riverhawk IM-278 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A
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
INSTRUCTIONMANUALIM‐278
ForHydraulicallyTensionedStudsandNuts

ApplicableBoltingConnections
9EGasTurbinetoLoadCoupling
LoadCouplingtoSubstituteShaft
SubstituteShafttoLoadCoupling
LoadCouplingto9A5Generator

ApplicableGEOrderingSheetPartNumbers
102T3330P001
102T3330P002
102T3330P003
102T3330P004
102T3330P005
102T3330P006
102T3330P007
104T5015P001
104T5015P002
104T5015P003
104T5015P004
104T5015P005
104T5015P006
104T5015P007


 
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
373A4054
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 at our
websitewww.riverhawk.com.

Instruction Manual IM-278
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
373A4054
GEDRAWINGNUMBER
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RevisionA
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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Check‐List 5
4.0 GeneralPreparations 9
5.0 HardwareSetPreparations 11
6.0 NutandStudAssembly 14
7.0 AssemblyofTensioneronStud 17
8.0 StudPullingandTensioning 19
9.0 ThreadLocking 22
10.0 Stud/NutRemoval 23
11.0 Storage 24
12.0 FrequentlyAskedQuestions 24
13.0 RevisionHistory 26
AppendixA1 ECDeclarationofConformity 27
AppendixA2 UKCADeclarationofConformity 28
AppendixB1 16‐BoltTensioningPatternRecordSheet 29
AppendixB2 14‐BoltTensioningPatternRecordSheet 30
AppendixB3 14‐BoltTensioningPatternRecordSheet 31
AppendixB4 14‐BoltTensioningPatternRecordSheet 32


Instruction Manual IM-278
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
373A4054
GEDRAWINGNUMBER
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RevisionA
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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INTERLOCK
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clean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.(ReferenceIM‐220)
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.

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.



Instruction Manual IM-278
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
373A4054
GEDRAWINGNUMBER
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RevisionA
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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;coupling/substituteshaft;substitute
shaft/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‐5369 269B8701
102T3330P001
102T3330P002#
104T5015P001
104T5015P002#
2‐3/4"hardwareforAll4bolted
joints.
- - 102T3330P003#
104T5015P003#
Hydraulicinstallationtoolingonly
HF‐5578 269B8737 102T3330P004
104T5015P004
2‐3/4"hardwarefortheturbine
endtoloadcouplingconnection.
HF‐5579 269B8738 102T3330P005
104T5015P005
2‐3/4"loadcouplingto
substituteshaftconnection.
HF‐5580 269B8739 102T3330P006
104T5015P006
2‐3/4"substituteshafttoload
couplingconnection.

Instruction Manual IM-278
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
373A4054
GEDRAWINGNUMBER
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RevisionA
Page5of32
HF‐5581 269B8740 102T3330P007
104T5015P007
2‐3/4"loadcoupling9A5
generatorconnection.

#denotesGEpartnumbersthatincludehydraulictooling

OtherImportantReferenceDocumentation:
IM‐293(GE373A4058) InstructionManualforGEHydraulicPumpKit
IM‐220(GE373A4025) CleaningProcedureoftheConicalThreadsonRiverhawkStuds


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hydraulichoseforanydamage.
□ Testpump,seepumpinstructionmanualIM‐293forprocedure.
□ Inspecttensionerforanydamage.
NUTANDSTUDPREPARATION
□ Inspectstudsandnutsforanydamage.
□ Cleanthestudsandnuts(ReferenceIM‐220).
□ Measurestudlengthsandrecordonstretchdatasheets.
(VERYIMPORTANT)
□ Installstudsandnutsintotheflange.
□ Setstick‐outdimensionontheconicalthreadendofstud.

Instruction Manual IM-278
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
373A4054
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RevisionA
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□ Handtightennutsonbacksideofstud.
□ 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nut.
□ Threadpullerscrewontothestud.
□ InsertAllenwrenchintothebacksideofthestudtostopthestudfromrotatingwhen
installing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pullerstud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.
□ Tightenknurledinterlockfittingbyhanduntilitpressesfirmlyagainsttensioner.(nogap)
□ Slideandengagecustomconnectorfromrearofguardtolocktensionerintoplace.
□ Tensionto50%.Consultmanualforcorrectpressure.

Instruction Manual IM-278
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
373A4054
GEDRAWINGNUMBER
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RevisionA
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□ Usethepinwrenchinspannerringtotightennut.
□ Releasepressure,allowtensionertofullyretract.
□ Disconnecthosefromtensioner.
□ Loosenknurledfittingandremoveguard.
□ Unscrewtensionerfrompullerscrew.Usecautiontoinsurethathandsarenotbetween
tensionerandcouplingwhentensionerbecomesdisengagedfrompullerscrew.
□ Removefoot.
□ Removepullerscrewfromstud.
□ Removespannerringfromnut,movetonextstudinpattern.
□ Tensionallstudsto50%beforeproceedingtofinalpressure.
□ Repeatabovestepsatfinalpressure.
□ Measurefinalstudlengthandrecordonstretchdatasheets.Calculatestretchandverify
persection8.2
□ Torquenuts’setscrewspersection10.


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Detensioning(Studremoval)
□  Loosennuts'setscrews
□
 Inspectandcleanstuds'conicalthreads.DonotcontinueuntilALLdebrisisremoved
fromthethreads!Reference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spannerringontonut.
□  Threadpullerscrewontothestud.
□  UsingAllenwrenchtightenthepullerscrew.Thenbackoffpullerscrew1/2aturn.
□  Lightlyretightenpullerscrewbyhanduntilitisfullyinserted.DONOTBACKOFFPULLER
SCREW.
□  Slidefootoverpullerstud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backsideofstud.
□
 Tightenknurledinterlockfittingbyhanduntilitfirmlypressesagainsttensioner.(no
gap)
□ Slideandengagecustomconnectorfromrearofguardtolocktensionerintoplace.
□ Applyfinalpressure.
□ Loosennutwiththespannerringandpinwrench.

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215ClintonRoad
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

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properpersonalsafetyequipmentmustbewornatalltimes.Contactthe
site’shealthandsafetyofficetodetermineallapplicablesafetyrulesandregulations.

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willberequired.Also,itwillbeadvantageousto
□ Releasepressure,allowtensionertofullyretract.
□ Disconnecthosefromtensioner.
□ Loosenknurledfittingandremoveguard.
□ Unscrewtensionerfrompullerscrew.
□ Removefoot.
□ Removepullerscrewfromstud.ItmaybenecessarytoinsertanAllenwrenchintothe
backsideofstudtoremovepullerscrew.
□ Removespannerringfromnut.
□ Movetonextstudinpattern.

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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
10”to11”micrometerorcaliper

4.5SpecialTools

HydraulicTensionerKit: HT‐5506HydraulicTensioner
(referenceGE269B8736)

 HT‐5506‐ITHydraulicTensioner
(Italian)
(referenceGE269B8749)

Instruction Manual IM-278
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
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
HydraulicPumpKit: AP‐0532Air‐OperatedHydraulic
Pump(recommended)
(referenceGE359B2502)

AP‐0523‐ITAir‐OperatedHydraulic
Pump(Italian)
(referenceGE269B8750)

 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.

Set Screw
1 of 2
Spanner
Ring Holes

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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.

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.UseinstructionmanualIM‐220formoredetailedinstructions.

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.

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.

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215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
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

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.

5.3StudLengthMeasurement

MeasureandrecordtheinitiallengthsofthestudsonthesuppliedstretchdatasheetinAppendix
B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)orbetter.
 Recordeachmeasurementonthestretchrecordsheetsinthismanual'sappendix.

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

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thru4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.



Figure1–CutawayViewofTurbineFlange
andCouplingFlangeBoltedJoint



Instruction Manual IM-278
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL
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


Figure2–CutawayViewofTurbineLoadCoupling
andSubstituteShaftBoltedJoint



Figure3–CutawayViewofSubstituteShaft
andGeneratorLoadCouplingBoltedJoint



Figure4–CutawayViewofGeneratorLoadCoupling
andGeneratorFlangeBoltedJoint

Instruction Manual IM-278
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215ClintonRoad
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

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)

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


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CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL
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
DigitalCalipers

SamplePicturesofaStick‐OutMeasurement


7.0AssemblyofTensioneronStud

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thru4.

7.1AssemblyofTensionerKitwithORANGESafetyGuard

RefertoTensionerdrawingandFigure6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. Insertthepullerscrewintothetaperedthreadofthestudandhandtighten.Besurenotto
cross‐threadtheassembly
7. UsinganAllenwrenchtightenpullerscrew,thenbackoffpullerscrew1/2aturn.
8. Retightenpullerscrewbyhanduntilitisfullyinserted.DONOTBACKOFFPULLERSCREW.
9. Placethefootoverpullerscrew,orientateintoposition.

Instruction Manual IM-278
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10. 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”)
11. Placeguardovertensionerandpositionguidepinintohexendofstud.
12. Tightenknurledinterlockfittingbyhanduntilitfirmlypressesagainsttensioner.(nogap)
13. 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.(Figure5)






Figure 5 – Activation of
custom connector

Instruction Manual IM-278
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



CAUTION
Personalinjuryandequipmentdamagecanoccurifthepullerscrewisnotsecurelyengaged
withtheconicalthreads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.


8.0StudPullingandTensioning

Thestudswillbetensionedintwosteps,at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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.
Figure 6 – Cutaway View of
Tensioner Installed on Flange

Instruction Manual IM-278
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8.1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 2‐3/4"
[71mm]
10000psi
[690bar]
Donotmeasure
Donotuse
CouplingtoSubstitute
Shaft
2‐3/4"
[71mm]
10000psi
[690bar]
Donotmeasure
Donotuse
SubstituteShaftto
Coupling
2‐3/4"
[71mm]
10000psi
[690bar]
Donotmeasure
Donotuse
CouplingtoGenerator 2‐3/4"
[71mm]
10000psi
[690bar]
Donotmeasure
Donotuse

8.1.1TighteningofNuts

Tightenthecylindricalnutshandtightusingthepinwrenchandspannerring,asdepictedinFigure
4.Turnthenutuntilitbottomsontheflange.Thenapplytorquetoturnthenutanadditional5
degrees.Thiswillaidinachievingthedesiredstretch.

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.

8.2RemovingtheTensionerfromanInstalledStud

Thetensionerremovalistobeaccomplishedbythefollowssteps:
1. Releasethetensionertoolpressurebyopeningthevalveonthepump.Leavevalveopen.(This
isautomaticontheair‐operatedhydraulicpump)Allowapproximately20secondsfor
tensionertofullyretract,thenremovehosefromtensioner.
2. Unscrewknurledfittingattheendoftheguardandremoveguard.
3. Unscrewtensionerfrompullerscrew.Usecautiontoensurethathandsarenotbetween
tensionerandcouplingwhentensionerbecomesdisengagedfrompullerscrew.