IM 251E 7FA.05 With Load Coupling Spacers

User Manual: IM-251E-7FA.05

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215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com



INSTRUCTIONMANUALIM‐251

ForGasTurbineTensioned

StudsandNuts



Note:Thismanualiswrittenspecificallyforconnectionsthat

employtheuseofLoadCouplingSpacersplacedunderthenuts.

Ifspacersarenotused,consultmanualIM‐327



ApplicableBoltingConnections–

Fr.7FA.05GasTurbineto7FH2BGenerator

Fr.7FA.05GasTurbinetoLoadCoupling

LoadCouplingto7FH2BGenerator



ApplicableGEOrderingSheetPartNumbers

110T2635P0001

110T2635P0002

110T2635P0003

110T2635P0004

110T2635P0005

110T2635P0006

110T2635P0007







 

GEPowerGeneration

GENERALELECTRICCOMPANY

MLI: ____ OF ____

DATE



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.

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373A4040

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updatethisdocumentwithoutdisseminationornotice.

ThelatestrevisionmaybeobtainedbycontactingRiverhawkCompanyorthruwww.riverhawk.com.

E

InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

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373A4040

GEDRAWINGNUMBER

Page2of40



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11

5.0HardwareSetPreparations14

6.0Stud,Nut,andLoadCouplingSpacerAssembly17

7.0HydraulicTensionerEquipmentAssembly20

8.0AssemblyofTensioneronStud23

9.0StudTensioning27

10.0ThreadLocking30

11.0Stud,Nut,andLoadCouplingSpacerRemoval30

12.0StorageInstructions34

13.0FrequentlyAskedQuestions35

14.0RevisionHistory38

Appendix

A118‐BoltTensioningPattern(GT‐LC)RecordSheet39

Appendix

A216‐BoltTensioningPattern(LC‐GEN)RecordSheet40





InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

REV

373A4040

GEDRAWINGNUMBER

Page3of40



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.



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.



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.



WARNING

Toavoidfailure,ensuresafety,andproperoperation,thetensionerassemblymustbeinstalled

onastudintheflangebeforebleedingand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.

InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

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GEDRAWINGNUMBER

Page4of40



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andnutsetssuppliedby

theRiverhawkCompanyintheflangesattheGasTurbine/LoadCouplingandLoad

Coupling/Generatorconnections.



ThevariousframeconfigurationscoveredinthismanualarelistedinSections2.1through2.4

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.





InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

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373A4040

GEDRAWINGNUMBER

Page5of40



2.1Frame7FA.05GasTurbineto7FH2BGenerator



GEPartNumberRiverhawkP/NGEVENDOCP/N

110T2635P0001

110T2635P0002

HF‐5117

GE269B8710



ThehydraulictoolingusedforinstallationandremovalisRiverhawkHT‐5144andHT‐6285for

thegasturbinesideoftheloadcouplingandHT‐6019forthegeneratorsideoftheload

coupling.



ThesehardwaredrawingsdepictthestudandnutsetfortheGasTurbinetoLoadCoupling(2‐

1/4”size,Qty18)aswellastheLoadCouplingto7FH2BGenerator(2‐3/4”size,Qty16).The

GasTurbinetoLoadCouplingstudandnutsetisusedwithasetofloadcouplingspacersthat

aresuppliedseparately.



2.2Frame7FA.05GasTurbinetoLoadCoupling



GEPartNumberRiverhawkP/NGEVENDOCP/N

110T2635P0004HF‐5411GE269B8711



ThehydraulictoolingusedforinstallationandremovalisRiverhawkHT‐5144andHT‐6285.



ThesehardwaredrawingsdepictthestudandnutsetfortheGasTurbinetoLoadCoupling(2‐

1/4”size,Qty18).TheGasTurbinetoLoadCouplingstudandnutsetisusedwithasetofload

couplingspacersthataresuppliedseparately.



2.3LoadCouplingto7FH2BGenerator



GEPartNumberRiverhawkP/NGEVENDOCP/N

110T2635P0005HF‐5412GE269B8712



ThehydraulictoolingusedforinstallationandremovalisRiverhawkHT‐6019.



ThesehardwaredrawingsdepictthestudandnutsetfortheLoadCouplingto7FH2BGenerator

(2‐3/4”size,Qty16).





InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

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Page6of40



2.4HydraulicTooling



GEPartNumberRiverhawkP/NGEVENDOCP/N

110T2635P0003



110T2635P0006

110T2635P0007

HT‐5144

HT‐6019

GT‐6030

AP‐0532

HT‐6285

HT‐5144

HT‐6019

GT‐6030

AP‐0532

HT‐6285

GE269B8713

GE269B8762

GE269B8763

GE359B2502

GE373A4069

GE269B8713

GE269B8762

GE269B8763

GE359B2502

GE373A4069



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.

□ Testpump.

□ Inspecttensionerforanydamage.



NUTANDSTUDPREPARATION

□ Inspectstudsandnutsforanydamage.

□ Cleanthestuds,nuts,andloadcouplingspacers(LoadCouplingSpacersongasturbine

toloadcouplingflangeonly)

InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

REV

373A4040

GEDRAWINGNUMBER

Page7of40



□ Measure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studs,nuts,andloadcouplingspacers(off‐center)intotheflange(LoadCoupling

Spacersareplacedontheloadcouplingsideofthegasturbinetoloadcouplingflange

only)

□ Setstick‐outdimensionontheloadcouplingsideoftheflange.

□ WithAllenwrenchinbacksideofstud,firmlyseatbacksidenutusingspannerringand

pinwrench.

□ Verifystick‐outmeasurement(VERYIMPORTANT)

□  Measureandrecordstartingstudinstallationgagereadings.(GeneratorSideOnly)



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.

□  Installtheretentionscrewsintotheadjacentstudsoneithersideofthestudtobe

tensioned.(GeneratorSideOnly)

□ 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.

□ 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tight.DONOTBACKOFFPULLERSCREW.

InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

REV

373A4040

GEDRAWINGNUMBER

Page8of40



□  Slidethefootoverthepullerstudandorientatethefootintoposition.

□ PlaceFootExtensionblocksoneithersideofthenut.(GasTurbineSideOnly)

□  Threadthetensioneronto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guidepinintotheholeinthebackside

ofthestud.(GasTurbineSideOnly)

□  Placetheguardovertensionerandpositiontheguard’spocketedslotsintoretention

screws.(GeneratorSideOnly)

□  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.(GeneratorSideOnly)

□  Pushthecenteroftheinterlockfittingtowardsthetensionerwhilepullingbackonthe

fitting’spulltabsuntilitlocksontothetensionerandreleasethepulltabs.

□  Installthebacksideguardtocoverstudtobetensioned.(GeneratorSideOnly)

□ 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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pulltabs.

□  Removethebacksideguard.(GeneratorSideOnly)

□  Loosentheknurledinterlockfittingandremovetheguard.

□  Unscrewthetensionerfromthepullerscrew.

InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

REV

373A4040

GEDRAWINGNUMBER

Page9of40



□  Removethefoot,footextensions(GasTurbineSideOnly),pullerscrew,spannerring,

andinthecaseofthegeneratorsidetheretentionscrews.

□  Movetothenextstudinthe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finalstretch

measurement.ThegeneratorsidemustuseGT‐6030gaugetoverifyinstallation.

□ Torquethenuts'setscrews.

DETENSIONING(StudRemoval)

□ 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.

□  Installtheretentionscrewsintotheadjacentstudsoneithersideofthestudtobe

tensioned.(GeneratorSideOnly)

□ 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.

□ 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tight.DONOTBACKOFFPULLERSCREW.

□  Placethefootextensionblocksoneithersideofthenut.(GasTurbineSideOnly)

□  Slidethefootoverthepullerstudandorientatethefootintoposition.

InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

REV

373A4040

GEDRAWINGNUMBER

Page10of40



□  Threadthetensioneronto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guidepinintotheholeinthebackside

ofthestud.(GasTurbineSideOnly)

□  Placetheguardovertensionerandpositiontheguard’spocketedslotsintoretention

screws.(GeneratorSideOnly)

□  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.(GeneratorSideOnly)

□  Pushthecenteroftheinterlockfittingtowardsthetensionerwhilepullingbackonthe

fitting’spulltabsuntilitlocksontothetensionerandreleasethepulltabs.

□  Installthebacksideguardtocoverstudtobetensioned.(GeneratorSideOnly)

□ Connectthehydraulicpumptothetensionerandtensiontofinalpressure.Consult

manualforcorrectpressure.

□ Loosen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pulltabs.

□  Removethebacksideguard.(GeneratorSideOnly)

□  Loosentheknurledinterlockfittingandremovetheguard.

□  Unscrewthetensionerfromthepullerscrew.

□

 Removethefoot,footextensions(GasTurbineSideOnly),pullerscrew,spannerring,

andinthecaseofthegeneratorsidetheretentionscrews.Itmaybenecessarytoinsert

anAllenwrenchintothebacksideofthestudtoremovethepullerscrew.

□ Movetonextstudinpattern



InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

REV

373A4040

GEDRAWINGNUMBER

Page11of40



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

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).



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).



InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

REV

373A4040

GEDRAWINGNUMBER

Page12of40



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.



Theloadcouplingspacersaresuppliedseparately.LoadcouplingspacerssuppliedbyRiverhawk

areincomponentbalancedsets.ARiverhawk‐suppliedloadcouplingspacercanbeexchanged

withanotherinitssetwithoutaffectingtheoverallbalanceoftheequipment.Donotexchange

aloadcouplingspacerfromonesetwithanotherspacerfromadifferentset.Whenshipped

fromRiverhawk,theloadcouplingspacers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).



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.



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

10”to11”MicrometerorCaliper





InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

REV

373A4040

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

4.5SpecialTools



HydraulicTensionerKit: HT‐5144HydraulicTensioner,2‐1/4”

(GasTurbineSideOnly)

(referenceGEVENDOC269B8713)

HT‐6285TensionerFootExtensions

(GasTurbineSideOnly)

(referenceGEVENDOC373A4069)

HT‐6019HydraulicTensioner,2‐3/4”

(GeneratorSideOnly)

(referenceGEVENDOC269B8762)



StudStretchMeasuringGauge:GT‐6030StretchGauge

(GeneratorSideOnly)

(referenceGEVENDOC269B8763)



HydraulicPumpKit:AP‐0532Air‐OperatedHydraulicPump

(recommended)

(referenceGEVENDOC359B2502)

MP‐0130ManualHand‐OperatedHydraulicPump

(referenceGEVENDOC359B2506)



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.





InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

REV

373A4040

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Page14of40



5.0HardwareSetPreparations



5.1NutandLoadCouplingSpacerPreparation



Picture5A‐RiverhawkLocknut



Ifthereisanyvisibledamageonanutorloadcouplingspacer,donotusethepartandcontact

theGeneralElectricorRiverhawkCompanyforareplacementpart.Pleasebepreparedto

supplytheturbinenumber,weightcertification,anddigitalphotographsforevaluation.



5.1.1NutandLoadCouplingSpacerCleaning‐NewInstallations



Fornewinstallations,thenutsshouldcomesealedfromthefactoryandwillneednocleaning.



5.1.2NutandLoadCouplingSpacerCleaning‐OldInstallations



Previouslyinstallednutsrequirecleaningasfollows:Wirebrushusingapetroleum‐based

solventtoremoveanyforeignmaterialonthethreads.Cleanmatingfaceswithapetroleum

basedsolventtoremoveanyforeignmaterial.



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.



(2)Spanner

RingHoles

(2)Locking

SetScrews

InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

REV

373A4040

GEDRAWINGNUMBER

Page15of40



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internal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



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.

InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

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373A4040

GEDRAWINGNUMBER

Page16of40



8. Verifythreadsarecleanbyusingadentalpicktolightlyscrapetherootofthethread.If

additionalmaterialcomesloose,repeatcleaningprocess.



9. Inspectthreadsforanydamagethatmayhavebeencausedbypreviousinstallation.



10. Donotapply“NeverSeize”tothestud’sthreads.



11. Finishthecleaningprocessbyrinsinginavolatilesolventsuchasacetoneandallowthe

studtodry.



5.3StudLengthMeasurement



5.3.1GasTurbineFlange2‐1/4”[58mm]Studs



Measureandrecordtheinitiallengthsofthestuds.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.





InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

REV

373A4040

GEDRAWINGNUMBER

Page17of40



5.3.2GeneratorFlange2‐3/4”[71mm]Studs



Thegeneratorflangestudsrequiretheuseofaspecialstudinstallationgauge.Thisgauge

measurestherelativedistancefromtheendofthestudtotheflangeface.



Picture5C–StudInstallationGauge



RefertotheGT‐6030StudInstallationGaugeinstructionmanual,IM‐309.Thelatestrevision

maybeobtainedbycontactingRiverhawkCompanyorthruwww.riverhawk.com.



6.0Stud,Nut,andLoadCouplingSpacer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.



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. Onthegasturbinesideonly,slidetheloadcouplingspaceroverthestuduntilit

contactswiththenut.



5. Slidethestud,nut,andspacerintotheflangeasshowninFigures6Aand6B.



GuideBlocks

OuterPin

Micrometer

InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

REV

373A4040

GEDRAWINGNUMBER

Page18of40



Figure6A–Cross‐sectionViewofGasTurbineto

LoadCouplingBoltedFlangeConnection



Figure6B–Cross‐sectionViewofLoadCouplingto

GeneratorBoltedFlangeConnection



BackSideNut

FrontSideNutStud

HexDrive

Tensioning

ConicalThread

*SetStudStick‐out

onthissideonly

LoadCoupling

FlangeGenerator

Flange

HexDrive

BackSideNutStud FrontSideNut

LoadCoupling

Flange

GasTurbine

Flange

Tensioning

ConicalThread

*SetStudStick‐out

onthissideonly

LoadCouplingSpacer

InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

REV

373A4040

GEDRAWINGNUMBER

Page19of40



6. Installtheothernutonthebackside.



7. 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.



Picture6C–UseofStick‐OutGageontheGas

TurbinesideoftheFlangeJoint



Picture6D–UseofDropGageto

measurestick‐out



Picture6E–UseofCalipersto

measurestick‐out



8. WithAllenwrenchinbacksideofstud,firmlyseatbacksidenutusingspannerringand

pinwrench.



9. Recheckthestudstick‐outlength.Ifthestick‐outlengthdoesnotmatchthehardware

drawing,adjustthenutsasnecessary.



10. Measureandrecordstartingstudinstallationgagereadings.(GeneratorSideOnly)



InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

REV

373A4040

GEDRAWINGNUMBER

Page20of40



7.0HydraulicTensionerEquipmentAssembly



7.1HydraulicEquipmentInspection



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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beforepressurizingthetensioner.Donotusethetensionerat

anypressureunlessthetoolisinstalledonastudinaflange.



Clean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.



InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

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

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.

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.





InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

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

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



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.



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.



InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

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

8.0AssemblyofTensioneron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.



Picture8A–FeaturesoftheHydraulicTensionerHT‐5144

SafetyGuard

Hose

Connection

Foot

PinWrench

Hydraulic

Cylinder

GasTurbine

Flange

LoadCoupling

Flange

Foot

Extension

FootExtension

InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

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

Figure8B–CutawayviewofHydraulicTensionerHT‐5144



Picture8C–FeaturesoftheHydraulicTensionerHT‐6019

PinWrench

FootSafetyGuardHose

Connection

KnurledInterlock

Fitting

HydraulicCylinderPullerScrewSpannerRing

Safety

Guard

Hose

Connection

Foot

PinWrench

Hydraulic

Cylinder

LoadCoupling

Flange

Retention

Screw

NutSpacer

InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

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

Figure8D–CutawayviewofHydraulicTensionerHT‐6019



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.



Assemblysequenceisasfollows:

1. Openthehydraulicreturnvalveonthepumptoallowhydraulicfluidtobepushedback

fromthepullertoolintothepumpreservoir.(Thisisautomaticontheair‐operated

hydraulicpump)

2. Threadtheretentionscrewsintotheadjacentstudsoneithersideofthestudtobe

tensioneduntilhandtight.(GeneratorSideTensionerOnly)

3. Placethespannerringonthenut.

4. Insertthepullerscrewintothetaperedthreadofthestudandhandtighten.Besurenotto

cross‐threadthepullerscrew.

5. Placethetwofootextensionsoneithersideofthenut(GasTurbineSideOnly)

6. UsinganAllenwrench,tightenthepullerscrewandthenbackoffthepullerscrew1/2a

turn.

7. Retightenthepullerscrewbyhanduntilitisfullyinserted.DONOTBACKOFFTHEPULLER

SCREW.

8. Placethefootoverthepullerscrewandorientateitintoposition.

PinWrench

Foot

SafetyGuard

Hose

Connection

KnurledInterlock

Fitting

HydraulicCylinder PullerScrew

SpannerRing

Backside

SafetyGuard

InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

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

9. Threadthetensionerontothepullerscrewuntilitstops.Pleasenotethattheinternalstop

insidethetensionerwillcauseagapinbetweenthefootandtensioner.Thegapshouldbe

1/16”[1.6mm]to3/16”[4.8mm].DONOTATTEMPTTOTIGHTENTHETENSIONERAGAINST

THEFOOT.

9A.Placetheguardoverthetensionerandpositiontheguidepinintotheholeinthebackside

ofthestud.(GasTurbineSideTensionerOnly)

9B.Placetheorangeguardoverthetensionerandpositionthepocketedslotsintothe

retentionscrews.(GeneratorSideTensionerOnly)

10. Tightentheknurledinterlockfittingbyhanduntilitfirmlypressesagainstthetensioner.

Thereshouldbenogapbetweenthetensionertheinterlockfitting.

11. Theretentionscrewsmustbeinsidetheguard’spocketedslots.(GeneratorSideTensioner

Only)

12. Activatethecustomconnectorfromthe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intothetensioner.Releasefingersfromthetabsandthenremove

thumb,Ensureconnectionisfirmlyengagedorelsethetensionerwillnotbeconnectedto

thepump.



Picture8E‐Activationofthesafetyinterlock



13. Installthebacksideguardandcentertheguardoverthestudtobetensioned.Threadthe

backsideguardintotheadjacentstudsuntilitstops.(GeneratorSideTensionerOnly)

14. Connectthehydraulicpumptothetensioner.Thetensionershouldnowbecompletely

assembledandreadyforuse.

Pulltabs

withfingers

Pulltabs

withfingers

Pushcenter

withthumb

InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

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

8.3BleedingHydraulicSystem



Bleedingofthehydraulicsystemisnotnecessarywiththistensionerdesign.



9.0Stud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recordsheetsfoundattheendof

thismanual.



9.1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.



WARNING

Thesafetycagemustbeinplaceatalltimes.Keephandsoutofdesignatedareasatalltimes

whenthetensionerispressurizedotherwisepersonalinjurycanoccur.



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exceedthemaximumpressuremarkedonthetensioner.Excessivepressurecan

damagethestudandpullerscrew.



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.





InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

REV

373A4040

GEDRAWINGNUMBER

Page28of40



FlangePositionStudSize50%Pressure50%Stretch

GasTurbinetoLoad

Coupling

2‐1/4"

[58mm]

9000psi

[620bar]

Donotmeasure

Donotuse

LoadCouplingto

Generator

2‐3/4"

[71mm]

10000psi

[690bar]

Donotmeasure

Donotuse



Firmlytightenthecylindricalnutswithapproximately20ft∙lbs[27N∙m]oftorqueusingthepin

wrenchandspannerring.Turnthenutuntilitbottomsontheflange.



9.2RemovingtheTensionerfromanInstalledStud



Thetensionerremovalisaccomplishedbythefollowssteps:

1. ReleasethehydraulicpressurebyeitherreleasingthehandswitchontheAP‐0532

PumpKitorbyopeningthevalveontheMP‐0130ManualPumpKitandleavethevalve

open.

2. Removethebacksideguard.(GeneratorSideTensionerOnly)

3. Unscrewtheknurledinterlockfittingattheendoftheguardandremovetheguardfrom

thetensioner.

4. Unscrewthetensionerfrompullerscrew.

5. Removethefootandthetwofootextensionsfromaroundthepullerscrew.

6. UnscrewthepullerscrewusinganAllenwrench.TappingtheAllenwrenchwitha

hammerortheuseofa3‐4’breakerbarmaybenecessarytoloosenthepullerscrew.

Donotuseanimpactwrenchasthiscandamagethepullerscrew.

7. Removethespannerringfromthenut.

8. Inthecaseofthegeneratorsideoftheloadcouplingflange,unscrewtheretention

screwsusinganAllenwrench.ItmaybenecessarytotaptheAllenwrenchwitha

hammerorusea3‐4’breakerbartoloosentheretentionscrews.Donotuseanimpact

wrenchasthiscandamagetheretentionscrews.

9. Movethetooltothenextboltholefollowingthetensioningpatternfromthestretched

recordsheetsattheendofthismanual.



9.3TensioningatFinalPressure



Repeatthepullingandtighteningprocedurestatedaboveatfullpressure.Afterallofthestuds

havebeentensioned,measurethefinalstudlength.Thefinalpressureandrequiredstretch

valuesarelistedinthefollowingtable.





InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

REV

373A4040

GEDRAWINGNUMBER

Page29of40



WARNING

Thesafetycagemustbeinplaceatalltimes.Keephandsoutofdesignatedareasatalltimes

whenthetensionerispressurizedotherwisepersonalinjurycanoccur.



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exceedthemaximumpressuremarkedonthetensioner.Excessivepressurecan

damagethestudandpullerscrew.



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.



FlangePositionStudSizeFinalPressureFinalStretchGaugeReading

GasTurbinetoLoad

Coupling

2‐1/4"

[58mm]

18000psi

[1240bar]

0.018"‐0.020"

[0.51mm‐0.56mm]

‐‐‐‐‐

LoadCouplingto

Generator

2‐3/4"

[71mm]

19000psi

[1310bar]

0.014"‐0.016"

[0.36mm‐0.41mm]

0.025”‐0.030”

[0.63mm‐0.76mm]



Firmlytightenthecylindricalnutswithapproximately20ft∙lbs[27N∙m]oftorqueusingthepin

wrenchandspannerring.Turnthenutuntilitbottomsontheflange.



Failuretoachievethecorrectfinalstretchvalueswillresultinanincorrectlytensionedstud.



Incorrectstretchvaluescanbecorrectedbyuninstallingsomeoralloftheselectedstuds.Re‐

measuretheinitiallengthofthestudsandrepeattheinstallationinstructionsstuds.Excessive

stretchvariationscanalsobecorrectedbythesamemethod.



Havefinalstretchvaluesapprovedbythesupervisorresponsiblefortheinstallation.





InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

REV

373A4040

GEDRAWINGNUMBER

Page30of40



10.0ThreadLocking



Picture10A‐RiverhawkLocknut



Mechanicallocknutshavetwosetscrewslocatedinthetopface.Beforethreadingthenut

ontothestud,checktobecertainthesetscrewsarefreetoturn.Oncethenutisseatedtorque

thesetscrewstothevaluesspecifiedinthefollowingtable.Whenseatedandtorquedtothe

valuesspecified,theloadcreatedbythesetscrewdisplacesthethreadofthenutintheareaof

thewebtherebycreatingthedesiredlockingaction.



FlangePositionStudSizeSetScrewSizeTorque

GasTurbinetoLoad

Coupling

2‐1/4"

[58mm]1/4"‐28UN70in∙lbs‐80in∙lbs

[7.9N∙m–9.0N∙m]

LoadCouplingto

Generator

2‐3/4"

[71mm]3/8"‐24UN200in∙lbs‐250in∙lbs

[22.6N∙m–28.2N∙m]



11.0Stud,Nut,andLoadCouplingSpacerRemoval



11.1HandlingoftheTensioner



Thetensionerusedinthisapplicationisdesignedfornospecialliftinginstructions.Donotdrop

anypartofthetensionerontheoperatororothernearbypersonnel.





(2)Spanner

RingHoles

(2)Locking

SetScrews

InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

REV

373A4040

GEDRAWINGNUMBER

Page31of40



11.2Stud,Nut,andLoadCouplingSpacerRemoval



WARNING

Thesafetycagemustbeinplaceatalltimes.Keephandsoutofdesignatedareasatalltimes

whenthetensionerispressurizedotherwisepersonalinjurycanoccur.



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exceedthemaximumpressuremarkedonthetensioner.Excessivepressurecan

damagethestudandpullerscrew.



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.



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.



Section8.0containsdiagramsofthetensionerequipment.



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.

Disassemblysequenceisasfollows:

1. Usingawirebrush(GT‐4253)andshopair,cleantheinternaltaperedthreadofthestudto

removeanydebris/depositswhichmayhaveaccumulatedduringserviceasdescribedin

section5.2.2.DonotcontinueuntilALLdebrisisremovedfromthethreads.



WARNING

Donotuseahydraulictensionertoremoveastudwithdamagedconicalthreads.



2. WithanAllen‐wrenchloosenthetwolockingsetscrewsbutdonotremovefromthenut.



InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

REV

373A4040

GEDRAWINGNUMBER

Page32of40



Picture11A‐Looseningofanut'ssetscrews



3. Connectthehydraulichosefromthehydraulicpumptothetensioner.

4. Openthehydraulicreturnvalveonthepumptoallowhydraulicfluidtobepushedback

fromthepullertoolintothepumpreservoir.(Thisisautomaticontheair‐operated

hydraulicpump)

5. Threadtheretentionscrewsintotheadjacentstudsoneithersideofthestudtobe

tensioneduntilhandtight.(GeneratorSideTensionerOnly)

6. Placethespannerringonthenut.

7. Insertthepullerscrewintothetaperedthreadofthestudandhandtighten.Besurenotto

cross‐threadthepullerscrew.

8. UsinganAllenwrench,tightenthepullerscrewandthenbackoffthepullerscrew1/2a

turn.

9. Retightenthepullerscrewbyhanduntilitisfullyinserted.DONOTBACKOFFTHEPULLER

SCREW.

10. Placethetwofootextensionsoneithersideofthenut(GasTurbineSideOnly)

11. Placethefootoverthepullerscrewandorientateitintoposition.

12. Threadthetensionerontothepullerscrewuntilitstops.Pleasenotethattheinternalstop

insidethetensionerwillcauseagapinbetweenthefootandtensioner.Thegapshouldbe

1/16”[1.6mm]to3/16”[4.8mm].DONOTATTEMPTTOTIGHTENTHETENSIONERAGAINST

THEFOOT.

12A.Placetheguardoverthetensionerandpositiontheguidepinintotheholeinthebackside

ofthestud.(GasTurbineSideTensionerOnly)

12B.Placetheorangeguardoverthetensionerandpositionthepocketedslotsintothe

retentionscrews.(GeneratorSideTensionerOnly)

13. Tightentheknurledinterlockfittingbyhanduntilitfirmlypressesagainstthetensioner.

Thereshouldbenogapbetweenthetensionertheinterlockfitting.

InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

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GEDRAWINGNUMBER

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

14. Theretentionscrewsmustbeinsidetheguard’spocketedslots.(GeneratorSideTensioner

Only)

15. Activatethecustomconnectorfromthe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intothetensioner.Releasefingersfromthetabsandthenremove

thumb,Ensureconnectionisfirmlyengagedorelsethetensionerwillnotbeconnectedto

thepump.



Picture11B‐Activationofthesafetyinterlock



16. Installthebacksideguardandcentertheguardoverthestudtobetensioned.Threadthe

backsideguardintotheadjacentstudsuntilitstops.(GeneratorSideTensionerOnly)

17. Connectthehydraulicpumptothetensionerandapplytheappropriatehydraulicpressure

perthistable.



FlangePositionStudSizeFinalPressure

GasTurbinetoLoad

Coupling

2‐1/4"

[58mm]

18000psi

[1240bar]

LoadCouplingto

Generator

2‐3/4"

[71mm]

19000psi

[1310bar]



Pulltabs

withfingers

Pulltabs

withfingers

Pushcenter

withthumb

InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

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

18. Turnthespannerringwiththepinwrench.Loosenandturnthenutapproximately3/4ofa

turn.

19. Releasethehydraulicpressure.



11.3.1RemovingtheTensionerfromaStud



Thetensionerremovalisaccomplishedbythefollowssteps:

1. ReleasethehydraulicpressurebyeitherreleasingthehandswitchontheAP‐0532

PumpKitorbyopeningthevalveontheMP‐0130ManualPumpKitandleavethevalve

open.

2. Removethebacksideguard.(GeneratorSideTensionerOnly)

3. Unscrewtheknurledinterlockfittingattheendoftheguardandremovetheguardfrom

thetensioner.

4. Unscrewthetensionerfrompullerscrew.

5. Removethefootandthetwofootextensionsfromaroundthepullerscrew.

6. UnscrewthepullerscrewusinganAllenwrench.TappingtheAllenwrenchwitha

hammerortheuseofa3‐4’breakerbarmaybenecessarytoloosenthepullerscrew.

Donotuseanimpactwrenchasthiscandamagethepullerscrew.

7. Removethespannerringfromthenut.

8. Inthecaseofthegeneratorsideoftheloadcouplingflange,unscrewtheretention

screwsusinganAllenwrench.ItmaybenecessarytotaptheAllenwrenchwitha

hammerorusea3‐4’breakerbartoloosentheretentionscrews.Donotuseanimpact

wrenchasthiscandamagetheretentionscrews.

9. Movethetooltothenextboltholefollowingthetensioningpatternfromthestretched

recordsheetsattheendofthismanual.



12.0StorageInstructions



Followthesedirectionstoproperlystoreyourhydraulictensionerandhydraulicpumpkitfor

longtermstorageandshipment.



Ifanydamageisobserved,contacttheRiverhawkCompanytoscheduleamaintenance

inspection.



12.1HydraulicPumpKitStorage



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.





InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

REV

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GEDRAWINGNUMBER

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

12.2HydraulicTensionerStorage



Checkthetensionerforanydamage

1. Cleanpullerscrewandcheckforanydebrisanddents.

2. Knurledinterlockfittingshouldbecleanandfreetorotate.

3. Inspectthetensionerguardforanysignsofdamage.Bentguardsmustbereplaced.



Ifanydamageisobserved,contacttheRiverhawkCompanytoscheduleamaintenance

inspection.



Placetheprotectiveplasticcapontheguard’sknurledinterlockfitting.



Coatthehydraulictensionerwithalightcoatofoilandplacethetensionerintotheoriginal

shippingcontainer.



12.3Storeshippingcontainer



Securethehydraulicpumpandhydraulictensionerintotheoriginalshippingcontainersusing

thesuppliedwoodbraces.



Sealtheoriginalshippingcontainerandstoreundershelterandprotectedfrommoisture,sand,

andgrit.



13.0FrequentlyAskedQuestions



Thissectioncontainssomefrequentlyaskedquestionsandproblems.Ifthestepslistedheredo

notsolveyourproblem,contacttheRiverhawkCompanythruourwebsite,email,orphonecall.



Q:



A:



CanIrentahydraulictensionerkit?



Yes,Riverhawkhasrentaltensionerkitsavailableformostofourhydraulictensioners.

Q:



A:

Atensionerhaspulleditselfoutofthestud'sconicalthreads.CanIcontinueusinga

tensioneronthisstud?



No.Boththetensionerandthestudmayhavebeendamagedandmustberemoved

fromtheworkarea.Ifthestudistensioned,aNutBusterrepairkit,fromRiverhawk,

mustbeusedtoremovethedamagedstudbydrillingoutthenut.Leavingadamaged

studinplacewillleadtoasafetyhazardonfutureoutages.



InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

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GEDRAWINGNUMBER

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

Riverhawkcansupplyareplacementstudandnutbasedontheinitialweight

certificationsuppliedwiththehardwareset(seesection4.2).Thedamagedtensioner

shouldalsobereturnedtoRiverhawkforinspectionandrepair.



Ifastudmustbeleftinplace,paintthedamagedstudwithagenerousamountof

indelible,bright‐coloredpaint.NotifytheappropriateGESafetyandServicepersonnel.

Notethelocationofthedamagedstudintheservicesnotesforthemachine.



Q:



A:

Thehydraulictensionerhasbeentakenuptoitsfinalpressure.Thefinalstretchlengthis

shortofthefinalstretchtarget.Whatisthenextstep?



Donotincreasethehydraulicpressure.Checkifthehydraulicpumpissettotheright

pressure.Installthetensionerandre‐pressurizethetensionertothefinalpressurethen

recheckthestretchmeasurement.Ifthestretchvalueisstillshort,removethestud

fromtheholeandre‐measurethestud'sinitiallengththentrytoinstallthestudagain.



Q:



A:

Thehydraulictensionerhasbeentakenuptoitsfinalpressure.Thefinalstretchlengthis

largerthanthefinalstretchtarget.Whatisthenextstep?



Removethestudfromthebolthole.Checkifthehydraulicpumpissettotheright

pressure.Re‐measurethestud'sinitiallengththentrytoinstallthestudagain.



Q:



A:

Thetensionerisatitsfinalpressure,butthenutcannotbeloosened.



Ifthenutscannotbeloosenedatthefinalpressure,continuallyincreasingthepressure

willnothelpandcanbedangerousandinsomecasesmakeithardertoremovethenut.

Checkthenuttoseeifitssetscrewshavebeenloosened.Checkforandremoveany

corrosionaroundthenut'sthreads.Applypenetratingoilbetweenthestudandthenut.



Q:



A:

HowdoIcleantheconicalthreadsonastud?



Theconicalthreadsarebestcleanedusingaspiralwoundbrassbrushinadrillas

describedinsection5.2.2



InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

REV

373A4040

GEDRAWINGNUMBER

Page37of40



Q:



A:

Duringtheinitialstepsofremovingatensionedstud,thestick‐outlengthisfoundtobe

wrong.



Donotproceed.ContactRiverhawkforassistance.Withthewrongstick‐outlength,the

hydraulictensionerhasalimitedstrokeandmaynotworkproperlyandcanbe

damaged.



Q:



A:

Thehydraulicpumpappearstobeleaking.



Checkthehoseconnectiontothehydraulicpump.Ifthe1/4"highpressurefittingisnot

assembledcorrectlyasshowninsection7.2,itmaylooklikethepumpisleaking.Ifthe

problemcontinues,itmaybenecessarytoopenthepumpkit.ContactRiverhawkfor

guidance.



Q:



A:

Thehydraulichosehasacollaronitthatcan'tbemovedbyhand



Thehydraulicfittingisshowninsection7.2.Thecollarissometimesheldinplacewitha

threadlockingcompound.Thispreventsthecollarfrommovingtooeasily.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‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

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14.0RevisionHistory



Revision

Letter

EffectiveDateDescription

EFeb16,2014Section3.0&6.0Removedhandtighten,addedtighten

withspannerring,Section3.0&6.0addedmeasureand

recordstartinggagereadings(generatorside),Section

5.3.2revisedstudstretchmeasurementgaugetoread

studinstallationgauge,Section9.3addedgagereading

columntofinalinstallationchart(generatorside),

Appendix2renamedfinalstretchtofinalgaugereading

D12/19/13UpdatedGEpartnumberfrom106T1751P003to

110T2635P0003page6,section2.4.RS.

C12/11/13Addednotetotitlepageandchangedstretchfrom

.020/.022to.018/.020ontheturbineend.RJD.

BOct25,2013RemovedGE106T1751fromthetitlepageandsection

2.0andreplaceditwithGE110T2635,Addedreferences

toloadcouplingspacerstosections3,4.2,5.0,and6.0,

Addedreferencestofootextensionstosections3,4.5,

8.2,9.2,and11.2

AMar25,2013Correctedtypoinrupturediscwarninginsections1.0

and7.1.1.1,CorrectedarrowlocationinFigure6A,Added

referencetotensionerlisttosections7.1.1and7.1.1.1,

Addedretentionscrewarrow/texttoPicture8C,

Correctedtypeinsection8.2step12andsection11.2

step15,added“approximately”tosections9.1and9.3

‐ Mar20,2013Released



InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

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AppendixA1



STRETCHRECORDSHEETFOR

THEGASTURBINETOLOADCOUPLING



TURBINENUMBER:



DATE:



TECHNICIAN:



SUPERVISOR:



HOLENUMBERSTARTINGLENGTHFINALLENGTHFINALSTRETCH

1 

10 

2 

11 

3 

12 

4 

13 

5 

14 

6 

15 

7 

16 

8 

17 

9 

18 

InstructionManualIM‐251



215ClintonRoad

NewHartford,NY13413

Tel:+13157684855

Fax:+13157684941

Email:info@riverhawk.com

REV

373A4040

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Page40of40



AppendixA2



STRETCHRECORDSHEETFOR

THELOADCOUPLINGTOGENERATOR



TURBINENUMBER:



DATE:



TECHNICIAN:



SUPERVISOR:



HOLENUMBERSTARTING

MEASUREMENTFINALMEASUREMENTFINALGAUGEREADING

1 

9 

5 

13 

15 

7 

3 

11 

8 

16 

12 

4 

10 

2 

6 

14 



IM 251E 7FA.05 With Load Coupling Spacers

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