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INSTRUCTIONMANUALIM‐477
ForGasTurbineTensioned
StudsandNuts
ApplicableBoltingConnections
SteamTurbineLPRotortoGenerator
ApplicableGEOrderingSheetPartNumbers
131T6314P0001
131T6314P0002
131T6314P0003
GEPower&Water
GENERALELECTRICCOMPANY
MLI: ____ OF ____
DATE
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL
ISSUED:
THISDOCUMENTSHALLBEREVISEDINI TSENTIRETY.ALLSHEETSOFTHI SDOCUMENTARE
THESAMEREVISIONLEVELASINDICATEDINTHISVENDORSUPPLIEDDRAWINGAPPLIQUE.
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GENOTTOREVISE.GEREVISI ONLEVELISSHOWNONTHISAPPLIQUE.
GESIGNATURES
CHECKED:
TheRiverhawkCompanyreservestherighttoupdatethisdocumentwithoutdisseminationornotice.The
latestrevisionmaybeobtainedbycontactingRiverhawkCompanyorthruwww.riverhawk.com.
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TableofContents
Section Description PageNumber
1.0 CautionsandSafetyWarnings 3
2.0 ScopeandGEPartNumberCrossReference 4
3.0 QuickChecklist 5
4.0 GeneralPreparations 10
5.0 HardwareSetPreparations 12
6.0 StudandNutAssembly 14
7.0 HydraulicTensionerEquipmentAssembly 16
8.0 AssemblyoftheTensionerontoaStud 19
9.0 StudTensioning 22
10.0 NutThreadLockingandWindagePlugInstallation 25
11.0 StudandNutRemoval 28
12.0 StorageInstructions 32
13.0 FrequentlyAskedQuestions 33
14.0 RevisionHistory 35
Appendix
A1 ECDeclarationofConformity 36
Appendix
A2 UKCADeclarationofConformity 37
Appendix
B1 16‐BoltTensioningPattern(LP‐GEN)RecordSheet 38
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1.0CautionsandSafetyWarnings
WARNING
Impropertooluseandthefailuretofollowthecorrectproceduresaretheprimaryroot
causesoftoolfailuresandpersonalinjuries.Alackoftrainingorexperiencecanleadto
incorrecthardwareinstallationorincorrecttooluse.Onlytrainedoperatorswithcareful,
deliberateactionsshouldusehydraulictensioners.ContactRiverhawkCompanywithany
trainingneeds.
WARNING
Riskofhighpressurefluidinjection.Riverhawktoolsoperateunderhighpressure.Thoroughly
inspectallhosesandconnectionsfordamageorleakspriortousingthisequipment.
CAUTION
Personalinjuryandequipmentdamagecanoccuriftheproperhealthandsafetycodesand
proceduresarenotfollowed.Contactthesite’shealthandsafetyofficetodetermineall
applicablesafetyrulesandregulations.
WARNING
Theproperpersonalprotectiveequipmentmustbewornatalltimes.Riverhawkrecommends
ataminimum,safetyglasses,longsleeveshirt,hardhat,heavyworkgloves,andsteeltoe
shoes.
CAUTION
Itisespeciallyimportanttochecktheconditionoftheconicalthreadusedtotensionthestud.
Threaddamagefrompreviousabusecanleadtofailureofthestudortensioningequipment.
CAUTION
RiverhawkrecommendsthatthetensionershouldbereturnedtoRiverhawkforperiodic
inspections.Replacementofobsoletetensionersisrecommended.Functionalupgradesarealso
recommended.TheRiverhawkServiceReturnsCoordinatorshouldbenotified3‐6monthsprior
toaplannedoutagetoscheduleaninspectionservice.
WARNING
Adamagedburstdiscmustbereplacedwithaburstdiscofthesamedesignandpressure
rating.Donotsubstituteadamagedburstdiscwithadifferentdisctype,adifferentpressure
rating,oraforeignobject.
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WARNING
Toavoidfailure,ensuresafety,andproperoperation,thetensionerassemblymustbeinstalled
onastudintheflangebeforepressurizingthetensioner.Donotusethetensioneratany
pressureunlessthetoolisinstalledonastudinaflange.
CAUTION
Personalinjuryandequipmentdamagecanoccurifthepullerscrewisnotsecurelyengaged
withthetaperedthreadsofthestud.Properengagementisachievedwhenthepullerscrewis
tightinthestudandthetensionerassemblyisfreetoturn.
WARNING
Thesafetycagemustbeinplaceatalltimes.Whenthetensionerispressurized,handsmustbe
keptoutofdesignatedareastoavoidanypotentialforpersonalinjury.
CAUTION
Beforethreadingthepullerscrewintothestud,carefullycheckthecleanlinessofboththe
stud'sandthepullerscrew'sconicalthreads.Applyalightcoatofcleanturbineoiloraspray
lubricanttothepullerscrew.Thisprocedurewilleaseassemblyandassurepositivematingof
thethreadsbeforetightening.Donotuse“NeverSeize”ontheconicalthreads.
CAUTION
Donottightenthenutwhilethetooliscominguptopressure;waituntilpressureisachieved
beforeattemptingtotightenthenutwiththespannerring.Ifthetoolisnotproperlyinstalled,
thetoolcouldjumpoffthestudwhilecominguptopressure.
CAUTION
Donotexceedthemaximumpressuremarkedonthetensioner.Excessivepressurecandamage
thestudandpullerscrew.
WARNING
FIREHAZARD:DONOTheatwhenpullerassemblyisinplace.Personalinjuryorequipment
damagemayoccur.UseofanOxy‐Acetylenetorchisnotrecommended
WARNING
Donotuseahydraulictensionertoremoveastudwithdamagedconicalthreads.
2.0ScopeandGEPartNumberCrossReference
Thisdocumentdescribestheproceduretobeusedtoinstallthestud,nut,andwindageplug
setssuppliedbytheRiverhawkCompanyintheflangesattheLPtoGeneratorconnection.
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ThehydraulictoolingusedinthisapplicationcanbeidentifiedbyitsORANGEsafetyguard.If
thesafetyguardisYELLOW,adifferentsetofinstructionsarerequired.ConsulttheRiverhawk
factoryforassistance.
ThevariousframeconfigurationscoveredinthismanualarelistedinSections2.1through2.2
withdifferencesasrelatedtoconnectivehardwaredefined.Listedalsoarethepertinent
hardwaredrawings(HF‐xxxx).Thesedrawingsaswellastoolingdrawings(HT‐xxxx)formpartof
thismanual.
2.1SteamTurbineLPRotortoGenerator
GEPartNumber RiverhawkP/N GEVENDOCP/N
131T6314P0001 HF‐8857 GE101B0770
ThehydraulictoolingusedforinstallationandremovalisRiverhawkHT‐9018.
Thishardwaredrawingdepictsthestud,nut,andwindageplugsetfortheLProtortoGenerator
(2‐1/4”size,Qty16).
2.2HydraulicTooling
GEPartNumber RiverhawkP/N GEVENDOCP/N
131T6314P0002
131T6314P0003
HT‐9018
AP‐0532
GE101B0774
GE359B2502
3.0QuickChecklist
ThefollowingchecklistisintendedasasummaryofthestepsneededtousetheRiverhawk‐
suppliedequipment.Newpersonnelorthoseexperiencedpersonnelwhohavenotusedthe
Riverhawkequipmentrecentlyareencouragedtoreadtheentiremanual.
EQUIPMENTINSPECTION
□Checktheoillevelinthehydraulicpump.
□Settheairpressureat80psi[5.5bar]minimum.(Forair‐drivenpumps)
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□Checkthehydraulichosefordamage.
□Testthepump.
□Inspectthetensionerforanydamage.
NUTANDSTUDPREPARATION
□Inspectthestuds,nutsandwindageplugsforanydamage.
□Cleanthestuds,nuts,andwindageplugs.
□Measureandrecordthestudlengths.(VERYIMPORTANT)
□Lubricatethestud’sthreadswithcleanturbineoilorspraylubricant.Lubricatethenut’s
threadsandnutfacewithcleanturbineoilorspraylubricant.
□Installthestudsandnuts(off‐center)intotheflange.
□Setthestick‐outdimensionontheLPsideoftheflange.
□WithanAllenwrenchinbacksideofstudtopreventrotation,firmlyseatthebacksidenut
usingthespannerringandpinwrench.
□Verifythestick‐outmeasurementontheLPsideoftheflange.(VERYIMPORTANT)
TENSIONING(BoltInstallation)
□Checkthetensionerdrawingforthecorrectpartsandpartnumbers.
□Applyalightcoatofcleanturbineoilorspraylubricanttothepullerscrewandthetwo
retentionscrews.DONOTUSE“NEVERSEIZE”ONTHECONICALTHREADS.
□Installtheretentionscrewsintotheadjacentstudsoneithersideofthestudtobe
tensioned.
□Installthespannerringontothenut.
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□Threadthepullerscrewintothestud.
□InsertanAllenwrenchintothebacksideofthestud.
□
InsertanotherAllenwrenchintothepullerscrew.Whileholdingthestudstill,tightenthe
pullerscrewuntilhandtightandthenloosenthepullerscrew1/2ofaturn.Retightenthe
pullerscrewandleavehandtight.DONOTBACKOFFPULLERSCREW.
□Slidethecorrectfootoverthepullerscrewandorientatethefootintoposition.
□Threadthetensionerontothepullerscrewuntilitstops.Thereshouldbea1/16”to3/16”
gapbetweenthefootandtensioner.
□Placetheguardovertensionerandpositiontheguard’spocketedslotsintotheretention
screws.
□Tightentheguard’sknurledinterlockfittingbyhanduntilitpressesfirmlyagainstthe
tensioner(nogap).
□Theretentionscrewsmustbeinsidetheguard’spocketedslots.
□Pushthecenteroftheinterlockfittingtowardsthetensionerwhilepullingbackonthe
fitting’souterpulltabsuntilitlocksontothetensionerandreleasethepulltabs.
□Installthebacksideguardtocoverthestudtobetensioned.
□Connectthehydraulicpumptothetensionerandtensionto50%.Consultmanualfor
correctpressure.
□Usethepinwrenchtoturnthespannerringtofirmlytightennutwith20ft∙lbs[27N∙m]of
torque.
□Releasethepressureandallowthetensionertofullyretract.
□Disconnectthehoseandreleasetheinterlockfittingbypushingthecenteroftheinterlock
fittingtowardsthetensionerwhilepullingbackonthefitting’souterpulltabs.
□Removethebacksideguard.
□Loosentheknurledinterlockfittingandremovetheguard.
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□Unscrewthetensionerfromthepullerscrew.
□Removethefoot,pullerscrew,spannerring,andretentionscrews.
□Movetothenextstudinthepattern.Tensionallstudsto50%beforeproceedingtothe
finalpressure.
□Repeattheabovestepsatthefinalpressure.
□Measurethefinalstudlengthandrecordonthestretchdatasheets.Calculatethefinal
stretchmeasurement.
□Torquethenuts'setscrews.
□Installthewindageplugsandtorquetheirsetscrews.
DETENSIONING(StudRemoval)
□Loosenthewindageplugs’setscrewsandremovethewindageplugsfromthestuds.
□Loosenthenuts'setscrews.
□
Inspectandcleanthestuds'conicalthreads.DonotcontinueuntilALLdebrisisremoved
fromthethreads!SeeinstructionmanualIM‐220.Donottrytousethetensionerto
removeadamagedstud!
□Applyalightcoatofcleanturbineoilorspraylubricanttothepullerscrewandtothetwo
retentionscrews.DONOTUSE“NEVERSEIZE”ONTHECONICALTHREADS.
□Installtheretentionscrewsintotheadjacentstudsoneithersideofthestudtobe
tensioned.
□Installthespannerringontothenut.
□Threadthepullerscrewintothestud.
□InsertanAllenwrenchintothebacksideofthestud.
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□
InsertanotherAllenwrenchintothepullerscrew.Whileholdingthestudstill,tightenthe
pullerscrewuntilhandtightandthenloosenthepullerscrew1/2ofaturn.Retightenthe
pullerscrewandleavehandtight.DONOTBACKOFFPULLERSCREW.
□Slidethecorrectfootoverthepullerstudandorientatethefootintoposition.
□Threadthetensionerontothepullerscrewuntilitstops.Thereshouldbea1/16”to3/16”
gapbetweenthefootandtensioner.
□Placetheguardoverthetensionerandpositiontheguard’spocketedslotsintoretention
screws.
□Tightentheguard’sknurledinterlockfittingbyhanduntilitpressesfirmlyagainst
tensioner(nogap).
□Theretentionscrewsmustbeinsidetheguard’spocketedslots.
□Pushthecenteroftheinterlockfittingtowardsthetensionerwhilepullingbackonthe
fitting’souterpulltabsuntilitlocksontothetensionerandreleasethepulltabs.
□Installthebacksideguardtocoverthestudtobetensioned.
□Connectthehydraulicpumptothetensionerandtensiontofinalpressure.Consult
manualforcorrectpressure.
□Loosenthenutwiththespannerringandpinwrench.
□Releasepressureandallowthetensionertofullyretract.
□Disconnectthehoseandreleasetheinterlockfittingbypushingthecenteroftheinterlock
fittingtowardsthetensionerwhilepullingbackonthefitting’souterpulltabs.
□Removethebacksideguard.
□Loosentheknurledinterlockfittingandremovetheguard.
□Unscrewthetensionerfromthepullerscrew.
□Removethefoot,pullerscrew,spannerring,andretentionscrews.Itmaybenecessaryto
insertanAllenwrenchintothebacksideofthestudtoremovethepullerscrew.
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□Movetonextstudinpattern
4.0GeneralPreparations
Readandunderstandallinstructionsbeforeinstallingandtensioningthestuds.
OperatorsshouldbetrainedorhavepreviousexperienceusingRiverhawktensioning
equipment.Trainingwillminimizethechanceofimproperuseoftheequipment.
Thehydraulictoolingincludingthehydraulichosesshouldbeinspectedpriortouse.Inspection
guidelinesarelistedinthefollowingsub‐sections.
Thisequipmentproducesveryhighhydraulicpressuresandveryhighforces.Operatorsmust
exercisecautionandweartheappropriatepersonalprotectiveequipmentwhenhandlingand
operatingthehydraulictooling.
High‐pressureoilfromthehydraulicpumppressurizesthetensionerwhichgeneratesavery
largeforcethatactuallystretchesthestud.Asthestudisstretched,thenutliftsofftheflange.
Thenutisthenturnedbyhandusingthesuppliedspannerringandpinwrench.Oncethenutis
tightagainsttheflange,thepressureinthetensionerisreleased.Thehardwareisnow
clampingtheflangetogether.
4.1MachinePreparation
Theflangetobetensionedmustbefullyclosedpriortopositioningofstudsintheflanges.
Turningtheturbineshaftsisnotrequired,butmaybeuseful.Also,itwillbeadvantageousto
removeasmanyobstructionsaspossiblefromtheflangearea,suchasspeedprobes,shipping
plates,andconduit.
4.2Hardware–Balance
Thestudsaresuppliedincomponentbalancedsets.Astudcanbeexchangedwithanotherstud
initssetwithoutaffectedtheoverallbalanceoftheequipment.Donotexchangeastudfrom
onesetwithanotherstudfromadifferentset.WhenshippedfromRiverhawk,thestudsare
notassignedtoanyspecificholeintheloadcouplingflange;thisisoptionalandcanbedoneat
theinstallationsite.ThesetsizeisdeterminedbytherelevantGEorderdrawing(seesection
2.0).
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