riverhawk IM-164 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C
Page1of34
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INSTRUCTIONMAUALIM‐164

ForSteamTurbineTensionedStudsandNuts


ApplicableEquipment
SteamTurbineto109FBCouplingand
109FBCouplingto450HGenerator

FORGE382A6118P001,
382A6118P002
SteamTurbinetoLoadCouplingand
LoadCouplingto450HGenerator

FORGE389A6185P001


 
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
373A4011
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makechangesupdatingthisdocumentwithout
dissemination or notice. The latest revision level may be obtained by contacting Riverhawk
Companydirectlyorvisitourwebsiteatwww.riverhawk.com

InstructionManualIM‐164
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
373A4011
GEDRAWINGNUMBER
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RevisionC
Page2of34
TableofContents

Section Description PageNumber
1.0 CautionsandSafetyWarnings 3
2.0 Scope 3
3.0 QuickCheck‐List 4
4.0 GeneralPreparations 7
5.0 HardwareSetPreparations 8
6.0 StudandNutAssembly 11
7.0 AssemblyofHydraulicTensionerEquipment 12
8.0 AssemblyofTensioneronStud 18
9.0 StudPullingandTensioning 17
10.0 ThreadLocking 18
11.0 Stud/NutRemoval 19
12.0 StorageInstructions 21
13.0 FrequentlyAskedQuestions 23
14.0 RevisionHistory 25
AppendixA1 ECDeclarationofConformity 26
AppendixA2 UKCADeclarationofConformity 27


InstructionManualIM‐164
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
373A4011
GEDRAWINGNUMBER
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RevisionC
Page3of34
1.0CautionsandSafetyWarnings

WARNING
TOAVOIDFAILURE,ENSURESAFETYANDPROPEROPERATIONTHETENSIONERASSEMBLY
MUSTBEMOUNTEDONTHESTUDBEFOREBLEEDINGTHESYSTEMANDTENSIONINGBEGINS.
DONOTUSETHETENSIONERASSEMBLYATANYPRESSUREUNLESSTHETOOLISMOUNTEDON
THESTUD.

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.

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.

CAUTION
DONOTEXCEEDTHEMAXIMUMPRESSUREVIBROSCRIBEDONTHEPULLERBODY.Excessive
pressurecandamagethestudandthepullerscrew.

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.

CAUTION
DONOTEXCEEDTHEMAXIMUMPRESSUREVIBROSCRIBEDONTHEPULLERBODY.Excessive
pressurecandamagethestudandpullerscrew

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.


2.0 Scope

Thisdocumentdescribesthestepstoinstallasetofhardwarecontainingthestudsandnuts
suppliedbyRiverhawkCompanyintheloadcouplingflangesattheturbinetocouplingand
couplingtogeneratorconnections.

InstructionManualIM‐164
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
373A4011
GEDRAWINGNUMBER

RevisionC
Page4of34
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Thishardwaresetisshownonthefollowingdrawing.Thisdrawingaswellastheinstallation
toolingdrawingformapartofthismanual.

GEPurchasing
OrderingPart
Number
GEHardwareSet
DrawingNumber
Riverhawk
HardwareSet
PartNumber Description
382A6118P001#
382A6118P002 359B2549 HF‐2658
1‐1/8"HardwareSetforSteam
TurbinetoCouplingto
Generator(bothendsofload
coupling)
389A6185P001 359B2549 HF‐2658
1‐1/8"HardwareSetforSteam
TurbinetoCouplingto
Generator(bothendsofload
coupling)

#denotesGEpartnumbersthatincludeinstallationtooling


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.
□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.

InstructionManualIM‐164
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
373A4011
GEDRAWINGNUMBER
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RevisionC
Page5of34
NUTANDSTUDPREPARATION
□Inspectstudandnutsforanydamage.
□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andinstallspannerringontonut.
□Insert1/2”hexAllenwrenchintothebacksideofthestud.
□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.
□Tightenpullernutandthenbacknutofftwoflatsor120degreestoallowforstudstretch.

InstructionManualIM‐164
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
373A4011
GEDRAWINGNUMBER

RevisionC
Page6of34
□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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.Thenbackoffpullerscrew1/2aturn.
□Retightenthepullerscrewandleavetight.DONOTBACKOFFPULLERSCREW.
□Tightenpullernutandthenbacknutofftwoflatsor120degreestoallowforstudstretch.

InstructionManualIM‐164
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
373A4011
GEDRAWINGNUMBER

RevisionC
Page7of34
□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.

Thisequipmentproducesveryhighhydraulicpressuresandveryhighforces.Operatorsmust
exercisecautionandwearpersonalprotectiveequipment(PPE)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.
Turningtheshaftsoftheturbineandthegeneratorare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.

4.2Hardware–Balance

 Hardwareissuppliedinweightbalancedsets
 StudsandNutsareinterchangeablewithinsets
 Donotmixwithothersets
 Saveweightcertificationdatasuppliedwitheachsetforpurchaseofspares



InstructionManualIM‐164
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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4.3Tensioner–CareandHandling
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 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.
 Wheninuse,thetensionershallbeprotectedfromsandandgrit.
 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
15/16"wrench
1”wrench
AsetofAllenWrenches
3’–4’BreakerBar[3m]
5”to6”micrometer[100mm–200mm]

4.5SpecialTools

HydraulicTensionerKit: HT‐2569HydraulicTensioner,1‐1/8”
(recommended)
(referenceGE359B2548)

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


InstructionManualIM‐164
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]

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REV
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5.1NutPreparation
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SamplePictureofa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.

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.

5.2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.

Theconicalthreadsofeachstudmustbecleanbeforeinstallationorremoval.Thisensuresthe
properseatingofthepullerscrew.

Set Screw
1 of 2
Spanner
Ring Holes

InstructionManualIM‐164
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
373A4011
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5.2.1StudCleaning‐NewInstallations
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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.

2. UseStudCleaningKit,GT‐4354orasimilar1/2"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.
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5. Blowoutthethreadswithcompressedairtoremovelooseneddebris.
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6. Visuallyinspectthreadsforcleanliness.Threadsshouldbebrightandshiny.
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7. Repeatifanydirtcanbeseeninthethreads.
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8. Inspectthreadsforanydamagethatmayhavebeencausedbypreviousinstallation.

Donotapplythreadlubricantstothethreads.

InstructionManualIM‐164
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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Finishthecleaningprocessbyrinsinginavolatilesolventsuchasacetoneandallowtodry.
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5.3StudLengthMeasurement
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Measureandrecordtheinitiallengthofthestuds.Thefollowingsuggestions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the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.
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6.0StudandNutAssembly
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RefertotheHardwareAssemblyDrawing(HF‐2658)listedinSection2.0ofthismanual.

1. Assemblethenuttotheconicalthreadend(TensioningEnd)ofthestud.

2. Slidethestudandnutassemblyintotheflangefromthecouplingsideasshownin
Figure1.Theninstalltheothernutonthebacksideoftheflange.

3. 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.
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4. Hand‐tightentheassemblytoasnugfit.


InstructionManualIM‐164
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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Figure1–SectionViewofaHardwareSet


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.
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Cleanpullerscrewandcheckforanydebrisanddents.

Pullerscrewshouldbefreetorotateandmovebackandforth.

Inspecttensionerguardforanysignsofdamage.Bentguardsshouldbereplaced.


InstructionManualIM‐164
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
373A4011
GEDRAWINGNUMBER
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Page13of34
7.1.1HydraulicFittings


Illustration1
TheRiverhawkhydraulichosemayusea1/4"High
PressureFittingtoconnecttoatensioner.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‐164
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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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7.2CheckHydraulicPumpKit
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Thepumpkitisshippedfullofhydraulicoil.Thepumpreservoircapissealedforshipment.

Replacethegreyshippingcapwiththeredplasticreservoircap.

Tousethepump,turncaptotheventpositionandfollowtheoperatinginstructionsonthe
insidecover.

Topreventoilspillage,closecapwhennotinuse.LostoilshouldbereplacedwithEnerpac
HydraulicOil.ISO32orequivalenthydraulicoilmaybesubstituted.

Testpumpbydead‐heading(leaveportpluginplace)andrunpump–shouldholdsteady
pressure.



SamplePictureofAP‐0532HydraulicPumpwithhydraulicconnectionpluggedfortesting

InstructionManualIM‐164
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
7.3BleedingHydraulicSystem

FollowthetensionerassemblyinstructionsofSection8.0.

WARNING
TOAVOIDFAILURE,ENSURESAFETYANDPROPEROPERATIONTHETENSIONERASSEMBLY
MUSTBEMOUNTEDONTHESTUDBEFOREBLEEDINGTHESYSTEMANDTENSIONINGBEGINS.
DONOTUSETHETENSIONERASSEMBLYATANYPRESSUREUNLESSTHETOOLISMOUNTED
ONTHESTUD.

1. MounttensioneronastudpertheassemblyinstructionsofSection8.0.Makesurethe
pumpissituatedbelowthetensionerassembly.
2. Thetensionerassemblyhastwoports,oneforpressurizingandoneforbleedingthe
system.Theseportsserviceacommonchamberandthereforemaybetreated
interchangeability.Thebleedportmustalwaysbeorientedintheuppermostposition.
3. Thepullertoolisshippedwitha5/8in.[16mm]hexconedstembleederfitting
installed.Withthisfittingloosened,strokethepumprepeatedlyuntilthestreamofoil
exitingthetoolisfreeofairthenretightenthefitting.

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duringuse.


8.0AssemblyofTensioneronStud

Alltensioning(pulling)willbeperformedfromthetaperedthreadendofthestudwith
orientationofthestudtotheflangeasshowninFigure1.

8.1AssemblyofTensionerwithIntegralSafetyCage

RefertoTensionerAssemblydrawingandFigure7(attheendofthismanual)fortensionerto
flangemounting.Thisassemblyhasthefollowingfeatureswhichshouldmakestudtensioning
saferandeasier.

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.Thisrequiresthattheoperatortightenthepullerscrew
intothestudandtheninstallapullernut.

InstructionManualIM‐164
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Assemblysequenceisasfollows:

1. Openthehydraulicreturnvalveonthepumptoallowhydraulicfluidtobepushedback
fromthepullertoolintothepumpreservoir.(Thisisautomaticon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pullertoolovertheendtobetightened.
5. Insertthepullerscrewthroughthepullertoolintothetaperedthreadofthestudand
tighten.
6. Besurenottocross‐threadtheassembly.
7. TightenthepullerscrewusingAllenwrenchesonthepullerscrewandthestud.DONOT
wrenchontheHexnutoppositethepullertool.
8. Installthepullernutuntilitseatssnuglyonthepistonandthenback‐off2flats.Thisis
particularlyimportantforremovalbecausethestudshortensduringdisassemblyandthe
tensionermaythenbind.
9. AtthispointtheTensionerAssemblyMUSTBEFREETOROTATE,thepullerscrewistightin
thestudandthepullernuthasbeenbacked‐offthe2flats.

Note:Ifthetoolisnotfreetorotateitismostlikelythatthenutsmustberepositionedsothat
thestudmaybeshiftedslightlytothepullertoolsideoftheflange.Thiscanbeaccomplishedas
follows:

1. Backoffthepullernutandslightlyloosenthepullerscrew.
2. BackofftheHexnutoppositethepullertoolabout1/2turn.
3. Tightenthepullerscrewsidecylindricalnuttotakeuptheslack
4. Retightenthepullerscrewperaboveandcheckfortoollooseness

Caution:Donotoverextendthestud.Overextensioncancausethepistontoloseitssealand
leakoil.



InstructionManualIM‐164
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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.


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.

FlangePosition StudSize 50%Pressure 50%Stretch
TurbinetoCoupling 1‐1/8”
[29mm]
9000psi
[620bar]
Donotmeasure
Donotuse
CouplingtoGenerator 1‐1/8”
[29mm]
9000psi
[620bar]
Donotmeasure
Donotuse

9.1.1Tighteningof11/8”Nuts
Tightenthecylindricalnutshandtightusingthepinwrenchandspannerring,ref.Figure7.



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9.2RemovingtheTensionerfromanInstalledStud

Pullertoolremovalistobeaccomplishedasfollows:

1. Releasethepullertoolpressurebyopeningthevalveonthepump.Leave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 1‐1/8”
[29mm]
18000psi
[1250bar]
0.009"‐0.011"
[0.23mm‐0.28mm]
CouplingtoGenerator 1‐1/8”
[29mm]
18000psi
[1250bar]
0.009"‐0.011"
[0.23mm‐0.28mm]

CAUTION
DO NOT EXCEED THE MAXIMUM PRESSURE VIBROSCRIBED ON THE PULLER BODY. Excessive
pressurecandamagethestudandpullerscrew.

Excessivestretchvariations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completedallstudnutsmustbelockedinposition


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10.1ThreadLockingUsingaMechanicalLockingDevice.















SamplePictureofaRiverhawkLocknut

Mechanicallocknutshavetwosetscrewslocatedinthetopface,seepicture.Beforethreading
thenutontothestudchecktobecertain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
1‐1/8”
[29mm] #10‐32UN 30in∙lbs‐36in∙lbs
[3.4N∙m–4.1N∙m]


11.0Stud/NutRemoval

Section12.1describestheprocedurestobefollowedinremovingnutsthathavebeenlocked
withmechanicallockingfeature.

11.1RemovalofAssemblieswithMechanicalLocknuts

Forthoseassemblieswhichhavebeenlockedwiththeliquidlockingcompound,removalis
accomplishedasfollows:
Set Screw
1 of 2
Spanner
Ring Holes

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1. Usingawirebrushandshopaircleantheinternaltaperedthreadofthestudtoremoveany
debris/depositsthatmayhaveaccumulatedduringservice.(seesection5.2.2)
2. InstalltheappropriatepullertooltothestudasdescribedinSection.8.0.
3. Applyhydraulicpressureperthefollowingtableandwithoutusingunreasonableforce
attempttoloosenthenutusingthespannerringandspannerwrenchasshowninFigure7.

FlangePosition StudSize FinalPressure
TurbinetoCoupling 1‐1/8”
[29mm]
18000psi
[1250bar]
CouplingtoGenerator 1‐1/8”
[29mm]
18000psi
[1250bar]

CAUTION
DONOTEXCEEDTHEMAXIMUMPRESSUREVIBROSCRIBEDONTHEPULLERBODY.Excessive
pressurecandamagethestudandthepullerscrew.

11.2RemovalofAssemblieswithMechanicalLocknuts

Forthoseassemblieswhichhavebeenlockedusingmechanicallocknuts,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5.2.2)
WithanAllen‐wrenchloosenthetwolockingsetscrewsbutdonotremovefromnut.



SamplePictureofthelooseningofanut'ssetscrews