandNutAssembly 14
7.0 HydraulicTensionerEquipmentAssembly 17
8.0 AssemblyofTensioneronStud 20
9.0 StudTensioning 23
10.0 ThreadLocking 25
11.0 StudandNutRemoval 26
12.0 StorageInstructions 30
13.0 FrequentlyAskedQuestions 31
14.0 RevisionHistory 33
AppendixA1 ECDeclarationofConformity 35
AppendixA2 UKCADeclarationofConformity 36
AppendixB1 18‐BoltTensioningPattern(GT‐LC)RecordSheet 37
AppendixB2 16‐BoltTensioningPattern(LC‐GEN)RecordSheet 38



InstructionManualIM‐125
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
373A4000
GEDRAWINGNUMBER

RevisionW
Page3of38

1.0CautionsandSafetyWarnings

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actionsshouldusehydraulictensioners.ContactRiverhawkCompanywithany
trainingneeds.
WARNING
Riskofhighpressurehydraulicfluidinjection.Riverhawktoolsoperateunderhighpressure.
Thoroughlyinspectallhosesandconnectionsfordamagepriortousingthisequipment.

CAUTION
Personalinjuryandequipmentdamagecanoccuriftheproperhealthandsafetycodesand
proceduresarenotfollowed.Contactthesite’shealthandsafetyofficetodetermineall
applicablesafetyrulesandregulations.

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.

CAUTION
Itisespeciallyimportanttochecktheconditionoftheconicalthreadusedtotensionthestud.
Threaddamagefrompreviousabusecanleadtofailureofthestudortensioningequipment

CAUTION
RiverhawkrecommendsthatthetensionershouldbereturnedtoRiverhawkforperiodic
inspections.Replacementofobsoletetensionersisrecommended.Functionalupgradesarealso
recommended.TheRiverhawkServiceReturnsCoordinatorshouldbenotified3‐6monthsprior
toaplannedoutagetoscheduleaninspectionservice.

WARNING
Adamagedburstdiscmustbereplacedwithawithaburstdiscofthesamedesignand
pressurerating.Donotsubstituteadamagedburstdiscwithadifferentdisctype,adifferent
pressurerating,oraforeignobject.

WARNING
Toavoidfailure,ensuresafety,andproperoperation,thetensionerassemblymustbeinstalled
onastudintheflangebeforebleedingandpressurizingthetensioner.Donotusethetensioner
atanypressureunlessthetoolisinstalledonastudinaflange.

InstructionManualIM‐125
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
373A4000
GEDRAWINGNUMBER

RevisionW
Page4of38
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CAUTION
Donotoverextendthetensioner.Overextensioncancausethepistontoloseitssealandleak
oil.

CAUTION
Personalinjuryandequipmentdamagecanoccurifthepullerscrewisnotsecurelyengaged
withthetaperedthreadsofthestud.Properengagementisachievedwhenthepullerscrewis
tightinthestudandthetensionerassemblyisfreetoturn.

WARNING
Thesafetycagemustbeinplaceatalltimes.Whenthetensionerispressurizedhandsmustbe
keptoutofdesignatedareastoavoidanypotentialforpersonalinjury.

CAUTION
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.Thisprocedurewilleaseassemblyandassurepositivematingof
thethreadsbeforetightening.Donotuse“NeverSeize”ontheconicalthreads.

CAUTION
Donottightenthenutwhilethetooliscominguptopressure;waituntilpressureisachieved
beforeattemptingtotightenthenutwiththespannerring.Ifthetoolisnotproperlyinstalled,
thetoolcouldjumpoffthestudwhilecominguptopressure.

CAUTION
Donotexceedthemaximumpressuremarkedonthetensioner.Excessivepressurecandamage
thestudandpullerscrew.

WARNING
FIREHAZARD:DONOTheatwhenpullerassemblyisinplace.Personalinjuryorequipment
damagemayoccur.UseofanOxy‐Acetylenetorchisnotrecommended


2.0Scope

Thisdocumentdescribestheproceduretobeusedtoinstallthestudandnutsetssuppliedby
theRiverhawkCompanyintheflangesattheTurbine/Coupling,Coupling/Generator,andSteam
Turbine/Generatorconnections.

ThevariousframeconfigurationscoveredinthismanualarelistedinSections2.1through2.6
withdifferencesasrelatedtoconnectivehardwaredefined.Listedalsoarethepertinent

InstructionManualIM‐125
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
373A4000
GEDRAWINGNUMBER

RevisionW
Page5of38

hardwaredrawings(HF‐xxxx).Thesedrawingsaswellastoolingdrawings(HT‐xxxx)formpartof
thismanual.

2.1Frame7FAGasTurbineto7FH2Generator

GEPARTNUMBER RIVERHAWKP/N GEVENDOCP/N
GE358A7202P001
GE358A7202P002
GE358A7202P012
HF‐0771
HF‐0771
HF‐0771
GE359B2514
GE359B2514
GE359B2514

ThehydraulictoolusedforinstallationandremovalisRiverhawkHT‐0342.

ThesehardwaredrawingsdepictthecompletestudandnutpackagefortheGasTurbineto
LoadCoupling(2‐1/4”size,Qty18)aswellastheLoadCouplingtoGenerator(2‐3/4”size,Qty
16).

2.2Frame7FAGasTurbinetoLoadCoupling

GEPARTNUMBER RIVERHAWKP/N GEVENDOCP/N
GE358A7202P031
GE358A7202P032
GE361A5218P001
HF‐2447
HF‐2447
HF‐2447
GE359B2539
GE359B2539
GE359B2539

ThehydraulictoolusedforinstallationandremovalisRiverhawkHT‐0342.

ThesehardwaredrawingsdepictthecompletestudandnutpackagefortheGasTurbineto
LoadCoupling(2‐1/4”size,Qty18).

2.3Frame7FBGasTurbineto7FH2Generator

GEPARTNUMBER RIVERHAWKP/N GEVENDOCP/N
GE377A9477P001
GE377A9477P002
HF‐0771
HF‐0771
GE359B2514
GE359B2514

ThehydraulictoolusedforinstallationandremovalisRiverhawkHT‐0342.

ThesehardwaredrawingsdepictthecompletestudandnutpackagefortheGasTurbineto
LoadCoupling(2‐1/4”size,Qty18)aswellastheLoadCouplingtoGenerator(2‐3/4”size,Qty
16).



InstructionManualIM‐125
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
373A4000
GEDRAWINGNUMBER

RevisionW
Page6of38

2.4Frame7FBGasTurbinetoLoadCoupling

GEPARTNUMBER RIVERHAWKP/N GEVENDOCP/N
GE377A9477P006 HF‐2447 GE359B239

ThehydraulictoolusedforinstallationandremovalisRiverhawkHT‐0342.

ThesehardwaredrawingsdepictthecompletestudandnutpackagefortheGasTurbineto
Load.

2.5LoadCouplingorSteamTurbineto7FH2Generator

GEPARTNUMBER RIVERHAWKP/N GEVENDOCP/N
GE358A7202P018
GE382A6121P003
GE382A6132P004
GE377A9477P003
GE377A9477P005
HF‐0803
HF‐0803
HF‐0803
HF‐0803
HF‐0803
GE359B2520
GE359B2520
GE359B2520
GE359B2520
GE359B2520

ThehydraulictoolusedforinstallationandremovalisRiverhawkHT‐0342.

ThesehardwaredrawingsdepictthecompletestudandnutpackagefortheLoadCouplingor
SteamTurbinetoGenerator(2‐3/4”size,Qty16).

2.6HydraulicTooling

GEPARTNUMBER RIVERHAWKP/N GEVENDOCP/N
GE358A7202P020
GE382A6121P006
GE377A9477P004
HT‐0342
HT‐0342
HT‐0342
GE359B2500
GE359B2500
GE359B2500


3.0QuickChecklist

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.

EQUIPMENTINSPECTION
□Checkoillevelinhydraulicpump.

InstructionManualIM‐125
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
373A4000
GEDRAWINGNUMBER

RevisionW
Page7of38

□Checkairpressureat80psi[5.5bar]minimum.(Forair‐drivenpumps)
□Checkhydraulichosefordamage.
□Testpump.
□nspecttensionerforanydamage.

NUTANDSTUDPREPARATION
□Inspectstudsandnutsforanydamage.
□Cleanthestudsandnuts.
□Measurestudlengths.(VERYIMPORTANT)
□Installstudsandnutsintotheflange.
□Setstick‐outdimensiononthecouplingsideoftheflange.
□Handtightennutsonturbine/generatorsideofflange.
□Verifystick‐outmeasurement(VERYIMPORTANT)

TENSIONING(BoltInstallation)
□Checktensionerdrawingforcorrectpartsandpartnumbers.
□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.
□Installthetensioneronthestudinflangeandslidespannerringontonut.
□Insert1/2”hexAllenwrenchintothebacksideofthestud.

InstructionManualIM‐125
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
373A4000
GEDRAWINGNUMBER

RevisionW
Page8of38

□Tightenthepullerscrew.Then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!
□Tensionto50%.Consultmanualforcorrectpressure.
□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the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!SeeinstructionmanualIM‐220.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.
□Installthetensioneronthestud.
□Installspannerringintonut.
□Tightenthepullerscrew.Thenbackoffpullerscrew1/2aturn.

InstructionManualIM‐125
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
373A4000
GEDRAWINGNUMBER

RevisionW
Page9of38

□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.
□Loosennutwiththespannerringandpinwrench.
□Movetonextstudinpattern


4.0GeneralPreparations

Readandunderstandallinstructionsbeforeinstallingandtensioningstuds.

OperatorsshouldbetrainedorhavepreviousexperienceusingRiverhawktensioning
equipment.Trainingwillminimizethechanceofimproperuseoftheequipment.

Thehydraulictoolingincludingthehydraulichosesshouldbeinspectedpriortouse.Inspection
guidelinesarelistedinthefollowingsub‐sections.

Thisequipmentproducesveryhighhydraulicpressuresandveryhighforces.Operatorsmust
exercisecautionandweartheappropriatepersonalprotectiveequipmentwhenhandlingand
operatingthehydraulictooling.

High‐pressureoilfromthehydraulicpumppressurizesthetensionerwhichgeneratesavery
largeforcethatactuallystretchesthestud.Asthestudisstretchedthenutliftsofftheflange.
Thenutisthenturnedbyhandusingthesuppliedspannerring.Oncethenutistightagainstthe
flange,thepressureinthetensionerisreleased.Thehardwareisnowclampingtheflange
together.

4.1MachinePreparation

Theflangetobetensionedmustbefullyclosedpriortopositioningofstudsintheflanges.
Turningtheturbineandgeneratorshaftsisnotrequired,butmaybeuseful.Also,itwillbe
advantageoustoremoveasmanyobstructionsaspossiblefromtheflangearea,suchasspeed
probes,shippingplates,andconduit.



InstructionManualIM‐125
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
373A4000
GEDRAWINGNUMBER

RevisionW
Page10of38

4.2Hardware–Balance

Hardwareissuppliedasweightbalancedsets.StudsandNutsareinterchangeablewithinsets.
Donotintermixsets.

Savetheweightcertificationsuppliedwitheachset.Itwillbeneededforthepurchaseof
replacementhardware.

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.

Seesection12forlongtermstoragerequirements.

4.4HandTools

Severalhandwrenchesandmicrometerswillberequiredtoperforminstallationand
measurementofthestuds:

5/8”wrench AsetofAllenWrenches  9”to10”micrometer
1”wrench 3’–4’BreakerBar   10”to11”micrometer

4.5SpecialTools

HydraulicTensionerKit: HT‐0342HydraulicTensioner
(referenceGEVENDOC359B2500)

ObsoleteHydraulicTensionerKits: HT‐0835HydraulicTensioner
(OBSOLETE,replacedbyHT‐0342)

HydraulicPumpKit: AP‐0532Air‐OperatedHydraulicPump
(recommended)
(referenceGEVENDOC359B2502)

InstructionManualIM‐125
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:[e-mail]


REV
373A4000
GEDRAWINGNUMBER

RevisionW
Page11of38

 MP‐0130ManualHand‐OperatedHydraulicPump
(referenceGEVENDOC359B2506)

CAUTION
RiverhawkrecommendsthatthetensionersbereturnedtoRiverhawkforperiodic
inspections.Replacementofobsoletetensionersisrecommended.Functionalupgradesare
alsorecommended.TheRiverhawkServiceReturnsCoordinatorshouldbenotified3‐6
monthspriortoaplannedoutagetoscheduleaninspectionservice.


5.0HardwareSetPreparations

5.1NutPreparation
















  Picture1.RiverhawkLocknut

Ifthereisanyvisibledamageonanut,donotusethenutandcontacttheRiverhawkCompany
forareplacementnut.Pleasebepreparedtosupplytheturbinenumber,weightcertification,
anddigitalphotographsforevaluation.

5.1.1NutCleaning‐NewInstallations

Fornewinstallations,thenutsshouldcomesealedfromthefactoryandwillneednocleaning.


Set Screw
1 of 2
Spanner
Ring Holes

InstructionManualIM‐125
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
373A4000
GEDRAWINGNUMBER

RevisionW
Page12of38

5.1.2NutCleaning‐OldInstallations

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.

5.1.3NutCleaning‐VeryOldInstallations

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.Finishthecleaningprocessby
rinsinginavolatilesolventsuchasacetoneandallowtodry.

RiverhawkCompanystronglyrecommendsreplacingthisstyleofnutwiththecurrentnutwith
are‐useablemechanicallockingfeature.

5.2StudPreparation

Checkthestudforanyvisibledamage.Ifthereisanyvisibledamage,donotusethestudand
contacttheRiverhawkCompanyforareplacementstud.Pleasebepreparedtosupplythe
turbinenumber,weightcertification,anddigitalphotographsforevaluation.

CAUTION
Itisespeciallyimportanttochecktheconditionoftheconicalthreadusedtotensionthe
stud.Threaddamagefrompreviousabusecanleadtofailureofthestudortensioning
equipment.

Theconicalthreadsofeachstudmustbecleanofgritanddirtbeforeinstallationorremoval.
Thisensurestheproperseatingofthepullerscrew.

5.2.1StudCleaning‐NewInstallations

Fornewinstallations,thestudsshouldcomesealedfromthefactoryandwillneednocleaning.

5.2.2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.

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CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL
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215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]
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

2. UseStudCleaningKit,GT‐4253orasimilar1"diameterBrasspowerbrush.


Picture2.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.

9. Donotapplythreadlubricantssuchas“NeverSeize”tothestud’sthreads.

10. Finishthecleaningprocessbyrinsinginavolatilesolventsuchasacetoneandallowto
dry.

5.2.3StudCleaning‐VeryOldInstallations

Ifpreviousinstallationemployedathreadlockingcompound,whichwillbevisibleasagrayish‐
greenresidue,removeasmuchofthiscompoundaspossiblefromthestud’s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suggestionswillimproveyour
results.

 Plantostartandfinishanyflangeinthesameday.

InstructionManualIM‐125
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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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
 Studsandflangemustbeatthesametemperature.
 Numbereachstudwithamarkerforlaterstretchmeasurementtracking.
 Markthelocationofmeasurementonstudendwithapermanentmarker.
 Measureeachstudtonearest0.001inch(.01mm).
 Recordeachmeasurementonthesuppliedrecordsheets.
 Donotallowthemeasuringinstrumentstositinthesun.
 Thesamepersonshouldmakeallmeasurements.


6.0StudandNutAssembly

RefertoHardwareSetPartNumberdrawinglistedinSection2.0ofthismanual.

Assemblethenuttotheconicalthreadend(TensioningEnd)ofthestud.

SlidetheassemblyintotheflangefromthecouplingsideasshowninFigures1&2(onthenext
page)theninstalltheothernutonthebackside.

ThenutsarethesameontheTurbineend(2.25”).ThenutsaredifferentontheGeneratorend
(2.75”);theshorternutgoesonthe“backside”orthesideclosesttotheGenerator.

Figure1–CutawayViewofTurbineFlange
andCouplingFlangeBoltedJoint

InstructionManualIM‐125
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CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL
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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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

Figure2–CutawayViewofGeneratorFlange
andCouplingFlangeBoltedJoint

Adjustthestud/nutassemblysothatthestudsticksoutfromthefaceofthenuttheamount
shownonthehardwaresetdrawing.Ifyoudon’thaveahardwaresetdrawing,itcanbe
foundintheGEVendocssystemorcontactRiverhawkCompany.(Seesection2)

SETTINGTHESTICK‐OUTLENGTHISCRITICALFORTHEHYDRAULICTENSIONERTOWORK
CORRECTLY.

THESTICK‐OUTLENGTHISALWAYSSETFROMTHECOUPLINGSIDEOFTHEFLANGE.

Thestick‐outlengthcanbecheckedthreedifferentways.

 
Stick‐OutGageDropGage

InstructionManualIM‐125
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CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL
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215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]
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


DigitalCalipers

SamplePicturesofaStick‐OutMeasurement

Handtightentheassemblytoasnugfit.SeePhotos1&2foraviewoftheassemblyofstuds
andnutsintheflangepriortotensioning.
 

CouplingSideTurbine/GeneratorSide
  Photo1 Photo2

InstructionManualIM‐125
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CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
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Tel:+13157684855
Fax:+13157684941
Email:[email protected]
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
7.0HydraulicTensionerEquipmentAssembly

7.1HydraulicEquipmentInspection

7.1.1HydraulicTensionerInspection

CAUTION
RiverhawkrecommendsthatthetensionerbereturnedtoRiverhawkforperiodicinspections.
Replacementofobsoletetensionersisrecommended.Functionalupgradesarealso
recommended.TheRiverhawkServiceReturnsCoordinatorshouldbenotified3‐6months
priortoaplannedoutagetoscheduleaninspectionservice.

Donotbleedtheairfromthehydrauliclinesandtensioneratthistime.Seesection8for
bleedinginstructionsonwhentobleedtheairfromthehydrauliclines.

WARNING
Toavoidfailure,ensuresafety,andproperoperation,thetensionerassemblymustbe
installedonastudintheflangebeforebleedingandpressurizingthetensioner.Donotuse
thetensioneratanypressureunlessthetoolisinstalledonastudinaflange.

CheckpullerscrewusagelifewithRiverhawkservicebulletinSB‐08001.

Cleanpullerscrewandcheckforanydebrisanddents.

Pullerscrewshouldbefreetorotateandmovebackandforth.

Seambetweencylindersclosedtightly.

Inspectthetensionerguardforanysignsofdamageincludingcrackedwelds.Anyguards
modifiedinthefieldshouldbereplaced.Bentguardsshouldbereplaced.Also,besurethe
rubberpadisinplaceontheendoftheguard,ifmissing,replace.

Inspecttheoutsideofthetensionerfordiscolorationpatternsthatmayindicatesubmersion
andinternaldamage.

Performaninventoryofthelooseequipmentsuppliedwiththetensioner.Aninventorylistis
providedonthetensioner’stechnicaldrawing(forexampleRiverhawkHT‐xxxx).Replacement
partsareavailablefromRiverhawk.


InstructionManualIM‐125
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CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL
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Tel:+13157684855
Fax:+13157684941
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
NOTE:PriortoSerialNumberS/N721theHT‐0342wassuppliedwithtwoadapterfeet.The
feetweremarked“TURBINE”and“GENERATOR”.Mounttheappropriatefootbefore
attemptinguseofthetensioner.

7.1.1.1HydraulicTensioner’sBurstDiscReplacement

Thehydraulictensioner’sburstdiscisakeyelementintheoverallsafeuseofthehydraulic
tensioner.

Eachtensionerisshippedfromourfactorywithoneburstdiscalreadyinstalledinthetensioner
andwithanothersparediscforfieldreplacement.Extraburstdiscsareavailablefrom
Riverhawkforreplacementpurposes.

Toreplaceadamagedburstdisc:
1. Removethehydraulicport’sdispersionnut,compressionring,anddamagedburstdisc.
2. Discardthedamagedburstdisc.
3. Cleanthedispersionnut,compressionring,newburstdisc,andthehydraulicportwitha
solventtoensureadirt‐freeinstallation.
4. Reassemblenewburstdisc,compressionring,anddispersionnutintothesame
hydraulicport.

Warning
Adamagedburstdiscmustbereplacedwithawithaburstdiscofthesamedesignand
pressurerating.Donotsubstituteadamagedburstdiscwithadifferentdisctype,adifferent
pressurerating,oraforeignobject.

7.1.2HydraulicPumpKitInspection

RefertotheHydraulicPumpKitInstructionManual,IM‐293(GEVENDOC373A4058).Thelatest
revisionmaybeobtainedbycontactingRiverhawkCompanyorthruwww.riverhawk.com.



InstructionManualIM‐125
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CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL
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215ClintonRoad
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Tel:+13157684855
Fax:+13157684941
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7.2HydraulicFittings


Illustration1
Riverhawktensionersusea1/4”HighPressure
porttoconnectitshydraulichoses.Thehose
connectorismadefromathreepieceassembly:a
glandnut,acollar,anda1/4”tubeor1/4”hose
end.(SeeIllustration1)

Toassemblythefitting,slidetheglandnutover
the1/4”tubeor1/4”hoseend.Turnthecollar
counter‐clockwise(lefthandthread)ontothe
tubeorhoseendasshowninIllustration1.


Illustration2


Thecollarshouldbeplaced.125”(3.2mm)from
thetipofthecone.(SeeIllustration2)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.






Illustration3
Slidetheglandnutdownoverthecollar.(See
Illustration3)Insertthe1/4”tubeor1/4”hose
endintotensionerorhydraulicpump.Whilefirmly
holdingthetubeorhoseendtostopitfrom
rotating,turntheglandnutclockwise(righthand
thread)andtorquetheglandnutto25FT‐LBS(34
N‐m).

Tips:
 Makesureallpartsarecleanandfreefrom
debris.
 Protecttheconeontheendofthe1/4”tube
or1/4”hoseendfromscratchesasthisisthe
sealingsurface.
 Replaceredplasticcapswhenfinishedto
protectthethreadsandcone.


InstructionManualIM‐125
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL
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Page20of38
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8.0AssemblyofTensioneronaStud
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8.1HandlingoftheTensioner

Restthetensionerontopofthecouplingshaft.Usingastrapjustlongenoughtogoaroundthe
couplingshaft,attacheachendtothehandlesofthetensioner.Onewaytodothisistoattach
thestrapbyloopingthestrapthroughitselfaroundthehandleofthetensionerononeside
thenaroundthecouplingshaftandfinallyattachedtothehandleontheothersidewithaD‐
shackle.Thiswillhelpholdthetensionerinplaceshoulditfalloffoftheshaft.Thestrapalso
helpstheoperatorsmovethetensioneraroundtheshaftwhiletensioning.

Ifpossible,usea‘Come‐along’orchainfallfromtheceilingofthecouplingroomandattachit
tothetensionerusingashortstrapwrappedthroughthehandlesandaroundthetopofthe
tensioner.Thiswillallowtheoperatorstoeasilymovethetensioneraroundthecouplingshaft
bysupportingtheweightofthetool.

8.2KitAssembly

Assemblethehydraulicpumpwithitshosetothetensionerandbleedouttheairperfollowing
instructionsinsection8.3.

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.

RefertoTensionerAssemblydrawingandphotoforviewsofthetensionertoflangemounting.
Alltensioningwillbeperformedonthecouplingsideoftheflangeconnections.

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