riverhawk IM-164 Manuel utilisateur
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INSTRUCTIONMAUALIM‐164
ForSteamTurbineTensionedStudsandNuts
ApplicableEquipment
SteamTurbineto109FBCouplingand
109FBCouplingto450HGenerator
FORGE382A6118P001,
382A6118P002
SteamTurbinetoLoadCouplingand
LoadCouplingto450HGenerator
FORGE389A6185P001
GEPower&Water
GENERALELECTRICCOMPANY
MLI: ____ OF ____
DATE
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THISDOCUMENTISFILEDUNDERTHEGEDRAWINGNUMBER.
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GESIGNATURES
CHECKED:
TheRiverhawkCompanyreservestherighttomakechangesupdatingthisdocumentwithout
dissemination or notice. The latest revision level may be obtained by contacting Riverhawk
Companydirectlyorvisitourwebsiteatwww.riverhawk.com
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TableofContents
Section Description PageNumber
1.0 CautionsandSafetyWarnings 3
2.0 Scope 3
3.0 QuickCheck‐List 4
4.0 GeneralPreparations 7
5.0 HardwareSetPreparations 8
6.0 StudandNutAssembly 11
7.0 AssemblyofHydraulicTensionerEquipment 12
8.0 AssemblyofTensioneronStud 18
9.0 StudPullingandTensioning 17
10.0 ThreadLocking 18
11.0 Stud/NutRemoval 19
12.0 StorageInstructions 21
13.0 FrequentlyAskedQuestions 23
14.0 RevisionHistory 25
AppendixA1 ECDeclarationofConformity 26
AppendixA2 UKCADeclarationofConformity 27
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1.0CautionsandSafetyWarnings
WARNING
TOAVOIDFAILURE,ENSURESAFETYANDPROPEROPERATIONTHETENSIONERASSEMBLY
MUSTBEMOUNTEDONTHESTUDBEFOREBLEEDINGTHESYSTEMANDTENSIONINGBEGINS.
DONOTUSETHETENSIONERASSEMBLYATANYPRESSUREUNLESSTHETOOLISMOUNTEDON
THESTUD.
CAUTION
Personalinjuryandequipmentdamagecanoccurifthepullerscrewisnotsecurelyengaged
withthetaperedthreadofthestud.Properengagementisachievedwhenthepullerscrewis
tightinthestudandtheTensionerAssemblyisfreetorotate.
WARNING
ThesafetycageMUSTbeinplaceandhandskeptoutofdesignatedareasatalltimeswhenthe
tensionerispressurizedotherwisepersonalinjurycanoccur.
CAUTION
DONOTEXCEEDTHEMAXIMUMPRESSUREVIBROSCRIBEDONTHEPULLERBODY.Excessive
pressurecandamagethestudandthepullerscrew.
WARNING
FireHazard!DONOTheatwhenthepullerassemblyisinplace.Personalinjuryorequipment
damagemayoccur.UseofanOxy‐Acetylenetorchisnotrecommended.
CAUTION
DONOTEXCEEDTHEMAXIMUMPRESSUREVIBROSCRIBEDONTHEPULLERBODY.Excessive
pressurecandamagethestudandpullerscrew
Note:Beforethreadingthepullerscrewintothestud,carefullycheckthecleanlinessofboth
thestud'sandthepullerscrew'sconicalthreads.Applyalightcoatofcleanturbineoilora
spraylubricanttothepullerscrew.Donotuse“NeverSeize”ontheconicalthreads.This
procedurewilleaseassemblyandassurepositivematingofthethreadsbeforetightening.
2.0 Scope
Thisdocumentdescribesthestepstoinstallasetofhardwarecontainingthestudsandnuts
suppliedbyRiverhawkCompanyintheloadcouplingflangesattheturbinetocouplingand
couplingtogeneratorconnections.
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Thishardwaresetisshownonthefollowingdrawing.Thisdrawingaswellastheinstallation
toolingdrawingformapartofthismanual.
GEPurchasing
OrderingPart
Number
GEHardwareSet
DrawingNumber
Riverhawk
HardwareSet
PartNumber Description
382A6118P001#
382A6118P002 359B2549 HF‐2658
1‐1/8"HardwareSetforSteam
TurbinetoCouplingto
Generator(bothendsofload
coupling)
389A6185P001 359B2549 HF‐2658
1‐1/8"HardwareSetforSteam
TurbinetoCouplingto
Generator(bothendsofload
coupling)
#denotesGEpartnumbersthatincludeinstallationtooling
3.0QuickChecklist
ThefollowingchecklistisintendedasasummaryofthestepsneededtousetheRiverhawk‐
suppliedequipment.Newpersonnelorthoseexperiencedpersonnelwhohavenotusedthe
Riverhawkequipmentrecentlyareencouragedtoreadtheentiremanual.
EQUIPMENTINSPECTION
□Checkoillevelinhydraulicpump.
□Checkairpressureat80psi[5.5bar]minimum.(Forair‐drivenpumps)
□Checkhydraulichosefordamage.
□Testpump.
□Inspecttensionerforanydamage.
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NUTANDSTUDPREPARATION
□Inspectstudandnutsforanydamage.
□Measurestudlength.
□Cleanthestudsandnuts.
□Installstudsandnuts(off‐center)intotheflange.
□Setstick‐outdimensiononthecouplingsideoftheflange.
□Handtightenallstuds.
□Verifystick‐outmeasurement(VERYIMPORTANT)
Tensioning(Boltinstallation)
□Matchthetensionersetuptotheflangejoint.
□Applyalightcoatofcleanturbineoilorspraylubricanttothepullerscrew.DONOTUSE
“NEVERSEIZE”ONTHECONICALTHREADS.
□Slidespannerringoverthepullerscrew.
□Mountthetensioneronthestudinflangeandinstallspannerringontonut.
□Insert1/2”hexAllenwrenchintothebacksideofthestud.
□Tightenthepullerscrew.Thenbackoffpullerscrew1/2aturn.
□Retightenthepullerscrewandleavetight.DONOTBACKOFFPULLERSCREW.
□Tightenpullernutandthenbacknutofftwoflatsor120degreestoallowforstudstretch.
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□Bleedthetensioner.DoNOTbleedtensioneroffofastud!Damagetothetoolwill
result!
□Tensionto50%.Consultmanualforcorrectpressure.
□Usethepinwrenchinspannerringtotightennut.
□Releasepressure,movetonextstudinpattern.
□Repeatabovestepsatfinalpressure.
□Measurefinalstudlengthandrecordonstretchdatasheets.Calculatestretch.
□Torquenuts'setscrews.
Detensioning(Studremoval)
□Loosennuts'setscrews
□Inspectandcleanstuds'conicalthreads.DonotcontinueuntilALLdebrisisremoved
fromthethreads!Donottrytousethetensionertoremoveadamagedstud!
□Applyalightcoatofcleanturbineoilorspraylubricanttothepullerscrew.DONOTUSE
“NEVERSEIZE”ONTHECONICALTHREADS.
□Slidespannerringoverthepullerscrew.
□Mountthetensioneronthestud.
□Installspannerringintonut.
□Tightenthepullerscrew.Thenbackoffpullerscrew1/2aturn.
□Retightenthepullerscrewandleavetight.DONOTBACKOFFPULLERSCREW.
□Tightenpullernutandthenbacknutofftwoflatsor120degreestoallowforstudstretch.
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□Bleedthetensioner.DoNOTbleedtensioneroffofastud!Damagetothetoolwill
result!
□Applyfinalpressure.
□Loosennutwiththespannerringandpinwrench.
□Movetonextstudinpattern
4.0GeneralPreparations
Readandunderstandallinstructionsbeforeinstallingandtensioningstuds.
Thisequipmentproducesveryhighhydraulicpressuresandveryhighforces.Operatorsmust
exercisecautionandwearpersonalprotectiveequipment(PPE)whenusingthisequipment.
High‐pressurefluidfromtheHydraulicPressureKitsystempressurizesthetensionerwhich
generatesastretchingforcethatactuallystretchesthestud.Asthestudisstretchedthenut
liftsofftheflange.Thenutisthenreseatedintopositionontheflangebyturninganutdriver
byhand.Whenthenutistightagainsttheflange,thepressureinthetensionerisreleased
leavingthestudloadedtoitspredeterminedvalue.
4.1MachinePreparation
Theflangetobetensionedmustbefullyclosedpriortopositioningofstudsintheflanges.
Turningtheshaftsoftheturbineandthegeneratorarenotrequired,butmaybeuseful.Also,it
willbeadvantageoustoremoveasmanyobstructionsaspossiblefromtheflangearea,suchas
speedprobes,shippingplates,andconduit.
4.2Hardware–Balance
Hardwareissuppliedinweightbalancedsets
StudsandNutsareinterchangeablewithinsets
Donotmixwithothersets
Saveweightcertificationdatasuppliedwitheachsetforpurchaseofspares
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4.3Tensioner–CareandHandling
Whennotinuse,thetensionershallbemaintainedinacleanenvironmentandallcapsand
plugsforhydraulicopeningsandfittingsmustbeinplace.
Wheninuse,thetensionershallbeprotectedfromsandandgrit.
Longtermstorage–coattensionerwithoil,returntooriginalcontainer,sealcontainerand
protectfrommoisture.
Shipment–coattensionerwithoilandshipinoriginalcontainer.
4.4 HandTools
Severalhandwrenchesandmicrometerswillberequiredtoperforminstallationand
measurementofthestuds:
5/8”wrench
15/16"wrench
1”wrench
AsetofAllenWrenches
3’–4’BreakerBar[3m]
5”to6”micrometer[100mm–200mm]
4.5SpecialTools
HydraulicTensionerKit: HT‐2569HydraulicTensioner,1‐1/8”
(recommended)
(referenceGE359B2548)
HydraulicPumpKit: AP‐0532Air‐OperatedHydraulicPump
(recommended)
(referenceGE359B2502)
MP‐0130ManualHand‐Operated
HydraulicPump
(referenceGE359B2506)
5.0HardwareSetPreparations
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5.1NutPreparation
SamplePictureofaRiverhawkLocknut
Ifthereisanyvisibledamageonanut,donotusethenutandcontacttheRiverhawkCompany
forareplacementnut.Pleasebepreparedtosupplytheturbinenumber,weightcertification,
anddigitalphotographsforevaluation.
5.1.1NutCleaning‐NewInstallations
Fornewinstallations,thenutsshouldcomesealedfromthefactoryandwillneednocleaning.
5.1.2NutCleaning‐OldInstallations
Previouslyinstallednutsrequirecleaningasfollows:Wirebrushusingapetroleumbased
solventtoremoveanyforeignmaterialontheexternalsurfacesandthreads.
5.2StudPreparation
Checkthestudforanyvisibledamage.Ifthereisanyvisibledamage,donotusethestudand
contacttheRiverhawkCompanyforareplacementstud.Pleasebepreparedtosupplythe
turbinenumber,weightcertification,anddigitalphotographsforevaluation.
Theconicalthreadsofeachstudmustbecleanbeforeinstallationorremoval.Thisensuresthe
properseatingofthepullerscrew.
Set Screw
1 of 2
Spanner
Ring Holes
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5.2.1StudCleaning‐NewInstallations
Fornewinstallations,thestudsshouldcomesealedfromthefactoryandwillneednocleaning.
5.2.2StudCleaning‐OldInstallations
Previouslyinstalledstudsmayrequirecleaning.Cleanconicalthreadsshouldhaveabrightand
shinyappearance.
Ifcleaningisrequired,followthesesteps:
1. Blowoutthethreadswithcompressedairtoremoveloosedebrisanddryconical
threads.Donotapplyasolventorothercleaningsolutiontothethreadsasthismay
chemicallyattackthestud.
2. UseStudCleaningKit,GT‐4354orasimilar1/2"diameterBrasspowerbrush.
PictureofBrassPowerBrush
3. Insertthebrushintoanelectricdrillandsetdrilltoruninacounterclockwisedirection
athighspeed.
4. Workthedrillinacircularmotionwhilemovingthebrushinandouttocleanallofthe
threads.Trynottoholdthebrushinoneplacetoolong,soasnottoremovethestud's
protectivecoating.
5. Blowoutthethreadswithcompressedairtoremovelooseneddebris.
6. Visuallyinspectthreadsforcleanliness.Threadsshouldbebrightandshiny.
7. Repeatifanydirtcanbeseeninthethreads.
8. Inspectthreadsforanydamagethatmayhavebeencausedbypreviousinstallation.
Donotapplythreadlubricantstothethreads.
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