riverhawk IM-257 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
Page1of37
WARNING:THISMANUALISONLYFORHYDRAULIC
TENSIONERSWITHTHEORANGESAFETYGUARD.
DONOTUSEIFTHEGUARDISADIFFERENTCOLOR.


INSTRUCTIONMANUALIM‐257
ForHydraulicallyTensionedStudsandNuts

ApplicableBoltingConnections
Fr.7FAGasTurbinetoLoadCoupling
Fr.7FBGasTurbinetoLoadCoupling
LoadCouplingto7FH2Generator
SteamTurbineto7FH2Generator

ApplicableGEOrderingSheetPartNumbers
101T3628P001
101T3628P002
101T3628P003
101T3628P004
101T3628P005
101T3628P0006
101T3628P0007
377A9477P001
377A9477P002
377A9477P003

361A5218P001
358A7202P001
358A7202P002
358A7202P012
358A7202P018
358A7202P020
358A7202P031
358A7202P032

 
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INDI CATEDINTHISVENDORSUPPLIEDDRAWINGAPPLIQUE.
REV
373A4035
GEDRAWINGNUMBER
VENDORSUPPLIED
THISDOCUMENTISFILEDUNDERTHEGEDRAWINGNUMBER.
GENOTTOREVISE.GEREVISI ON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 at our website
www.riverhawk.com.

InstructionManualIM‐257
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
373A4035
GEDRAWINGNUMBER

RevisionH
Page2of37
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Check‐List 6
4.0 GeneralPreparations 10
5.0 HardwareSetPreparations 12
6.0 NutandStudAssembly 15
7.0 HydraulicEquipmentPreparations 18
8.0 AssemblyofTensioneronStud 19
9.0 StudPullingandTensioning 22
10.0 ThreadLocking 24
11.0 Stud/NutRemoval 25
12.0 Storage 27
13.0 FrequentlyAskedQuestions 28
14.0 RevisionHistory 30
AppendixA1 ECDeclarationofConformity 31
AppendixA2 UKCADeclarationofConformity 32
AppendixB1 HydraulicFittings 33
AppendixB2 PullerScrewReleaseTape 34
AppendixB3 HydraulicTensioner’sBurstDiscReplacement 35

InstructionManualIM‐257
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
373A4035
GEDRAWINGNUMBER

RevisionH
Page3of37
AppendixC1 18‐BoltTensioningPattern(GT‐LC)RecordSheet 36
AppendixC2 16‐BoltTensioningPattern(LC‐GEN)RecordSheet 37


1.0CautionsandSafetyWarnings

NOTICE
Asofsummer2011,thismanualistobeusedinrelationtotheinterlockingstyletensioner.This
new tensioner can be identified buy its ORANGE safety guard.  Note: yellow guarded tensioner
requirestheuseofdifferentsetofinstructions,consultRiverhawkforassistance

TOAVOIDFAILURE,ENSURESAFETYANDPROPEROPERATIONTHETENSIONERANDINERLOCK
SAFETYGUARDMUSTINSTALLEDONTHEFLANGEBEFORETENSIONINGBEGINS. DO NOT USE
THETENSIONERASSEMBLYATANYPRESSUREUNLESSTHETOOLISINSTALLEDONTHEFLANGE.

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fluidinjection.Riverhawktoolsoperateunderhighpressure.Thoroughlyinspect
allhosesandconnectionsfordamageorleakspriortousingthisequipment.

CAUTION
Personalinjuryandequipmentdamagecanoccurifthepullerscrewisnotsecurelyengagedwith
theconicalthreadofthestud.Properengagementisachievedwhenthepullerscrewistightinthe
studandisnotcross‐threadedintotheconicalthread.

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.



InstructionManualIM‐257
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
373A4035
GEDRAWINGNUMBER

RevisionH
Page4of37
WARNING
Thesafetyguard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MARKEDONTHETENSIONER.Excessivepressurecan
damagethestudandthepullerscrew.

WARNING:
Keephandsclearofthetoolwhilethepressureisbuildingup.Thisincludesthepinwrenchfor
tighteningthespannerring(nut).Oncethetoolisstabilizedatpressurethenandonlythencanthe
nutbetightened.Thisreducesthepotentialofpersonalinjury.

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 at the turbine/coupling and coupling/generator connections.
Thishardwareisdepictedonthefollowingdrawings.Thesedrawingsaswellastoolingdrawings
formpartofthismanual.

Riverhawk
HardwareSetPart
Number
GEDrawing
Numberfor
HardwareSet
GEOrderingSheet
PartNumber
HardwareSet
Description
HF‐0771 359B2514 101T3628P001
101T3628P002#
2‐1/4"hardwarefortheturbine
endand2‐3/4"hardwareforthe
generatorendforthe7FA/7FB
loadcoupling.
HF‐2447 359B2539 101T3628P004
2‐1/4"hardwarefortheturbine
endforthe7FA/7FBload
coupling.

InstructionManualIM‐257
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
373A4035
GEDRAWINGNUMBER

RevisionH
Page5of37
HF‐0803 359B2520
101T3628P005
101T3628P0006
101T3628P0007#
2‐3/4"hardwareforthe
generatorendofthe7FA/7FB
loadcouplingandforthesteam
turbineto7FH2generator
connection.

#denotesGEpartnumbersthatincludehydraulictooling

Hydraulictensionerswithsafetyinterlock(seesection4.5)canalsobeusedwithothertensioned
hardwaresets.

Riverhawk
HardwareSetPart
Number
GEDrawing
Numberfor
HardwareSet
GEOrderingSheet
PartNumber
HardwareSet
Description
HF‐0771 359B2514
358A7202P001
358A7202P012#

361A5218P001

377A9477P001
377A9477P002#
2‐1/4"hardwarefortheturbineend
and2‐3/4"hardwareforthe
generatorendforthe7FA/7FBload
coupling.
HF‐2447 359B2539 358A7202P031#
358A7202P032
2‐1/4"hardwarefortheturbineend
forthe7FA/7FBloadcoupling.
HF‐0803 359B2520
358A7202P018
358A7202P020#

377A9477P003#
2‐3/4"hardwareforthegenerator
endofthe7FA/7FBloadcouplingand
forthesteamturbineto7FH2
generatorconnection.
HF‐0769
(OBSOLETE) 359B2501 358A7202P002
2‐1/4"hardwarefortheturbineend
and2‐3/4"hardwareforthe
generatorendforthe7FA/7FBload
coupling.Thesetincludeswindage
covers.
HF‐0338
(OBSOLETE)  358A7202P001
2‐1/4"hardwarefortheturbineend
and2‐3/4"hardwareforthe
generatorendforthe7FAload
coupling.

InstructionManualIM‐257
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
373A4035
GEDRAWINGNUMBER

RevisionH
Page6of37
HF‐0372
(OBSOLETE)  358A7202P002
2‐1/4"hardwarefortheturbineend
and2‐3/4"hardwareforthe
generatorendforthe7FAload
coupling.Thesetincludeswindage
covers.

#denotesGEpartnumbersthatincludeolderinstallationtoolingthatdonotincludeabuilt‐insafety
interlock.


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anydamage.
□ Testpump.
□ Inspect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)

InstructionManualIM‐257
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
373A4035
GEDRAWINGNUMBER

RevisionH
Page7of37
□ 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(StudInstallation)
□ Checktensioner’s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.
□Installspannerringontothenut.
□ Installonepullerscrewreleasetapestripintostud.(AppendixB2)
□Threadpullerscrewontothestud.
□InsertAllenwrenchintothebacksideofthestudtostopthestudfromrotatingwhen
installingthepullerscrew.
□UsinganAllenwrench,tightenthepullerscrew.Thenbackoffpullerscrew1/2aturn.
□Retightenpullerscrewbyhanduntilitisfullyinserted.DONOTBACKOFFPULLERSCREW.
□Slidefootoverthepullerscrewandorientateintoposition.
□Threadthetensionerontopullerscrew.Lightlyturnthetensionerontothepullerscrew
untilitstops.Thegapbetweenthefootandtensionerisabout1/16”to3/16”
□Placeguardovertensionerandpositionguidepinintotheholeinthebacksideofthestud.

InstructionManualIM‐257
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CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

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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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□Tightenknurledinterlockfittingbyhanduntilitpressesfirmlyagainsttensioner.(nogap)
□Slideandengagecustomerconnectorfromrearofguardtolocktensionerintoplace.
□Tensionto50%.Consultmanualforcorrectpressure.
□Usethepinwrenchinthespannerringtotightennut.
□Releasepressureandallowthetensionertofullyretract.
□Disconnectthehosefromthetensioner.
□Loosentheknurledfittingandremovethesafetyguard.
□
Unscrewthetensionerfromthepullerscrew.Usecautiontoensurethathandsarenot
betweenthetensionerandthecouplingwhenthetensionerbecomesdisengagedfrom
thepullerscrew.
□Removethefoot.
□Removethepullerscrewfromthestud.
□Removethespannerringfromthenutandmovetothenextstudinthepattern.
□Tensionallstudsto50%beforeproceedingtofinalpressure.
□ Repeattheabovestepsatthefinalpressure.
□ Measurethefinalstudlengthandrecordonthestretchdatasheets.Calculatethestretch
andverifypersection9.2
□ Torquethenuts’setscrewspersection10



InstructionManualIM‐257
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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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REV
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Detensioning(StudRemoval)
□ Loosenthenuts’setscrews
□
Inspectandcleanstuds’conicalthreads.DonotcontinueuntilALLdebrisisremoved
fromthethreads!Referto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.
□Installthespannerringontothenut.
□Threadthepullerscrewontothestud.
□UsinganAllenwrench,tightenthepullerscrew.Thenbackoffthepullerscrew1/2aturn.
□Lightlyretightenthepullerscrewbyhanduntilitisfullyinserted.DONOTBACKOFFTHE
PULLERSCREW.
□Slidethefootoverthepullerscrewandorientateintoposition.
□Threadthetensionerontothepullerscrew.Lightlyturnthetensionerontothepuller
screwuntilitstops.Thegapbetweenthefootandtensionerisabout1/16”to3/16”.
□Placethesafetyguardoverthetensionerandpositiontheguidepinintotheholeinthe
backsideofthestud.
□Tightentheknurledinterlockfittingbyhanduntilitfirmlypressesagainstthetensioner.
(nogap).
□Slideandengagethecustomconnectorfromtherearofthesafetyguardtolockthe
tensionerintoplace.
□Applythefinalpressure.
□Loosenthenutwiththespannerringandpinwrench.

InstructionManualIM‐257
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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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REV
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□Releasethehydraulicpressureandallowthetensionertofullyretract.
□Disconnectthehosefromthetensioner.
□Loosentheknurledfittingandremovethesafetyguard.
□
Unscrewthetensionerfromthepullerscrew.Usecautiontoensurethathandsarenot
betweenthetensionerandcouplingwhentensionerbecomesdisengagedfromthepuller
screw
□Removethefoot
□Removethepullerscrewfromthestud.ItmaybenecessarytoinsertandanAllenwrench
intothebacksideofthestudtoremovethepullerscrew.
□Removethespannerringfromthenut.
□Movetothenextstudinthe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,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spannerringwiththe
pinwrench.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

InstructionManualIM‐257
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CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL
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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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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asweightbalancedsets.StudsandNutsareinterchangeablewithinaset.Do
notmixstudandnutsfrommultiplesets.

Savetheweightcertificationthatis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withallcapsandplugs
forhydraulicopeningsandfittingsinplace.

UseISO32gradeoil.

Wheninuse,thetensionershallbeprotectedfromsandandgrit.

4.4HandTools

Severalhandwrenchesandmicrometersmayberequiredtoperforminstallationand
measurementofthestuds:

5/8”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‐5222HydraulicTensioner
(forcounterboreflanges)
(referenceGE269B8697)

InstructionManualIM‐257
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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:[e-mail]
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
REV
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 HT‐7591HydraulicTensioner
(forcounterboreflanges)

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PreparationofHardware

5.1NutPreparation













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.

Set Screw
1 of 2
Spanner
Ring Holes

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Tel:+13157684855
Fax:+13157684941
Email:[email protected]
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GEDRAWINGNUMBER
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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

Obsoletehardwaresetsemployedathread‐lockingcompoundwhichisvisibleasagrayish‐green
residue.

RiverhawkCompanystronglyrecommendsreplacingthistypewiththecurrentnutthathasare‐
useablemechanicallockingfeature.

SpecialinstructionsareavailablefromRiverhawkifithasbeendecidedtocontinuetousethe
obsoletehardware.

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.

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willrequirecleaning.Cleanconicalthreadsshouldhaveabrightand
shinyappearance.

Notice:
Failuretoproperlycleanthestudscouldresultinimpropermatingofthreads.Personalinjuryand
equipmentdamagecanoccurifthepullerscrewisnotsecurelyengagedwiththetaperedthread
ofthestud.


InstructionManualIM‐257
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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Ifcleaningisrequired,followthesesteps:

1. Blowoutthethreadswithcompressedairtoremoveloosedebrisanddryconicalthreads.
ReferenceinstructionmanualIM‐220formoredetailedinstructions.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.

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.

5.2.3VeryOldInstallations

Obsoletehardwaresetsemployedathread‐lockingcompoundwhichisvisibleasagrayish‐green
residue.

RiverhawkCompanystronglyrecommendsreplacingthistypewiththecurrenthardwarethathas
are‐useablemechanicallockingfeature.


InstructionManualIM‐257
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
373A4035
GEDRAWINGNUMBER
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SpecialinstructionsareavailablefromRiverhawkifithasbeendecidedtocontinuetousethe
obsoletehardware.

5.3StudLengthMeasurement

MeasureandrecordtheinitiallengthsofthestudsonthesuppliedstretchdatasheetinAppendix
Cofthismanual.

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.
 Keepthemeasuringinstrumentsoutofthesunlight.
 Numbereachstudwithamarkerforlaterstretchmeasurementtracking.
 Markthelocationofmeasurementonstudendwithapermanentmarker.
 Thesamepersonshouldmakeallmeasurements.
 Measureeachstudtonearest0.001inch(.01mm).
 Recordeachmeasurementonthestretchrecordsheetsinthismanual'sappendix.


6.0StudandNutAssembly

RefertoHardwareSetPartNumberdrawinglistedinSection2.0ofthismanual.Ifyoudon’thave
ahardwaresetdrawing,itcanbefoundintheGEdrawingsystemorcontactRiverhawkCompany.

Assemblethenuttotheconicaltensioningthreadend(frontside)ofthestud.

SlidetheassemblyintotheflangefromthecouplingsideasshowninFigures1&2theninstallthe
othernutonthebackside.

Ensurethatbackside’snutorientationiscorrectwiththreadlockingscrewsfacingoutwardofthe
flange.

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.


InstructionManualIM‐257
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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373A4035
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

Figure1–CutawayViewofTurbineFlange
andCouplingFlangeBoltedJoint


Figure2–CutawayViewofGeneratorFlange
andCouplingFlangeBoltedJoint

Adjustthefrontside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drawingsystemorcontactRiverhawkCompany.(Seesection2)


InstructionManualIM‐257
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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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



DigitalCalipers

SamplePicturesofaStick‐OutMeasurement

Handtightentheassemblytoasnugfit.SeeFigures1&2foraviewoftheassemblyofstudsand
nutsintheflangepriortotensioning.


InstructionManualIM‐257
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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
7.0HydraulicEquipmentPreparations

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.

Thistensionerdoesnotrequiretheairtoberemoved(orbled)fromitshydraulics.Thishasbeen
doneatthefactory.

WARNING
Toavoidfailure,ensuresafety,andproperoperation,thetensionerassemblymustbeinstalled
onastudintheflangebeforepressurizingthetensioner.Donotusethetensioneratany
pressureunlessthetoolisinstalledonastudinaflange.

Cleanpullerscrewandcheckforanydebrisanddents.

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.Iftheguardhasrubberparts,they
shouldbeingoodcondition.Anymissingrubberpartsneededtobereplaced.

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(RiverhawkHT‐xxxxlistedinsection2.0and4.5).
ReplacementpartsareavailablefromRiverhawk.

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.Theburstdisc’slocationisshownonthetensioner’stechnicaldrawing(RiverhawkHT‐
xxxxlistedinsection2.0and4.5).

InstructionManualIM‐257
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
373A4035
GEDRAWINGNUMBER
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RevisionH
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
BurstdiscreplacementinstructionsareshowninAppendixB3orrefertoRiverhawkInstruction
ManualIM‐363(GEVENDOC373A4077)formoreinformation.

Warning
Adamagedburstdiscmustbereplaced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.

7.1.3HydraulicHoseInspection

Checkthehydraulichoseforanydamageincludingbenthoseendsandsplitouterlining.Ifany
damagedisfound,replacethehoseimmediatelybycontactingtheRiverhawkCompany.

7.2HydraulicFittings

Informationonthecorrectassemblyofthehydraulicpump’sandhydraulichose’shydraulic
fittingscanbefoundinAppendixB1.

7.3BleedingHydraulicSystem

Bleedingofthehydraulicsystemisnotnecessarywiththistensionerdesign.


8.0AssemblyofTensioneronStud

ThistensionerkitismostreadilyidentifiedbythesafetyORANGEcages(guardassembly)they
employ.

NOTICE
Asofsummer2011,thismanualistobeusedinrelationtotheinterlockingstyletensioner.This
new tensioner can be identified buy its ORANGE safety guard.  Note: yellow guarded tensioner
requirestheuseofdifferentsetofinstructions,consultRiverhawkforassistance.


InstructionManualIM‐257
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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Alltensioningwillbeperformedfromtheconicaltensioningthreadendofthestudwith
orientationofthestudtotheflangeasshowninFigures1&2.

8.1AssemblyofTensionerKitwithORANGESafetyGuard

RefertoTensionerdrawingandFigure4fortensionertoflangemounting.Assemblysequenceisas
follows:
1. Carefullycheckthecleanlinessofboththestud'sandthepullerscrew'sconicalthreads.
2. Ensurestudlengthmeasurementisdocumented.
3. Verifystickoutlengthofstudtonut.
4. 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.
5. Placethespannerringontothenut
6. Installonepullerscrewreleasetapestripintoendofstud.(AppendixB2)
7. Insertthepullerscrewintothetaperedthreadofthestudandhandtighten.Besurenotto
cross‐threadtheassembly
8. UsinganAllenwrenchtightenpullerscrew,thenbackoffpullerscrew1/2aturn.
9. Retightenpullerscrewbyhanduntilitisfullyinserted.DONOTBACKOFFPULLERSCREW.
10. Placethefootoverpullerscrew,orientateintoposition.
11. Threadtensionerontopullerscrew.Note:Internalstopintensionerwillresultingapwith
foot.DONOTTIGHTENTENSIONERAGAINSTFOOT.(GAPSHOULDBE1/16”to3/16”)
12. Placeguardovertensionerandpositionguidepinintohexendofstud.
13. Tightenknurledinterlockfittingbyhanduntilitfirmlypressesagainsttensioner.(nogap)
14. Activatecustomconnectorfromrearofguardbypushingonthecenterwithyourthumband
pullingthetabswithyourforefingerandmiddlefinger.Pushtheassemblyforwarduntilit
locksontothetensioner.Releasefingersfromtabsandthenremovethumb.Ensure
connectionisfirmlyengagedorelsethetensionerwillnotbeconnectedtopump.