riverhawk IM-477 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38
INSTRUCTIONMANUALIM‐477
ForGasTurbineTensioned
StudsandNuts


ApplicableBoltingConnections
SteamTurbineLPRotortoGenerator



ApplicableGEOrderingSheetPartNumbers
131T6314P0001
131T6314P0002
131T6314P0003







 
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I TSENTIRETY.ALLSHEETSOFTHI SDOCUMENTARE
THESAMEREVISIONLEVELASINDICATEDINTHISVENDORSUPPLIEDDRAWINGAPPLIQUE.
REV
138T6569
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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‐477

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
138T6569
GEDRAWINGNUMBER

RevisionC
Page2of38

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 5
4.0 GeneralPreparations 10
5.0 HardwareSetPreparations 12
6.0 StudandNutAssembly 14
7.0 HydraulicTensionerEquipmentAssembly 16
8.0 AssemblyoftheTensionerontoaStud 19
9.0 StudTensioning 22
10.0 NutThreadLockingandWindagePlugInstallation 25
11.0 StudandNutRemoval 28
12.0 StorageInstructions 32
13.0 FrequentlyAskedQuestions 33
14.0 RevisionHistory 35
Appendix
A1 ECDeclarationofConformity 36
Appendix
A2 UKCADeclarationofConformity 37
Appendix
B1 16‐BoltTensioningPattern(LP‐GEN)RecordSheet 38



InstructionManualIM‐477

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
138T6569
GEDRAWINGNUMBER

RevisionC
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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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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.



InstructionManualIM‐477

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
138T6569
GEDRAWINGNUMBER

RevisionC
Page4of38

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.

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

WARNING
Donotuseahydraulictensionertoremoveastudwithdamagedconicalthreads.


2.0ScopeandGEPartNumberCrossReference

Thisdocumentdescribestheproceduretobeusedtoinstallthestud,nut,andwindageplug
setssuppliedbytheRiverhawkCompanyintheflangesattheLPtoGeneratorconnection.

InstructionManualIM‐477

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
138T6569
GEDRAWINGNUMBER

RevisionC
Page5of38
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
ThehydraulictoolingusedinthisapplicationcanbeidentifiedbyitsORANGEsafetyguard.If
thesafetyguardisYELLOW,adifferentsetofinstructionsarerequired.ConsulttheRiverhawk
factoryforassistance.

ThevariousframeconfigurationscoveredinthismanualarelistedinSections2.1through2.2
withdifferencesasrelatedtoconnectivehardwaredefined.Listedalsoarethepertinent
hardwaredrawings(HF‐xxxx).Thesedrawingsaswellastoolingdrawings(HT‐xxxx)formpartof
thismanual.

2.1SteamTurbineLPRotortoGenerator

GEPartNumber RiverhawkP/N GEVENDOCP/N
131T6314P0001 HF‐8857 GE101B0770

ThehydraulictoolingusedforinstallationandremovalisRiverhawkHT‐9018.

Thishardwaredrawingdepictsthestud,nut,andwindageplugsetfortheLProtortoGenerator
(2‐1/4”size,Qty16).

2.2HydraulicTooling

GEPartNumber RiverhawkP/N GEVENDOCP/N
131T6314P0002
131T6314P0003
HT‐9018
AP‐0532
GE101B0774
GE359B2502


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theoillevelinthehydraulicpump.
□Settheairpressureat80psi[5.5bar]minimum.(Forair‐drivenpumps)

InstructionManualIM‐477

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
138T6569
GEDRAWINGNUMBER

RevisionC
Page6of38
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□Checkthehydraulichosefordamage.
□Testthepump.
□Inspectthetensionerforanydamage.

NUTANDSTUDPREPARATION
□Inspectthestuds,nutsandwindageplugsforanydamage.
□Cleanthestuds,nuts,andwindageplugs.
□Measureandrecordthestudlengths.(VERYIMPORTANT)
□Lubricatethestud’sthreadswithcleanturbineoilorspraylubricant.Lubricatethenut’s
threadsandnutfacewithcleanturbineoilorspraylubricant.
□Installthestudsandnuts(off‐center)intotheflange.
□Setthestick‐outdimensionontheLPsideoftheflange.
□WithanAllenwrenchinbacksideofstudtopreventrotation,firmlyseatthebacksidenut
usingthespannerringandpinwrench.
□Verifythestick‐outmeasurementontheLPsideoftheflange.(VERYIMPORTANT)

TENSIONING(BoltInstallation)
□Checkthetensionerdrawingforthecorrectpartsandpartnumbers.
□Applyalightcoatofcleanturbineoilorspraylubricanttothepullerscrewandthetwo
retentionscrews.DONOTUSE“NEVERSEIZE”ONTHECONICALTHREADS.
□Installtheretentionscrewsintotheadjacentstudsoneithersideofthestudtobe
tensioned.
□Installthespannerringontothenut.

InstructionManualIM‐477

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
138T6569
GEDRAWINGNUMBER

RevisionC
Page7of38

□Threadthepullerscrewintothestud.
□InsertanAllenwrenchintothebacksideofthestud.
□
InsertanotherAllenwrenchintothepullerscrew.Whileholdingthestudstill,tightenthe
pullerscrewuntilhandtightandthenloosenthepullerscrew1/2ofaturn.Retightenthe
pullerscrewandleavehandtight.DONOTBACKOFFPULLERSCREW.
□Slidethecorrectfootoverthepullerscrewandorientatethefootintoposition.
□Threadthetensionerontothepullerscrewuntilitstops.Thereshouldbea1/16”to3/16”
gapbetweenthefootandtensioner.
□Placetheguardovertensionerandpositiontheguard’spocketedslotsintotheretention
screws.
□Tightentheguard’sknurledinterlockfittingbyhanduntilitpressesfirmlyagainstthe
tensioner(nogap).
□Theretentionscrewsmustbeinsidetheguard’spocketedslots.
□Pushthecenteroftheinterlockfittingtowardsthetensionerwhilepullingbackonthe
fitting’souterpulltabsuntilitlocksontothetensionerandreleasethepulltabs.
□Installthebacksideguardtocoverthestudtobetensioned.
□Connectthehydraulicpumptothetensionerandtensionto50%.Consultmanualfor
correctpressure.
□Usethepinwrenchtoturnthespannerringtofirmlytightennutwith20ft∙lbs[27N∙m]of
torque.
□Releasethepressureandallowthetensionertofullyretract.
□Disconnectthehoseandreleasetheinterlockfittingbypushingthecenteroftheinterlock
fittingtowardsthetensionerwhilepullingbackonthefitting’souterpulltabs.
□Removethebacksideguard.
□Loosentheknurledinterlockfittingandremovetheguard.

InstructionManualIM‐477
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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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REV
138T6569
GEDRAWINGNUMBER
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
□Unscrewthetensionerfromthepullerscrew.
□Removethefoot,pullerscrew,spannerring,andretentionscrews.
□Movetothenextstudinthepattern.Tensionallstudsto50%beforeproceedingtothe
finalpressure.
□Repeattheabovestepsatthefinalpressure.
□Measurethefinalstudlengthandrecordonthestretchdatasheets.Calculatethefinal
stretchmeasurement.
□Torquethenuts'setscrews.
□Installthewindageplugsandtorquetheirsetscrews.

DETENSIONING(StudRemoval)
□Loosenthewindageplugs’setscrewsandremovethewindageplugsfromthestuds.
□Loosenthenuts'setscrews.
□
Inspectandcleanthe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andtothetwo
retentionscrews.DONOTUSE“NEVERSEIZE”ONTHECONICALTHREADS.
□Installtheretentionscrewsintotheadjacentstudsoneithersideofthestudtobe
tensioned.
□Installthespannerringontothenut.
□Threadthepullerscrewintothestud.
□InsertanAllenwrenchintothebacksideofthestud.

InstructionManualIM‐477

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
138T6569
GEDRAWINGNUMBER

RevisionC
Page9of38

□
InsertanotherAllenwrenchintothepullerscrew.Whileholdingthestudstill,tightenthe
pullerscrewuntilhandtightandthenloosenthepullerscrew1/2ofaturn.Retightenthe
pullerscrewandleavehandtight.DONOTBACKOFFPULLERSCREW.
□Slidethecorrectfootoverthepullerstudandorientatethefootintoposition.
□Threadthetensionerontothepullerscrewuntilitstops.Thereshouldbea1/16”to3/16”
gapbetweenthefootandtensioner.
□Placetheguardoverthetensionerandpositiontheguard’spocketedslotsintoretention
screws.
□Tightentheguard’sknurledinterlockfittingbyhanduntilitpressesfirmlyagainst
tensioner(nogap).
□Theretentionscrewsmustbeinsidetheguard’spocketedslots.
□Pushthecenteroftheinterlockfittingtowardsthetensionerwhilepullingbackonthe
fitting’souterpulltabsuntilitlocksontothetensionerandreleasethepulltabs.
□Installthebacksideguardtocoverthestudtobetensioned.
□Connectthehydraulicpumptothetensionerandtensiontofinalpressure.Consult
manualforcorrectpressure.
□Loosenthenutwiththespannerringandpinwrench.
□Releasepressureandallowthetensionertofullyretract.
□Disconnectthehoseandreleasetheinterlockfittingbypushingthecenteroftheinterlock
fittingtowardsthetensionerwhilepullingbackonthefitting’souterpulltabs.
□Removethebacksideguard.
□Loosentheknurledinterlockfittingandremovetheguard.
□Unscrewthetensionerfromthepullerscrew.
□Removethefoot,pullerscrew,spannerring,andretentionscrews.Itmaybenecessaryto
insertanAllenwrenchintothebacksideofthestudtoremovethepullerscrew.

InstructionManualIM‐477

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
138T6569
GEDRAWINGNUMBER

RevisionC
Page10of38

□Movetonextstudinpattern


4.0GeneralPreparations

Readandunderstandallinstructionsbeforeinstallingandtensioningthe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andpinwrench.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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.

4.2Hardware–Balance

Thestudsaresuppliedincomponentbalancedsets.Astudcanbeexchangedwithanotherstud
initssetwithoutaffectedtheoverallbalanceoftheequipment.Donotexchangeastudfrom
onesetwithanotherstudfromadifferentset.WhenshippedfromRiverhawk,thestudsare
notassignedtoanyspecificholeintheloadcouplingflange;thisisoptionalandcanbedoneat
theinstallationsite.ThesetsizeisdeterminedbytherelevantGEorderdrawing(seesection
2.0).


InstructionManualIM‐477
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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
138T6569
GEDRAWINGNUMBER
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Page11of38

Thenutsaresuppliedincomponentbalancedsets.Anutcanbeexchangedwithanothernutin
itssetwithoutaffectedtheoverallbalanceoftheequipment.Donotexchangeanutfromone
setwithanothernutfromadifferentset.WhenshippedfromRiverhawk,thenutsarenot
assignedtoanyspecificholeintheloadcouplingflange;thisisoptionalandcanbedoneatthe
installationsite.ThesetsizeisdeterminedbytherelevantGEorderdrawing(seesection2.0).

Thewindageplugsaresuppliedincomponentbalancedsets.Awindageplugcanbeexchanged
withanotherwindagepluginitssetwithoutaffectedtheoverallbalanceoftheequipment.Do
notexchangeawindageplugfromonesetwithanotherwindageplugfromadifferentset.
WhenshippedfromRiverhawk,thewindageplugsarenotassignedtoanyspecificholeinthe
loadcouplingflange;thisisoptionalandcanbedoneattheinstallationsite.Thesetsizeis
determinedbytherelevantGEorderdrawing(seesection2.0).

Aweightbalancecertificationissuppliedwitheachorder.Storethiscertificationinan
appropriatelocationasitwillbeneededforthepurchaseofreplacementequipment.

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mayberequiredtoperforminstallationand
measurementofthestuds:

5/8”Wrench
3/4”Wrench
AsetofAllenWrenches
3’to4’BreakerBar
16”to20”MicrometerorCaliper



InstructionManualIM‐477

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
138T6569
GEDRAWINGNUMBER

RevisionC
Page12of38

4.5SpecialTools

HydraulicTensionerKit: HT‐9018HydraulicTensioner,2‐1/4”
(referenceGEVENDOC101B0774)

HydraulicPumpKit: AP‐0532Air‐OperatedHydraulicPump
(referenceGEVENDOC359B2502)

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5A‐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.
(2)Spanner
RingHoles
(2)Locking
SetScrews

InstructionManualIM‐477

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
138T6569
GEDRAWINGNUMBER

RevisionC
Page13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.

5.2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.

2. UseStudCleaningKit,GT‐4253orasimilar1"diameterBrasspowerbrush.


Picture5B‐BrassPowerBrush

InstructionManualIM‐477

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
138T6569
GEDRAWINGNUMBER

RevisionC
Page14of38


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“NeverSeize”tothestud’sthreads.

10. Finishthecleaningprocessbyrinsinginavolatilesolventsuchasacetoneandallowthe
studtodry.

5.3StudLengthMeasurement

Measureandrecordtheinitialstudlengths.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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thehardwareassemblydrawing(HF‐xxxx)listedinSection2.0ofthemanual.

1. Assemblethecylindricalnuttotheinternal,conicalthreadendofthestud.


InstructionManualIM‐477

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
138T6569
GEDRAWINGNUMBER
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
2. Lubricatethestud’sthreadswithcleanturbineoilorspraylubricant.

3. Lubricatethenut’sthreadsandnutfacewithcleanturbineoilorspraylubricant.

4. SlidethestudandcylindricalnutassemblyintotheflangeasshowninFigure6A.



Figure6A–Cross‐sectionViewofSteamTurbineLPRotorto
GeneratorBoltedFlangeConnection

5. Installtheothernutonthebackside.

6. Adjustthenut/studassemblysothatthestudprotrudes(orsticksout)fromthefaceof
thecylindricalnutthedistancespecifiedonthehardwaredrawing(HF‐xxxx).SETTING
THISPROTRUSIONOFSTUDTONUTISCRITICALFORPROPERTENSIONEROPERATION.
Ametalstick‐outgageisprovidedwiththetensionertoassisttheoperatorinsettingthe
protrusiondimension.

HexDrive
FrontsideNut Stud BacksideNut
Generator
Flange
LPRotor
Flange
Tensioning
ConicalThread
*SetStudStick‐out
onthissideonly

InstructionManualIM‐477

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
138T6569
GEDRAWINGNUMBER

RevisionC
Page16of38




Picture6B–UseofStick‐OutGageontheSteamTurbine
LPFlangetoGeneratorFlangeJoint



Picture6C–UseofDropGageto
measurestick‐out


Picture6D–UseofCalipersto
measurestick‐out

7. WithAllenwrenchinbacksideofthestud,firmlyseatthebacksidenutusingthe
spannerringandpinwrench.

8. Recheckthestudstick‐outlength.Ifthestick‐outlengthdoesnotmatchthehardware
drawing,adjustthenutsasnecessary.


7.0HydraulicTensionerEquipmentAssembly

7.1HydraulicEquipmentInspection



InstructionManualIM‐477

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
138T6569
GEDRAWINGNUMBER

RevisionC
Page17of38

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airbleeding.Seesection8.3

WARNING
Toavoidfailure,ensuresafety,andproperoperation,thetensionerassemblymustbe
installedonastudintheflangepressurizingthetensioner.Donotusethetensioneratany
pressureunlessthetoolisinstalledonastudinaflange.

Cleanthe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.Also,besurethe
rubberpadisinplaceonthebackside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(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).

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.

InstructionManualIM‐477

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
138T6569
GEDRAWINGNUMBER
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
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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.

7.2HydraulicFittings


Illustration1
Riverhawkhydraulicpumps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
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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.




InstructionManualIM‐477

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
138T6569
GEDRAWINGNUMBER

RevisionC
Page19of38
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Illustration3
Slidetheglandnutdownoverthecollar.(See
Illustration3)Insertthe1/4”tubeor1/4”hose
endintothetensioner’squickcoupler.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.


8.0AssemblyoftheTensionerontoaStud

ThetensionerusedinthisapplicationcanbeidentifiedbyitsORANGEsafetyguard.Ifthe
tensioner’ssafetyguardisYELLOW,adifferentsetofinstructionsarerequired.Consultthe
Riverhawkfactoryforassistance.

8.1HandlingoftheTensioner

Thetensionerusedinthisapplicationisdesignedtorequirenospecialliftinginstructions.Do
notdropanypartofthetensionerontheoperatororothernearbypersonnel.

8.2KitAssembly

Connectthehydraulichosefromthehydraulicpumptothetensioner.

Refertothehardwareassemblydrawing(HF‐xxxx)listedinSection2.0ofthismanualandthe
tensionerassemblydrawing(HT‐xxxx)listedinSection4.5ofthismanualtodeterminehowthe
tensionermustbeassembledontheloadcouplingforitscorrectoperation.


InstructionManualIM‐477

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
138T6569
GEDRAWINGNUMBER

RevisionC
Page20of38
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Picture8A–FeaturesoftheHydraulicTensionerHT‐9018
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Figure8B–CutawayviewoftheHydraulicTensionerHT‐9018
Safety
Guard
Hose
Connection
PinWrench
Hydraulic
Cylinder
Generator
PinWrench
Foot
SafetyGuard
Hose
Connection
Knurled
InterlockFitting HydraulicCylinder
PullerScrew
SpannerRing
Backside
SafetyGuard
Retention
Screw
LPFlange
BacksideSafetyGuard