INSTRUCTION MANUAL IM 368 For Gas Turbine Tensioned Studs

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For Gas Turbine Tensioned Studs and Nuts GE DRAWING NUMBER Page 5 of 32 hardware drawings HF xxxx These drawings as well as tooling drawings HT xxxx form part of this manual 2 1 Frame 6F 01 Gas Turbine to Generator GE PART NUMBER RIVERHAWK P N GE VENDOC P N GE 114T4434P004 GE 114T4434P005 HF 7405 HF 7405 101B0676 101B0676 The hydraulic tools used for installation and removal

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Instruction Manual IM 368,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 6,4 0 General Preparations 9,5 0 Hardware Set Preparations 11. 6 0 Stud and Nut Assembly 14,7 0 Hydraulic Tensioner Equipment Assembly 14. 8 0 Assembly of Tensioner on Stud 17,9 0 Stud Tensioning 20.
10 0 Thread Locking 22,11 0 Stud and Nut Removal 23. 12 0 Storage Instructions 26,13 0 Frequently Asked Questions 27. 14 0 Revision History 30,EC Declaration of Conformity 31. 20 Bolt Tensioning Pattern LG GEN Record Sheet 32,215 Clinton Road GE DRAWING NUMBER REV. New Hartford NY 13413,Tel 1 315 768 4855,Fax 1 315 768 4941.
373A4082 C,Email info riverhawk com Page 2 of 32,Instruction Manual IM 368. 1 0 Cautions and Safety Warnings, 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, 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. 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, 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. 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. 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. A damaged burst disc must be replaced with a 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, Do not use the tensioner at any pressure unless the tool is installed on a stud in a flange.
215 Clinton Road GE DRAWING NUMBER REV,New Hartford NY 13413. Tel 1 315 768 4855,Fax 1 315 768 4941,373A4082 C,Email info riverhawk com Page 3 of 32. Instruction Manual IM 368, Do not over stroke the tensioner Over stroke can cause the piston to lose its seal and leak oil. 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. 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. 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. 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. Do not exceed the maximum pressure marked on the tensioner Excessive pressure can damage. the stud and puller screw, FIRE HAZARD DO NOT heat when tensioner is in place Personal injury or equipment damage. may occur Use of an Oxy Acetylene torch is not recommended. This document describes the procedure to be used to install the stud and nut sets supplied by. the Riverhawk Company for the flange at the Load Gear Generator connection The Gas. Turbine Load Coupling and Load Coupling Load Gear connections are described by a different. manual IM 367 GE 373A4081, The various frame configurations covered in this manual are listed in Sections 2 1 through 2 3.
with differences as related to connective hardware defined Listed also are the pertinent. 215 Clinton Road GE DRAWING NUMBER REV,New Hartford NY 13413. Tel 1 315 768 4855,Fax 1 315 768 4941,373A4082 C,Email info riverhawk com Page 4 of 32. Instruction Manual IM 368, hardware drawings HF xxxx These drawings as well as tooling drawings HT xxxx form part of. this manual,2 1 Frame 6F 01 Gas Turbine to Generator. GE PART NUMBER RIVERHAWK P N GE VENDOC P N,GE 114T4434P004 HF 7405 101B0676.
GE 114T4434P005 HF 7405 101B0676, The hydraulic tools used for installation and removal are Riverhawk HT 6865 load coupling. and HT 6866 generator, These hardware drawings depicts the complete stud and nut package for both Gas Turbine to. Load Coupling and Load Coupling to Load Gear 1 1 8 size Qty 24 as well as Load Gear to. Generator 1 5 8 size Qty 20, Note This manual covers HT 6866 tensioner 1 5 8 hardware only. See manual IM 367 GE 373A4081 for instructions to other tooling listed above. 2 2 Frame 6F 01 Gas Turbine to A30 Generator,GE PART NUMBER RIVERHAWK P N GE VENDOC P N. GE 114T4434P012 HF 8657 101B0752,GE 114T4434P013 HF 8657 101B0752.
The hydraulic tools used for installation and removal are Riverhawk HT 6865 load coupling. and HT 6866 generator, These hardware drawings depicts the complete stud and nut package for both Gas Turbine to. Load Coupling and Load Coupling to Load Gear 1 1 8 size Qty 24 as well as Load Gear to. Generator 1 5 8 size Qty 20, Note This manual covers HT 6866 tensioner 1 5 8 hardware only. See manual IM 367 GE 373A4081 for instructions to other tooling listed above. 2 3 Hydraulic Tooling,GE PART NUMBER RIVERHAWK P N GE VENDOC P N. GE 114T4434P006 HT 6865 GE 101B0649,HT 6866 GE 101B0650. MP 0130 GE 359B2506,215 Clinton Road GE DRAWING NUMBER REV.
New Hartford NY 13413,Tel 1 315 768 4855,Fax 1 315 768 4941. 373A4082 C,Email info riverhawk com Page 5 of 32,Instruction Manual IM 368. GE 114T4434P014 HT 6865 GE 101B0649,HT 6866 GE 101B0650. MP 0130 GE 359B2506, Note Hydraulic tooling list is for all related tooling for the gas turbine to generator connections. This manual covers HT 6866 tensioner 1 5 8 hardware only. See manual IM 367 GE 373A4081 for instructions to other tooling listed above. 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 80psi 5 5 bar minimum For air driven pumps. Check hydraulic hose for damage,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. Loosely place studs and nuts into the flange The studs are not centered in the flange. Set stick out dimension on the load gear side of the flange. 215 Clinton Road GE DRAWING NUMBER REV,New Hartford NY 13413.
Tel 1 315 768 4855,Fax 1 315 768 4941,373A4082 C,Email info riverhawk com Page 6 of 32. Instruction Manual IM 368,Hand tighten nuts on generator side of flange. Verify stick out measurement VERY IMPORTANT,TENSIONING Bolt Installation. Check tensioner 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,Place spanner ring on the load gear side nut. Insert 3 8 hex Allen wrench into the back side of the stud. Thread puller screw into the stud s conical thread. Tighten the puller screw Then back off puller screw 1 2 a turn. Retighten the puller screw and leave tight DO NOT BACK OFF PULLER SCREW. Slide the tensioner over the puller screw, Thread the puller nut onto the puller screw Then back the nut off two flats or 120.
degrees to allow for the stud to stretch, Tensioner should be free to rotate If tight against flange remove and check stick out. dimension of the stud, Place guard over assembly and tighten threaded hydraulic interlock knob firmly into. tensioner body,Tension to 50 Consult manual for correct pressure. Use the pin wrench in spanner ring to tighten nut,Release pressure move to next stud in pattern. Repeat above steps at final pressure,215 Clinton Road GE DRAWING NUMBER REV.
New Hartford NY 13413,Tel 1 315 768 4855,Fax 1 315 768 4941. 373A4082 C,Email info riverhawk com Page 7 of 32,Instruction Manual IM 368. Measure final stud length and record on stretch datasheets Calculate stretch. Torque the nuts set screws,DETENSIONING Stud Removal. If present loosen the windage plugs set screws and remove the windage plugs from the. Loosen nuts set screws, Inspect and clean 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 DO NOT USE.
NEVER SEIZE ON THE CONICAL THREADS,Place spanner ring on the load gear side nut. Insert 3 8 hex Allen wrench into the back side of the stud. Thread puller screw into the stud s conical thread. Tighten the puller screw Then back off puller screw 1 2 a turn. Retighten the puller screw and leave tight DO NOT BACK OFF PULLER SCREW. Slide the tensioner over the puller screw, Thread the puller nut onto the puller screw Then back the nut off two flats or 120. degrees to allow for the stud to shrink, Tensioner should be free to rotate If tight against flange remove and inspect. Place guard over assembly and tighten threaded hydraulic interlock firmly into tensioner. Apply final pressure,215 Clinton Road GE DRAWING NUMBER REV. New Hartford NY 13413,Tel 1 315 768 4855,Fax 1 315 768 4941.
373A4082 C,Email info riverhawk com Page 8 of 32,Instruction Manual IM 368. Loosen nut with the spanner ring and pin wrench,Move to next stud in pattern. 4 0 General Preparations, Read and understand all instructions before installing and tensioning 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 Once the nut is tight against the. flange the pressure in the tensioner is released The hardware is now clamping the flange. 4 1 Machine Preparation, The flange to be tensioned must be fully closed prior to positioning the studs in the flanges.
There must be provisions for turning the shafts of the gas turbine load coupling load gear and. generator Also it will be advantageous to remove as many obstructions as possible from the. flange area such as speed probes and conduit,4 2 Hardware Balance. The studs are supplied in component balanced sets A stud can be exchanged with another 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. 215 Clinton Road GE DRAWING NUMBER REV,New Hartford NY 13413. Tel 1 315 768 4855,Fax 1 315 768 4941,373A4082 C,Email info riverhawk com Page 9 of 32. Instruction Manual IM 368, The nuts are supplied in component balanced sets A nut can be exchanged with another in its. set without affecting 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. 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 will be required to perform installation and. measurement of the studs,5 8 Wrench 3 to 4 90cm 120cm Breaker Bar. 22mm Wrench 5 to 6 125mm 150mm Micrometer, A set of Allen Wrenches inch series 7 to 8 175mm 200mm Micrometer. 1 to 2 30cm 60cm Breaker Bar,4 5 Riverhawk Tools, Hydraulic Tensioner Kits HT 6865 Hydraulic Tensioner 1 1 8.
see manual IM 367 GE VENDOC 373A4081,reference GE VENDOC 101B0649. HT 6866 Hydraulic Tensioner 1 5 8,reference GE VENDOC 101B0650. Hydraulic Pump Kit MP 0130 Manual Hand Operated Hydraulic Pump. recommended,reference GE VENDOC 359B2506,215 Clinton Road GE DRAWING NUMBER REV. New Hartford NY 13413,Tel 1 315 768 4855,Fax 1 315 768 4941. 373A4082 C,Email info riverhawk com Page 10 of 32,Instruction Manual IM 368.
AP 0532 Air Operated Hydraulic Pump,reference GE VENDOC 359B2502. Stud Cleaning Kit GT 4354 Stud Cleaning Kit,recommended. reference GE VENDOC 373A4027, 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,1 of 2 Spanner Ring Holes. 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. 215 Clinton Road GE DRAWING NUMBER REV,New Hartford NY 13413. Tel 1 315 768 4855,Fax 1 315 768 4941,373A4082 C,Email info riverhawk com Page 11 of 32. Instruction Manual IM 368, Before threading the nut onto the stud the set screws should be loose and free to turn. 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. Before threading the nut onto the stud the set screws should be loose and free to turn. 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. 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. 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 Reference Riverhawk IM 220,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 4354 or a similar 1 2 diameter Brass power brush.
215 Clinton Road GE DRAWING NUMBER REV,New Hartford NY 13413. Tel 1 315 768 4855,Fax 1 315 768 4941,373A4082 C,Email info riverhawk com Page 12 of 32. Instruction Manual IM 368,Picture 5B 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 Use a sharp dental pick or seal pick to lightly scrape the root of the threads to check for. debris 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 thread lubricants such as Never Seize to the stud s threads. 10 Finish the cleaning process by rinsing in a volatile solvent such as acetone and allow to. 5 3 Stud Length Measurement, Measure and record the initial lengths of the studs The following suggestions will improve your. 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,215 Clinton Road GE DRAWING NUMBER REV. New Hartford NY 13413,Tel 1 315 768 4855,Fax 1 315 768 4941.
373A4082 C,Email info riverhawk com Page 13 of 32,Instruction Manual IM 368. 6 0 Stud and Nut Assembly, Refer to the hardware assembly drawing HF xxxx listed in Section 2 0 of this manual. 1 Assemble the cylindrical nut to the internal conical thread end of the stud. 2 Slide the stud and cylindrical nut assembly into the flange as shown in Figure 6A. Nut Stud Nut,Tensioning Conical,Set Stud Stick out Hex Drive. on this side only,Load Gear Generator,Flange Flange. Figure 6A Cross section View of Load Gear to,Generator Bolted Flange Connection.
3 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. 4 Hand tighten the assembly to a snug fit, 5 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,215 Clinton Road GE DRAWING NUMBER REV. New Hartford NY 13413,Tel 1 315 768 4855,Fax 1 315 768 4941. 373A4082 C,Email info riverhawk com Page 14 of 32,Instruction Manual IM 368.
7 1 1 Hydraulic Tensioner Inspection, 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. Do not bleed the air from the hydraulic line and tensioner at this time See section 8 for. bleeding instructions on when to bleed the air from the hydraulic line. 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. Check puller screw usage life with Riverhawk service bulletin SB 08001. Clean puller screw and check for any debris and dents. Puller screw should be free to rotate and move back and forth. Seam between cylinders must be closed tightly, 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. 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 for example Riverhawk HT xxxx 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. 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,215 Clinton Road GE DRAWING NUMBER REV.
New Hartford NY 13413,Tel 1 315 768 4855,Fax 1 315 768 4941. 373A4082 C,Email info riverhawk com Page 15 of 32,.

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