IM 419 (D602)
User Manual: IM-419
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INSSTRUCTION MANUA AL IM‐419 For Gas Tu urbine Ten nsioned Stud ds and Nutts onnections Applicable Bolting Co D602 Ste eam Turbine HPIP Rotor to LP Rotor Applicable GE Orderiing Sheet Paart Numbers 126T8064P0001 126T8064P0002 126T8064P0003 GE Pow wer Generattion GENERAL ELECTRIIC COMPANY VEN NDOR SUPPLIED GE NO OT TO REVISE. GE REVISION LEVEL IS SHOWN N ON THIS APPLIQUE. TH HIS DOCUMENT IS FILEED UNDER THE GE DRAAWING NUMBER. THIS DOCUMENTT SHALL BE REVISED IN N ITS ENTIRETY. ALL SH HEETS OF THIS DOCUM MENT ARE THE SAME REVISSION LEVEL AS INDICATTED IN THIS VENDOR SSUPPLIED DRAWING AAPPLIQUE. MLI: M _____ OF ____ GE SIGNATUREES DATEE GE D DRAWING NUMBER REV CHECKED: ISSSUED: 1000A1467 The Riverrhawk Compaany reserves the right to update this ddocument wiithout dissem mination or n notice. The latestt revision mayy be obtained d by contactin ng Riverhawkk Company orr thru www.riverhawk.com m. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 m Email: inffo@riverhawk.com Instructio on Manual IM ‐419 Table of Conten nts Sectio on De escription Page Num mber 1.0 0 Cautions an nd Safety Waarnings 3 2.0 0 Scope and GE Partt Number Cr oss Reference 4 3.0 0 Quicck Checklist 5 4.0 0 Generaal Preparatioons 9 5.0 0 Hardware Set Preparaations 11 6.0 0 Stud and d Nut Assem mbly 14 7.0 0 Hydraaulic Tension ner Equipmeent Assemblyy 16 8.0 0 Assembly off Tensioner oon Stud 19 9.0 0 Stud d Tensioning 22 10.0 0 Thread Locking and d Windage Plug Installation 25 11.0 0 Stud and Nut Remooval 27 12.0 0 Storagge Instructionns 31 13.0 0 Frequentlyy Asked Queestions 31 14.0 0 Revission Historyy 34 Appen ndix A1 EC Declarattion of Confoormity 35 Appen ndix B1 16‐Bolt Te ensioning Pattern (HPIP‐‐LP) Record SSheet 36 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Pagee 2 of 36 Instructio on Manual IM ‐419 1.0 Cautiions and Saffety Warninggs WARNING W Improper tool use an nd the failurre to follow the correct proceduress are the prim mary root causes of tool failure es and perso onal injuriess. A lack of training or exxperience caan lead to incorrectt hardware installation i or incorrectt tool use. O Only trained operators w with careful,, deliberatte actions sh hould use hyydraulic tensioners. Con ntact Riverh hawk Compaany with anyy training needs. n WARNING W Risk of higgh pressure fluid f injectio on. Riverhaw wk tools ope rate under h high pressure. Thorough hly inspect all hoses and connections c s for damage e or leaks pr ior to using this equipment. CAUTION C e damage d can occur if the proper heallth and safetty codes and d Personal injury and equipment f Contact the sitte’s health a nd safety offfice to determine all procedurres are not followed. applicablle safety rule es and regulations. WARNING W The prop per personal protective equipment e must m be worrn at all timees. Riverhaw wk recommen nds at a minimum, safetyy glasses, lon ng sleeve shirt, hard hatt, heavy worrk gloves, and steel toe sshoes CAUTION C It is especially importtant to checck the condittion of the coonical thread used to teension the sttud. d from m previous ab buse can leaad to failure of the stud or tensionin ng equipmen nt Thread damage CAUTION C wk recomme ends that the e tensioner should s be reeturned to Riiverhawk for periodic Riverhaw inspectio ons. Replacement of obssolete tensio oners is recommended. FFunctional u upgrades aree also recomme ended. The Riverhawk R Service Returrns Coordinaator should b be notified 3 3‐6 months p prior to a planned outage to schedule an inspectio on service. WARNING W A damagged burst disc must be re eplaced with h a burst discc of the sam me design and d pressure rating. Do not substittute a damaaged burst diisc with a diffferent disc type, a diffeerent pressure rating, orr a foreign object. WARNING W To avoid failure, ensu ure safety, and a proper operation, o thhe tensionerr assembly m must be instaalled on a stud d in the flangge before ble eeding and pressurizing p the tension ner. Do not u use the tensiioner at any prressure unlesss the tool iss installed on n a stud in a flange. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Pagee 3 of 36 Instructio on Manual IM ‐419 CAUTION C Personal injury and equipment e damage d can occur if the puller screw w is not securely engaged with the tapered threads of the stud. s Properr engagemennt is achieveed when the puller screw w is he stud and the tensioner assemblyy is free to tuurn. tight in th WARNING W The safetty cage mustt be in place e at all times. When the ttensioner is pressurized d hands mustt be kept out of designate ed areas to avoid a any po otential for ppersonal inju ury. CAUTION C hreading the e puller screw w into the sttud, carefull y check the cleanliness of both the Before th stud's an nd the puller screw's con nical threadss. Apply a lig ht coat of clean turbine oil or a spraay lubricantt to the pulle er screw. Thiis procedure e will ease asssembly and d assure positive mating of the threaads before tiightening. Do D not use “N Never Seize”” on the con nical threadss. CAUTION C ure is achievved Do not tighten the nut while the tool is comiing up to preessure; waitt until pressu o tighten the e nut with th he spanner rring. If the to ool is not pro operly installed, before atttempting to the tool could c jump off o the stud while comin ng up to presssure. CAUTION C m pre essure marked on the teensioner. Exccessive pressure can dam mage Do not exxceed the maximum the stud and puller screw. WARNING W FIRE HAZZARD: DO NOT heat when puller asssembly is in place. Perso onal injury o or equipment damage may occur. Use U of an Oxxy‐Acetylene e torch is not recommen nded WARNING W onical thread ds. Do not use a hydraullic tensionerr to remove a stud with damaged co e and GE Part Number Cross C Refere ence 2.0 Scope This docu ument descrribes the pro ocedure to be b used to innstall the stud, nut, and w windage plu ug sets supp plied by the Riverhawk Company C in the flanges aat the HPIP tto LP connecctions. The hydrraulic toolingg used in thiss application n can be idenntified by itss ORANGE saafety guard. If the safetty guard is YEELLOW, a diffferent set of o instructionns are requirred. Consultt the Riverhaawk factory fo or assistance e. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Pagee 4 of 36 Instructio on Manual IM ‐419 The vario ous frame co onfigurationss covered in this manua l are listed in Sections 2 2.1 through 2 2.2 with diffe erences as related to connective hardware definned. Listed aalso are the pertinent hardware e drawings (HF‐xxxx). Th hese drawinggs as well ass tooling draw wings (HT‐xxxxx) form paart of this manual. 2 Steam Turb bine HPIP Ro otor to LP Ro otor 2.1 D602 GE Part Number N 126T8064P0001 Riverhaw wk P/N HF‐7956 6 GE VENDOC P P/N GE 101B0709 9 The hydrraulic toolingg used for installation an nd removal i s Riverhawkk HT‐7967. These haardware drawings depicct the stud, nut, and wi ndage plug set for the HPIP rotor to LP rotor (2‐3 3/4” size, Qtty 16). 2.2 Hydraulic Toolingg N GE Part Number 126T8064P0002 126T8064P0003 Riverhaw wk P/N HT‐7967 7 AP‐6048 8 GEE VENDOC P P/N GEE 101B0710 GEE 269B8768 3.0 Quickk Checklist The following checklist is intende ed as a summ mary of the steps needeed to use thee Riverhawkk‐ supplied equipment.. New person nnel or those experienc ed personneel who have not used th he Riverhaw wk equipmen nt recently are a encouragged to read tthe entire m manual. EQUIPMENT INSPECTION □ Che eck oil level in hydraulic pump. □ Che eck air presssure at 80psii [5.5 bar] minimum. (Foor air‐driven pumps) □ Che eck hydraulicc hose for daamage. □ Tesst pump. □ Insp pect tension ner for any damage. d 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Pagee 5 of 36 Instructio on Manual IM ‐419 NUT AND D STUD PREP PARATION □ Insp pect studs, nuts n and win ndage plugs for any dam mage. □ Clean the studss, nuts, and windage w plu ugs. □ Me easure and re ecord stud le engths. (VER RY IMPORTA ANT) □ Lub bricate the sttud’s thread ds with clean n turbine oil or spray lub bricant. Lubrricate the nu ut’s threads and nu ut face with clean c turbine oil or sprayy lubricant. □ Insttall studs and nuts (off‐ccenter) into the flange. □ Sett stick‐out dimension on the HPIP sid de of the flannge. □ Witth Allen wrench in backsside of stud, firmly seat backside nut using span nner ring and d pin wre ench. □ Verrify stick‐outt measureme ent (VERY IM MPORTANT)) TENSION NING (Bolt In nstallation) □ Che eck tensione er drawing fo or correct paarts and partt numbers. □ App ply a light co oat of clean turbine t oil or o spray lubriicant to the puller screw w. DO NOT U USE “NEEVER SEIZE” ON THE CO ONICAL THREEADS. □ Insttall the reten ntion screwss into the ad djacent studss on either sside of the sttud to be ten nsioned. □ Insttall the span nner ring ontto the nut. □ Thrread the puller screw intto the stud. □ Inse ert an Allen wrench into o the back sid de of the stuud. □ Inse ert another Allen wrench into the puller screw. While holding the stud still, tighten n the puller screw un ntil hand tigh ht and then loosen the ppuller screw 1/2 of a turn. Retighten n the puller screw an nd leave tigh ht. DO NOT BACK B OFF PU ULLER SCREW W. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Pagee 6 of 36 Instructio on Manual IM ‐419 □ Slid de the correcct foot over the puller sttud and orieentate the fo oot into posittion. □ Thrread the tensioner onto puller screw w until it stopps. There should be a 1//16” to 3/16 6” gap bettween the fo oot and tensioner. □ Place the guard d over tensio oner and possition the guuard’s pockeeted slots intto retention scre ews. □ Tighten the guaard’s knurled d interlock fitting by hannd until it prresses firmlyy against ten nsioner (no gap). g □ The e retention screws s must be inside th he guard’s poocketed slotts. □ Pussh the center of the interlock fitting towards thee tensioner w while pullingg back on the fitting’s pull tab bs until it loccks onto the tensioner aand release tthe pull tabss. □ Insttall the backkside guard to t cover stud d to be tensiioned. □ Con nnect the hyydraulic pum mp to the ten nsioner and ttension to 550%. Consultt manual for corrrect pressurre. □ Use e the pin wre ench to turn n the spanne er ring to firm mly tighten n nut with 20 fft∙lbs [27 N∙m m] of torque. □ Release pressure and allow w the tension ner to fully rretract. □ Disconnect the hose and re elease the in nterlock fittinng by pushin ng the centeer of the inteerlock fitting towards the tensioner while pulling back onn the fitting’ss pull tabs. □ Rem move the baackside guard d. □ Loo osen the knu urled interlocck fitting and d remove thhe guard. □ Unsscrew the te ensioner from m the pullerr screw. □ Rem move the foo ot, puller scrrew, spanne er ring, and tthe retention n screws. □ Mo ove to the ne ext stud in th he pattern. Tension T all sttuds to 50% % before procceeding to fiinal pre essure. □ Rep peat above steps s at final pressure. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Pagee 7 of 36 Instructio on Manual IM ‐419 □ Me easure final stud s length and a record on o stretch daatasheets. C Calculate finaal stretch measurement. □ Torrque the nutts' set screws. □ ws. Insttall the wind dage plugs and torque th heir set screw DETENSIONING (Stud Removal) □ Loo osen the win ndage plugs’ set screws and a remove the windage plugs from m the studs. □ Loo osen nuts' se et screws. □ Insp pect and clean studs' co onical thread ds. Do not co ontinue unttil ALL debriss is removed d from the threa ads! See insttruction man nual IM‐220 . Do not tryy to use the tensioner to o rem move a dama aged stud! □ App ply a light co oat of clean turbine t oil or o spray lubriicant to the puller screw w. DO NOT U USE “NEEVER SEIZE” ON THE CO ONICAL THREEADS. □ Insttall the reten ntion screwss into the ad djacent studss on either sside of the sttud to be ten nsioned. □ Insttall the span nner ring ontto the nut. □ Thrread the puller screw intto the stud. □ Inse ert an Allen wrench into o the back sid de of the stuud. □ Inse ert another Allen wrench into the puller screw. While holding the stud still, tighten n the puller screw un ntil hand tigh ht and then loosen the ppuller screw 1/2 of a turn. Retighten n the nd leave tigh ht. DO NOT BACK B OFF PU ULLER SCREW W. puller screw an □ Slid de the correcct foot over the puller sttud and orieentate the fo oot into posittion. □ Thrread the tensioner onto puller screw w until it stopps. There should be a 1//16” to 3/16 6” gap bettween the fo oot and tensioner. □ Place the guard d over tensio oner and possition the guuard’s pockeeted slots intto retention ews. scre 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Pagee 8 of 36 Instructio on Manual IM ‐419 □ Tighten the guaard’s knurled d interlock fitting by hannd until it prresses firmlyy against ten nsioner (no gap). g □ The e retention screws s must be inside th he guard’s poocketed slotts. □ Pussh the center of the interlock fitting towards thee tensioner w while pullingg back on the fitting’s pull tab bs until it loccks onto the tensioner aand release tthe pull tabss. □ Insttall the backkside guard to t cover stud d to be tensiioned. □ Con nnect the hyydraulic pum mp to the ten nsioner and ttension to fiinal pressuree. Consult manual for correct pressurre. □ osen nut with the spanner ring and pin p wrench. Loo □ Release pressure and allow w the tension ner to fully rretract. □ Disconnect the hose and re elease the in nterlock fittinng by pushin ng the centeer of the inteerlock fitting towards the tensioner while pulling back onn the fitting’ss pull tabs. □ Rem move the baackside guard d. □ Loo osen the knu urled interlocck fitting and d remove thhe guard. □ Unsscrew the te ensioner from m the pullerr screw. □ Rem move the foo ot, puller scrrew, spanne er ring, and tthe retention n screws. It m may be neccessary to insert an Allen n wrench intto the backside of the sttud to removve the pullerr scre ew. □ ove to next stud in pattern Mo 4.0 Gene eral Preparattions Read and d understand d all instructtions before installing annd tensionin ng studs. Operatorrs should be trained or have h previou us experiencce using Riveerhawk tensiioning equipme ent. Training will minimizze the chancce of impropper use of the equipmen nt. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Pagee 9 of 36 Instructio on Manual IM ‐419 The hydrraulic toolingg including the hydraulicc hoses shouuld be inspeccted prior to o use. Inspecction guideline es are listed in the follow wing sub‐secctions. This equiipment prod duces very high hydraulic pressures and very higgh forces. O Operators mu ust exercise caution and wear the ap ppropriate personal p protective equipment when handling aand ulic tooling. operatingg the hydrau High‐pressure oil from the hydraaulic pump pressurizes p t he tensioner which generates a very large forcce that actuaally stretche es the stud. As A the stud iis stretched the nut lifts off the flangge. The nut is then turne ed by hand using u the sup pplied spannner ring. Oncce the nut is tight againsst the flange, th he pressure in the tensio oner is released. The harrdware is no ow clampingg the flange together. 4.1 Mach hine Prepara ation The flangge to be tenssioned mustt be fully clossed prior to positioning of studs in tthe flanges. Turning the t turbine shafts s is not required, bu ut may be usseful. Also, iit will be advvantageous tto remove as a many obsstructions as possible fro om the flangge area, such h as speed probes, shipp ping plates, an nd conduit. 4.2 Hardware – Balance The studs are supplie ed in compo onent balancced sets. A sttud can be eexchanged w with another stud in its set without affe ected the ovverall balance of the equuipment. Do not exchangge a stud fro om one set with w anotherr stud from a different set. When shhipped from Riverhawk, the studs arre not assiggned to any specific s hole e in the load coupling fla nge; this is o optional and d can be don ne at the installation site. The T set size is determine ed by the reelevant GE order drawingg (see sectio on 2.0). d in compon nent balance ed sets. A nuut can be excchanged with another nut in The nuts are supplied o the equip ment. Do no ot exchange a nut from o one its set without affectted the overall balance of set with another nut from a diffe erent set. When shippedd from Riverrhawk, the nuts are not assigned to any speccific hole in the load coupling flange;; this is optio onal and can n be done att the on site. The set size is de etermined by b the relevaant GE orderr drawing (seee section 2..0). installatio A weightt balance cerrtification is supplied witth each ordeer. Store thiss certificatio on in an appropriate location as it will be needed for the purchasse of replaceement equip pment. 4.3 Tensiioner – Care e and Handliing When no ot in use, the e tensioner shall s be main ntained in a clean enviro onment and all caps and d plugs for hydraulic openings and d fittings musst be in placce. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 1 10 of 36 Instructio on Manual IM ‐419 Use ISO 32 3 grade oil.. When in use, the ten nsioner shall be protecte ed from sandd and grit. ements. See section 12 for long term storrage require 4.4 Hand d Tools Several hand h wrench hes and micrrometers maay be requireed to perforrm installatio on and measurement of the studs: 5/8” Wre ench 3/4” Wre ench A set of Allen A Wrenches 3’ to 4’ Breaker B Bar 12” to 13 3” Micrometter or Caliper 4.5 Speciial Tools Hydraulicc Tensioner Kit: HT‐‐7967 Hydraaulic Tension ner, 2‐3/4” (referencee GE VENDOC C 101B0710 0) Hydraulicc Pump Kit: AP‐‐6048 Air‐Opperated Hyd draulic Pump p (referencee GE VENDOC C 269B8768) CAUTION C wk recomme ends that the tensionerss be returneed to Riverhawk for perriodic Riverhaw inspectio ons. Replace ement of ob bsolete tensioners is reccommended d. Functionaal upgrades are also reco ommended. The Riverhawk Service e Returns Co oordinator sshould be no otified 3‐6 months prior p to a pla anned outagge to schedu ule an inspeection servicce. 5.0 Hardware Set Preparations 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 1 11 of 36 Instructio on Manual IM ‐419 5.1 Nut Preparation P (2) ( Locking Set S Screws (2 2) Spanner R Ring Holes Picture 5A ‐ Riverhawk Locknut If there iss any visible damage on a nut, do no ot use the nuut and contaact the Riverrhawk Comp pany for a replacement nu ut. Please be e prepared to o supply thee turbine num mber, weigh ht certificatio on, and digital photograp phs for evalu uation. 5.1.1 Nutt Cleaning ‐ New Installaations For new installationss, the nuts sh hould come sealed from m the factoryy and will need no cleaniing. 5.1.2 Nutt Cleaning ‐ Old Installations Previously installed nuts n require cleaning as follows: Wirre brush usin ng a petroleeum‐based solvent to remove an ny foreign material m on th he external ssurfaces and d threads. 5.2 Stud Preparation n Check the stud for an ny visible damage. If the ere is any vissible damagee, do not usee the stud an nd contact the t Riverhaw wk Companyy for a replaccement studd. Please be prepared to o supply the turbine number, n weight certificaation, and diggital photoggraphs for evvaluation. CAUTION C It is espe ecially imporrtant to checck the condiition of the conical threead used to ttension the stud. Thrread damage from prevvious abuse can c lead to ffailure of th he stud or teensioning equipme ent. The coniccal threads of o each stud must be cle ean of grit annd dirt beforre installatio on or removaal. This ensu ures the proper seating of o the pullerr screw. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 1 12 of 36 Instructio on Manual IM ‐419 5.2.1 Stu ud Cleaning ‐ New Installlations For new installationss, the studs should s come e sealed from m the factorry and will neeed no clean ning. ud Cleaning ‐ Old Installaations 5.2.2 Stu Previously installed studs s may re equire cleaniing. Clean coonical thread ds should haave a bright and shiny app pearance. If cleanin ng is required d, follow the ese steps: ed air to rem move loose d debris and dry conical 1. Blow out the threads with compresse th hreads. Do not n apply a solvent or other cleaningg solution to o the threadss as this mayy ch hemically attack the stud. U Stud Cleaaning Kit, GTT‐4253 or a similar s 1" diaameter Brass power bru ush. 2. Use Picture 5B ‐ Brass Poweer Brush nsert the bru ush into an electric e drill and a set drill to run in a ccounterclockkwise direction 3. In att high speed d. 4. Work W the drill in a circulaar motion wh hile moving tthe brush in n and out to clean all of tthe th hreads. Try not n to hold the t brush in one place tooo long, so aas not to rem move the stu ud's protective coating. ed air to rem move loosened debris. 5. Blow out the threads with compresse V inspe ect threads for f cleanliness. Threads should be bright and shiny. 6. Visually 7. Repeat if any dirt can be seen in the threads. t 8. In nspect threads for any damage that may have b een caused by previouss installation. 9. Do D not apply “Never Seizze” to the stu ud’s threadss. 10. Finish the cleaning process by rinsingg in a volatilee solvent succh as aceton ne and allow w the sttud to dry. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 1 13 of 36 Instructio on Manual IM ‐419 5.3 Stud Length Mea asurement Measure e and record the initial sttud lengths. The followinng suggestio ons will imprrove your results. Plan to start and finish any flange in n the same d day. Sttuds and flange must be e at the sam me temperatture. Number N each h stud with a marker forr later stretcch measurem ment trackin ng. Mark M the loca ation of meaasurement on o stud end d with a perm manent marrker. Measure M each stud to ne earest 0.001 inch (.01 m mm). Record R each measureme ent on the su upplied reco ord sheets. Do D not allow the measurring instrum ments to sit in the sun. The same person should make all measurementts. 6.0 Stud and Nut Asssembly manual. Refer to the hardwarre assembly drawing (HFF‐xxxx) listedd in Section 2.0 of the m 1. Assemble A the e cylindrical nut to the in nternal, coniical thread eend of the stud. 2. Lu ubricate the e stud’s threaads with cleaan turbine ooil or spray lu ubricant. 3. Lu ubricate the e nut’s threads and nut face f with cleean turbine o oil or spray lubricant. 4. Slide the stud d and cylindrrical nut asse embly into tthe flange ass shown in Figure 6A. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 1 14 of 36 Instructio on Manual IM ‐419 Stud Fro ont Side Nutt Back Side Nut Hex Drive Tensioning T Coniccal Thread * Set Stu ud Stick‐out on th his side only LP Rotor Flange HP PIP Rotor Flange Fiigure 6A – Cross‐section View V of Steam m Turbine HPIIP Rotor to LP Rotor Boltted Flange Coonnection 5. In nstall the oth her nut on th he backside.. 6. Adjust A the nu ut/stud assem mbly so thatt the stud prrotrudes (or sticks out) ffrom the face of th he cylindricaal nut the disstance speciffied on the hhardware drrawing (HF‐xxxxx). SETTIN NG THIS PROTRU USION OF STTUD TO NUTT IS CRITICALL FOR PROPEER TENSION NER OPERATTION. A metal stick‐‐out gage is provided wiith the tensiooner to assisst the operaator in setting the protrusion dimension. e 6B – Use of o Stick‐Out Gage G on the D602 HPIP‐LP Flange Jo oint Picture Note e: The D202 stick‐out gagge is used onn this speciaal application n 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 1 15 of 36 Instructio on Manual IM ‐419 Picture 6C 6 – Use of Drop Gage to t measure m sticck‐out Picture 66D – Use of Calipers to measure stickk‐out W Allen wrrench in bacckside of stud d, firmly seaat backside n nut using spaanner ring and 7. With pin wrench. 8. Recheck the stud s stick‐ou ut length. If the t stick‐outt length doees not match h the hardwaare drawing, adju ust the nuts as necessaryy. 7.0 Hydraulic Tensio oner Equipm ment Assemb bly 7.1 Hydraulic Equipm ment Inspection draulic Tenssioner Inspecction 7.1.1 Hyd CAUTION C Riverhaw wk recomme ends that the tensioner be returned d to Riverhaawk for perio odic inspecttions. Replacem ment of obso olete tensio oners is reco ommended. Functional u upgrades arre also recomme ended. The Riverhawk Service S Retu urns Coordin nator should d be notified d 3‐6 month hs prior to a planned outage to sch hedule an inspection serrvice. n require bleeding. b See section 8.33 This tenssioner does not WARNING W a proper operation, tthe tensioneer assemblyy must be To avoid failure, enssure safety, and n the flange before blee eding and prressurizing tthe tensioneer. Do not usse installed on a stud in nless the too ol is installeed on a stud in a flange. the tensiioner at anyy pressure un Clean puller screw an nd check forr any debris and dents. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 1 16 of 36 Instructio on Manual IM ‐419 Inspect the tensioner guard for any a signs of damage inclluding cracked welds. An ny guards modified d in the field should be re eplaced. Ben nt guards shhould be replaced. Also, be sure the rubber pad is in place e on the bacck side guard d, if missing,, replace. o the tensio oner for disco oloration paatterns that m on Inspect the outside of may indicatee submersio e. and interrnal damage Perform an inventoryy of the loosse equipmen nt supplied w with the tenssioner. An in nventory listt is provided d on the tenssioner’s tech hnical drawin ng (Riverhaw wk HT‐xxxx liisted in section 2.0 and 4.5). Replacem ment parts are available from Riverh hawk. H Ten nsioner’s Bu urst Disc Rep placement 7.1.1.1 Hydraulic The hydrraulic tension ner’s burst disc d is a key element e in tthe overall safe use of th he hydraulic tensioner. The burst disc’s location is shown on the tenssioner’s tech hnical drawin ng (Riverhaw wk l in secttion 2.0 and 4.5). HT‐xxxx listed Each tensioner is shipped from our o factory with w one burrst disc alreaady installed in the tensioner and with another spaare disc for field f replace ement. Extraa burst discs are available from wk for replaccement purp poses. Riverhaw To replacce a damage ed burst disc: 1. Remove the hydraulic h po ort’s dispersion nut, com mpression rin ng, and damaaged burst d disc. 2. Discard D the damaged burrst disc. 3. Clean the disp persion nut, compressio on ring, new burst disc, aand the hydraulic port w with a so olvent to ensure a dirt‐free installation. 4. Reassemble new n burst diisc, compresssion ring, annd dispersion nut into th he same hydraulic porrt. Warning W me design and pressuree A damagged burst dissc must be replaced witth a burst dissc of the sam rating. Do D not substiitute a damaaged burst disc d with a d different disc type, a diffferent presssure rating, or a foreign object. o draulic Pump Kit Inspecction 7.1.2 Hyd Refer to the Hydraulic Pump Kit Instruction Manual, M IM‐‐293 (GE VEN NDOC 373A4 4058). The laatest revision may m be obtaained by con ntacting Rive erhawk Comppany or thru u www.riverhawk.com. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 1 17 of 36 Instructio on Manual IM ‐419 7.2 Hydraulic Fittings Riverhawk hhydraulic pu umps use a 1 1/4” High Pressure poort to connecct its hydrau ulic hoses. Th he hose conneector is madee from a threee piece assembly: a gland nut, a collar, and d a 1/4” tubee or 1/4” hose eend. (See Illu ustration 1) To assemblyy the fitting,, slide the gland nut oveer the 1/4” tubbe or 1/4” h hose end. Turn the collarr counter‐cloockwise (left hand thread) on to the tube or hosse end as sho own in Illustration 1. Illustratio on 1 The collar should be plaaced .125” (3 3.2 mm) from the tip of thhe cone. (Seee Illustration n 2) It may b be necessary t o adjust thiss collar with a set of visee‐ grip pliers. Be careful tto not strip the threads o off the tube or hose end. Illustratio on 2 Slide the glaand nut dow wn over the ccollar. (See Illustration 3) Insert the 1/4” tube or 1/4” hosee end into thee tensioner’s quick coup pler. While firmly holding the tube or hose end d to stop it frrom rotating, tu rn the gland d nut clockwise (right haand o 25 FT‐LBS (34 thread) andd torque the gland nut to N‐m). Illustratio on 3 Tips: Make suure all parts are clean an nd free from m debris. Protect the cone on n the end of the 1/4” tub be or 1/4” hose end fro om scratchees as this is the sealing ssurface. Replacee red plastic caps when ffinished to protect the threadss and cone. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 1 18 of 36 Instructio on Manual IM ‐419 8.0 Assem mbly of Tensioner on a Stud The tensioner used in this application can be e identified bby its ORANG GE safety gu uard. If the tensioner’s safety gu uard is YELLO OW, a differe ent set of insstructions arre required. Consult the wk factory fo or assistance. Riverhaw 8.1 Hand dling of the Tensioner T The tensioner used in this application is desiigned to req uire no speccial lifting insstructions. D Do not drop any part of the tensioner on the op perator or otther nearby personnel. 8.2 Kit Asssembly Connect the hydraulic hose from m the hydrau ulic pump to the tensioner. Refer to the hardwarre assembly drawing (HFF‐xxxx) listedd in Section 2.0 of this m manual and tthe tensioner assembly drawing d (HT‐‐xxxx) listed in Section 44.5 of this maanual to dettermine how w the tensioner must be asssembled on n the load co oupling for itts correct op peration. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 1 19 of 36 Instructio on Manual IM ‐419 Pin Wreench HPIP Rottor Flange Safety Guard Foot Reten ntion Screw w Hose Conne ection Hydrauulic Cylindeer Picture P 8A – Features of the Hydraul ic Tensionerr HT‐7967 Safetty Guard Pin Wrencch Foot Hose Con nnection Backside Saafety Guard Knurled Interlocck Fitting Hydrraulic Cylinde er Spannerr Ring Puuller Screw Fiigure 8B – Cutaway view w of Hydraullic Tensionerr HT‐7967 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 2 20 of 36 Instructio on Manual IM ‐419 Note: Be efore threading the pulle er screw into the stud, ccarefully cheeck the cleaanliness of b both the stud''s and the pu uller screw'ss conical thrreads. Applyy a light coatt of clean tu urbine oil or a spray lub bricant to th he puller scre ew. Do not use u “Never Seize” on th he conical th hreads. This procedurre will ease assembly an nd assure po ositive mati ng of the threads beforre tighteningg. Assemblyy sequence is i as follows: 1. Open n the hydrau ulic return vaalve on the pump p to alloow hydraulic fluid to be p pushed backk from the puller to ool into the pump reservoir. (This iss automatic o on the air‐op perated hydraaulic pump) 2. Threaad the reten ntion screws into the adjacent studs on either side of the stu ud to be tensioned until hand tight. 3. Place e the spanne er ring on the e nut. 4. Insert the puller screw s releasse tape per Riverhawk R m manual IM‐336. 5. Insert the puller screw s into the tapered thread t of thee stud and h hand tighten n. Be sure no ot to crosss‐thread the puller screw w. 6. Usingg an Allen wrrench, tighte en the pullerr screw and then back o off the pullerr screw 1/2 a turn. Retighten the puller scrrew by hand d until it is fuully inserted.. DO NOT BA ACK OFF THEE PULLER SCREW. 7. Place e the foot ovver the puller screw and orientate it into position. 9. Thread the tensioner onto th he puller scrrew until it stops. Pleasee note that the internal sstop inside e the tension ner will causse a gap in between b the foot and tensioner. Thee gap should d be 1/16””[1.6mm] to o 3/16”[4.8m mm]. DO NOTT ATTEMPT TO TIGHTEN N THE TENSIIONER AGAIINST THE FOOT. F 10. Place e the orange guard over the tensione er and posit ion the pockketed slots into the reten ntion screws. 11. Tighten the knurled interlockk fitting by hand until it ffirmly pressees against th he tensionerr. There e should be no gap betw ween the ten nsioner the i nterlock fitting. 12. The retention r scrrews must be inside the guard’s poccketed slots. 13. Activate the custom connecttor from the rear of guarrd by pushin ng on the cen nter with yo our thum mb and pullin ng the tabs with w your forre finger andd middle fingger. Push thee assembly forwaard until it lo ocks into the e tensioner. Release finggers from thee tabs and then removee thum mb, Ensure co onnection is firmly engaged or else tthe tensioneer will not bee connected d to the pump. p 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 2 21 of 36 Instructio on Manual IM ‐419 Pull tabs with finggers Push h center with h thumb Pull tabs with fingers Pictu ure 8C ‐ Activvation of thee safety interlock 14. In nstall the backside guard d by attachin ng it to the f lange face. IIt should be centered ovver th he stud to be e tensioned and lightly threaded t intto backside o of the adjaceent studs. 15. Connect the hydraulic h pu ump to the te ensioner. Thhe tensionerr should now w be complettely asssembled an nd ready for use. 8.3 Bleed ding Hydraulic System Bleeding of the hydraaulic system m is not necessary with thhis tensioneer design. 9.0 Stud Tensioning The studs will be tensioned in tw wo steps, at 50% 5 pressurre and at finaal pressure. Follow the tensionin ng sequence e for each flaange joint as defined on the record ssheets found d at the end of this manual. 9.1 Tensiioning at 50% pressure After the e tensioner iss properly in nstalled applly hydraulic pressure to the tool. Briing the presssure to the 50 0% level in acccordance with w the follo owing table. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 2 22 of 36 Instructio on Manual IM ‐419 WARNING W The safetty cage musst be in place e at all times. Keep hands out of deesignated arreas at all tim mes when the e tensioner is pressurize ed otherwisse personal iinjury can occcur. CAUTION C hreading the e puller scre ew into the stud, s carefu lly check thee cleanliness of both the Before th stud's an nd the pullerr screw's con nical threads. Apply a liight coat of clean turbin ne oil or a sp pray lubricantt to the pulle er screw. Th his procedurre will ease aassembly an nd assure po ositive matin ng of the threa ads before tightening. t Do D not use “Never “ Seizee” on the con nical thread ds. CAUTION C m prressure markked on the ttensioner. Exxcessive preessure can Do not exceed the maximum damage the stud and d puller scre ew. CAUTION C Do not tiighten the nut n while the e tool is com ming up to p ressure; wait until presssure is achieeved before atttempting to o tighten the nut with the t spanner ring. If the ttool is not p properly installed, the tool co ould jump offf the stud while w comingg up to presssure. Flangge Position Stu ud Size 50% Preessure 50% % Stretch D602 Stteam Turbin ne HP PIP to LP 2‐3/4" [71 1 mm] 115000 psi [800 bbar] Do no ot measure Do not use Firmly tigghten the cyylindrical nutts with appro oximately 200 ft∙lbs [27 N N∙m] of torqu ue using thee pin wrench and a spanner ring. Turn the nut until it bottoms oon the flangee. 9.2 Remo oving the Te ensioner from an Installed Stud The tensioner removval is accomp plished by th he follows stteps: h pre essure by eitther releasinng the hand sswitch on th he AP‐0532 1. Release the hydraulic b opening the valve on the MP‐01330 Manual Pump Kit and d leave the valve Pump Kit or by open. b guaard. 2. Remove the backside U the knurled inte erlock fittingg at the end oof the guard d and removve the guard from 3. Unscrew th he tensionerr. 4. Unscrew U the tensioner frrom puller sccrew. 5. Remove foot from around the puller screw. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 2 23 of 36 Instructio on Manual IM ‐419 6. Unscrew U the puller screw w using an Alllen wrench.. Tapping thee Allen wren nch with a hammer or th he use of a 3‐4’ 3 breaker bar may be necessary to o loosen thee puller screw w. Do D not use an n impact wre ench as this can damagee the puller sscrew. 7. Remove the spanner s ringg from the nu ut. U the retention sccrews using an a Allen wreench. It may be necessary to tap thee 8. Unscrew Allen A wrench with a hammer or use a 3‐4’ breakeer bar to loo osen the reteention screw ws. Do D not use an n impact wre ench as this can damagee the retentiion screws. 9. Move M the too ol to the nexxt bolt hole following thee tensioning pattern from the stretcched re ecord sheetss at the end of this manu ual. 9.3 Tensiioning at Fin nal Pressure Repeat th he pulling an nd tightening procedure e stated abovve at full preessure. Afterr all of the sttuds have bee en tensioned d, measure the final stud d length. Thee final pressure and requ uired stretch h values arre listed in th he followingg table. WARNING W The safetty cage musst be in place e at all times. Keep hands out of deesignated arreas at all tim mes when the e tensioner is pressurize ed otherwisse personal iinjury can occcur. CAUTION C Before th hreading the e puller scre ew into the stud, s carefu lly check thee cleanliness of both the stud's an nd the pullerr screw's con nical threads. Apply a liight coat of clean turbin ne oil or a sp pray lubricantt to the pulle er screw. Th his procedurre will ease aassembly an nd assure po ositive matin ng of the threa ads before tightening. t Do D not use “Never “ Seizee” on the con nical thread ds. CAUTION C Do not exceed the maximum m prressure markked on the ttensioner. Exxcessive preessure can damage the stud and d puller scre ew. CAUTION C n while the e tool is com ming up to p ressure; wait until presssure is achieeved Do not tiighten the nut before atttempting to o tighten the nut with the t spanner ring. If the ttool is not p properly installed, the tool co ould jump offf the stud while w comingg up to presssure. Flangge Position Stu ud Size Final Preessure Finaal Stretch D602 Stteam Turbin ne HP PIP to LP 2‐3/4" [71 1 mm] 230000 psi [1585 bar] 0.019 9" ‐ 0.022" [0.48 mm m ‐ 0.56 mm m] 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 2 24 of 36 Instructio on Manual IM ‐419 Firmly tigghten the cyylindrical nutts with appro oximately 200 ft∙lbs [27 N N∙m] of torqu ue using thee pin wrench and a spanner ring. Turn the nut until it bottoms oon the flangee. Failure to o achieve the correct fin nal stretch vaalues will ressult in an inccorrectly ten nsioned stud d. ues can be corrected c by uninstallingg some or alll of the seleccted studs. R Re‐ Incorrectt stretch valu measure the initial le ength of the studs and re epeat the innstallation in nstructions sttuds. Excesssive stretch variations can n also be corrected by th he same meethod. Have finaal stretch values approve ed by the su upervisor ressponsible forr the installaation. 10.0 Thre ead Locking and Windagge Plug Instaallation 10.1 Thre ead Locking (2) ( Locking Set S Screws (2 2) Spanner R Ring Holes Picture P 10A ‐ Riverhawkk Locknut Mechanical lock nutss have two set s screws lo ocated in thee top face. Before thread ding the nut onto the stud, check to be certaiin the set screws are freee to turn. Once the nut is seated torque e values speccified in the following taable. When sseated and ttorqued to th he the set sccrews to the values sp pecified, the load created by the set screw displaaces the thrread of the n nut in the areea of the web thereby creaating the desired lockingg action. Flange e Position Stud Size Set Screw Size TTorque D602 Ste eam Turbine e HPIP to LP 2‐3//4" [71 mm] m 1/4"‐28 U UN 70 in∙llbs ‐ 80 in∙lb bs [7.9 N∙∙m – 9.0 N∙m m] 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 2 25 of 36 Instructio on Manual IM ‐419 10.2 Win ndage Plug In nstallation Refer to the hardwarre assembly drawing (HFF‐xxxx) listedd in Section 2.0 of this m manual. Nut Windagge Plug Lockin ng Set Sccrews Stud HPIP Ro otor Flange Figu ure 10B – Windage Plug Installation quired: Tools Req Torqu ue Wrench 1/2" Allen Driver for windage e plug 1/8” Allen Driverr for set screws 1. Be sure intern nal threads in i the stud are a clean andd free from oil. nsert the win ndage plug full f and tightten to 200‐2250 in‐lbs (222.6‐28.2 Nm) torque. 2. In 3. Tighten the set screws to o 80‐90 in‐lbss (3‐4 Nm) toorque. 4. Caution – the e plug must rest r a minim mum of .12” ((3mm) below w the face o of the stud. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 2 26 of 36 Instructio on Manual IM ‐419 11.0 Stud d and Nut Re emoval The tensioner used in this application can be e identified bby its ORANG GE safety gu uard. If the tensioner’s safety gu uard is YELLO OW, a differe ent set of insstructions arre required. Consult the wk factory fo or assistance. Riverhaw 11.1 Han ndling of the e Tensioner The tensioner used in this application is desiigned for no special liftin ng instructio ons. Do not d drop any part of the tensio oner on the operator orr other nearbby personneel. d and Nut Re emoval 11.2 Stud WARNING W The safetty cage musst be in place e at all times. Keep hands out of deesignated arreas at all tim mes when the e tensioner is pressurize ed otherwisse personal iinjury can occcur. CAUTION C Before th hreading the e puller scre ew into the stud, s carefu lly check thee cleanliness of both the stud's an nd the pullerr screw's con nical threads. Apply a liight coat of clean turbin ne oil or a sp pray lubricantt to the pulle er screw. Th his procedurre will ease aassembly an nd assure po ositive matin ng of the threa ads before tightening. t Do D not use “Never “ Seizee” on the con nical thread ds. CAUTION C Do not exceed the maximum m prressure markked on the ttensioner. Exxcessive preessure can damage the stud and d puller scre ew. CAUTION C Do not tiighten the nut n while the e tool is com ming up to p ressure; wait until presssure is achieeved before atttempting to o tighten the nut with the t spanner ring. If the ttool is not p properly installed, the tool co ould jump offf the stud while w comingg up to presssure. Refer to the hardwarre assembly drawing (HFF‐xxxx) listedd in Section 2.0 of this m manual and tthe tensioner assembly drawing d (HT‐‐xxxx) listed in Section 44.5 of this maanual to dettermine how w the n the load co oupling for itts correct op peration. tensioner must be asssembled on Section 8.0 8 contains diagrams off the tension ner equipmeent. Note: Be efore threading the pulle er screw into the stud, ccarefully cheeck the cleaanliness of b both the stud''s and the pu uller screw'ss conical thrreads. Applyy a light coatt of clean tu urbine oil or a spray lub bricant to th he puller scre ew. Do not use u “Never Seize” on th he conical th hreads. This procedurre will ease assembly an nd assure po ositive mati ng of the threads beforre tighteningg. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 2 27 of 36 Instructio on Manual IM ‐419 Disassem mbly sequencce is as follows: 1. Usingg a wire brussh (GT‐4253)) and shop air, a clean thee internal tap pered thread d of the stud d to remo ove any debrris/deposits which may have h accumuulated durin ng service as described in n sectio on 5.2.2. Do not continu ue until ALL debris d is rem moved from the threads. WARNING W e a stud with h damaged cconical threaads. Do not use a hydraulic tensioner to remove n the two loccking set scr ews but do not remove from the nu ut. 2. With an Allen‐wrrench loosen Piccture 11A ‐ Loosening L off a nut's set sscrews nect the hydrraulic hose from f the hyd draulic pumpp to the tenssioner. 3. Conn 4. Open n the hydrau ulic return vaalve on the pump p to alloow hydraulic fluid to be p pushed backk from the puller to ool into the pump reservoir. (This iss automatic o on the air‐op perated hydraaulic pump) 5. Threaad the reten ntion screws into the adjacent studs on either side of the stu ud to be tensioned until hand tight. 6. Place e the spanne er ring on the e nut. 7. Insert the puller screw s releasse tape per Riverhawk R m manual IM‐336. 8. Insert the puller screw s into the tapered thread t of thee stud and h hand tighten n. Be sure no ot to crosss‐thread the puller screw w. 9. Usingg an Allen wrrench, tighte en the pullerr screw and then back o off the pullerr screw 1/2 a turn. Retighten the puller scrrew by hand d until it is fuully inserted.. DO NOT BA ACK OFF THEE PULLER SCREW. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 2 28 of 36 Instructio on Manual IM ‐419 10. Place e the foot ovver the puller screw and orientate it into position. 11. Threaad the tensio oner onto th he puller scre ew until it sttops. Please note that th he internal sstop inside e the tension ner will causse a gap in between b the foot and tensioner. Thee gap should d be 1/16””[1.6mm] to o 3/16”[4.8m mm]. DO NOTT ATTEMPT TO TIGHTEN N THE TENSIIONER AGAIINST THE FOOT. F 12. Place e the orange guard over the tensione er and posit ion the pockketed slots into the reten ntion screws. 13. Tighten the knurled interlockk fitting by hand until it ffirmly pressees against th he tensionerr. There e should be no gap betw ween the ten nsioner the i nterlock fitting. 14. The retention r scrrews must be inside the guard’s poccketed slots. 15. Activate the custom connecttor from the rear of guarrd by pushin ng on the cen nter with yo our mb and pullin ng the tabs with w your forre finger andd middle fingger. Push thee assembly thum forwaard until it lo ocks into the e tensioner. Release finggers from thee tabs and then removee thum mb, Ensure co onnection is firmly engaged or else tthe tensioneer will not bee connected d to the pump. p Pull tabs with finggers Push h center with h thumb Pull tabs with fingers Picturre 11B ‐ Actiivation of th e safety inteerlock hould be centered over tthe 16. Install the backside guard by attaching it to the flangge face. It sh t be tensioned and ligh htly threaded d into backsside of the ad djacent stud ds. stud to 17. Conn nect the hydrraulic pump to the tensioner and appply the appropriate hyd draulic presssure per th his table. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 2 29 of 36 Instructio on Manual IM ‐419 Flange F Positiion Stud Sizze Rem moval Presssure D602 Ste eam Turbine HPIP to LP 2‐3/4"" [71 mm m] 23000 psi [1585 bar] 18. Turn the spannerr ring with th he pin wrencch. Loosen aand turn the nut approxiimately 3/4 of a turn. 19. Releaase the hydraulic pressure. emoving the e Tensioner from a Stud d 11.3.1 Re plished by th he follows stteps: The tensioner removval is accomp 1. Release the hydraulic h pre essure by eitther releasinng the hand sswitch on th he AP‐0532 Pump Kit or by b opening the valve on the MP‐01330 Manual Pump Kit and d leave the valve open. 2. Remove the backside b guaard. 3. Unscrew U the knurled inte erlock fittingg at the end oof the guard d and removve the guard from th he tensionerr. 4. Unscrew U the tensioner frrom puller sccrew. 5. Remove foot from around the puller screw. 6. Unscrew U the puller screw w using an Alllen wrench.. Tapping thee Allen wren nch with a hammer or th he use of a 3‐4’ 3 breaker bar may be necessary to o loosen thee puller screw w. Do D not use an n impact wre ench as this can damagee the puller sscrew. 7. Remove the spanner s ringg from the nu ut. 8. In n the case off the generator side of th he load couppling flange,, unscrew th he retention sccrews using an Allen wre ench. It mayy be necessa ry to tap thee Allen wren nch with a hammer or use a 3‐4’ bre eaker bar to loosen the rretention screws. Do no ot use an imp pact wrench w as thiis can damagge the reten ntion screws. 9. Move M the too ol to the nexxt bolt hole following thee tensioning pattern from the stretcched re ecord sheetss at the end of this manu ual. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 3 30 of 36 Instructio on Manual IM ‐419 12.0 Storrage Instructtions Follow th hese directio ons to prope erly store you ur hydraulic tensioner and hydraulicc pump kit fo or long term m storage an nd shipment. erved, contaact the Riverrhawk Comppany to schedule a maintenance If any damage is obse inspectio on. 12.1 Hyd draulic Pump p Kit Storage e Refer to the Hydraulic Pump Kit Instruction Manual, M IM‐‐293 (GE VEN NDOC 373A4 4058). The laatest m be obtaained by con ntacting Rive erhawk Comppany or thru u www.riverhawk.com. revision may 12.2 Hyd draulic Tensioner Storagge mage Check the tensioner for any dam s and ch heck for any debris and dents. 1. Clean puller screw s be cle ean and freee to rotate. 2. Knurled interrlock fitting should nspect the te ensioner guaard for any signs s of dam age. Bent gu uards must b be replaced.. 3. In If any damage is obse erved, contaact the Riverrhawk Comppany to schedule a maintenance inspectio on. Place the e protective plastic cap on o the guard d’s knurled innterlock fittiing. Coat the hydraulic te ensioner with a light coaat of oil and pplace the tensioner into o the original shipping container. 12.3 Storre shipping container c he hydraulic pump and hydraulic h ten nsioner into the originall shipping co ontainers usiing Secure th the supplied wood braces. pping contain ner and store under sheelter and pro otected from m moisture, ssand, Seal the original ship and grit. quently Aske ed Question ns 13.0 Freq This section containss some frequ uently asked d questions aand problem ms. If the step ps listed herre do not solve e your proble em, contact the Riverhawk Companny thru our w website, emaail, or phonee call. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 3 31 of 36 Instructio on Manual IM ‐419 Q: Can I rent a hydraulic ten nsioner kit? A: Ye es, Riverhaw wk has rental tensioner kits k availablee for most off our hydrau ulic tensioneers. Q: A tensioner has h pulled itsself out of th he stud's connical threadss. Can I contiinue using a ensioner on this stud? te A: No. Both the tensioner an nd the stud may have beeen damageed and must be removed d frrom the worrk area. If the e stud is tensioned, a Nuut Buster rep pair kit, from m Riverhawkk, must m be used d to remove the damage ed stud by drrilling out the nut. Leaving a damageed sttud in place will lead to a safety hazaard on futurre outages. Riverhawk can supply a re eplacement stud and nuut based on the initial w weight ce ertification supplied s with the hardw ware set (seee section 4.2)). The damaged tensioner sh hould also be returned to t Riverhawkk for inspecttion and repair. If a stud mustt be left in place, paint the damagedd stud with a generous aamount of ndelible, brigght‐colored paint. p Notifyy the approppriate GE Saffety and Servvice personn nel. in Note the locaation of the damaged d stu ud in the serrvices notes for the macchine. Q: Th he hydraulicc tensioner has h been takken up to its final pressure. The finall stretch lenggth is sh hort of the final stretch target. t What is the nextt step? A: Do not increaase the hydraaulic pressure. Check if tthe hydrauliic pump is seet to the righ ht pressure. Insttall the tensiioner and re e‐pressurize tthe tensioneer to the finaal pressure tthen re echeck the stretch meassurement. If the stretch value is still short, remo ove the stud frrom the hole e and re‐meaasure the stu ud's initial leength then try to install the stud agaain. Q: he hydraulicc tensioner has h been takken up to its final pressure. The finall stretch lenggth is Th laarger than th he final strettch target. What W is the nnext step? A: s from the bolt hole. Check if thee hydraulic p pump is set tto the right Remove the stud e stud's initial length theen try to insttall the stud again. pressure. Re‐measure the 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 3 32 of 36 Instructio on Manual IM ‐419 Q: Th he tensionerr is at its finaal pressure, but the nut cannot be lo oosened. A: If the nuts cannot be loossened at the e final pressuure, continuaally increasin ng the presssure will w not help and a can be dangerous d and in some ccases make it harder to remove thee nut. Check the nutt to see if itss set screws have been loosened. Ch heck for and remove anyy orrosion aro ound the nutt's threads. Apply A penetrrating oil between the stud and the nut. co Q: How do I cleaan the conicaal threads on n a stud? A: Th he conical th hreads are best b cleaned using a spir al wound brrass brush in n a drill as described in section s 5.2.2 2 Q: During the iniitial steps off removing a tensioned sstud, the sticck‐out length is found to o be wrong. w A: Do not proceed. Contact Riverhawk for f assistancce. With the wrong stick‐out length, the hyydraulic tensioner has a limited stro oke and mayy not work properly and can be daamaged. Q: he hydraulicc pump appe ears to be leaaking. Th A: Check the hosse connectio on to the hyd draulic pum p. If the 1/44" high presssure fitting iss not asssembled co orrectly as sh hown in secttion 7.2, it m may look like the pump iss leaking. If tthe problem conttinues, it maay be necessary to open the pump kit. Contact R Riverhawk fo or gu uidance. Q: he hydraulicc hose has a collar on it that t can't bee moved by h hand Th A: Th he hydraulicc fitting is shown in sectiion 7.2. The collar is som metimes held d in place wiith a th hread locking compound d. This preve ents the collaar from movving too easiily. It may bee necessary to adjust this collar c with a set of vise‐ggrip pliers. Be careful to not strip thee th hreads off th he tube or ho ose end. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 3 33 of 36 Instructio on Manual IM ‐419 14.0 Revvision Historyy Revisio on Lette er Efffective Date e ‐ Oct O 20, 2017 Descriptio n Releassed 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 3 34 of 36 Instructio on Manual IM ‐419 Appendixx A1 EC Declaration off Conformity Manufaccturer: Address: Riverhawkk Company 215 Clinto on Road New Hartfford NY, 134 413, USA nsioning tooll described iin this manu ual are used for installingg and The hydrraulic pump and bolt ten applying tension to laarge bolts th hat are specifically desiggned by Riveerhawk Comp pany to be tensioned hydraulicaally. All appliccable section ns of Europe ean Directive e 2006/42/EC C for machin nery have beeen applied and fulfilled in the design n and manuffacture of the hydraulic pump and b bolt tensioning tool described d in this man nual. Reference also ISO O 12100:20100, ISO 4413, and ISO 441 14. Furtherm more, this eq quipment has been manufactured unnder the Rivverhawk quaality system p per EN ISO 90 001:2008 Consult the t Declaration of Confo ormance inclluded with tthe shipment of this equ uipment thatt identifiess the authorized Riverhaawk representative, app licable seriaal numbers, aand approprriate signature e. 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 3 35 of 36 Instructio on Manual IM ‐419 Appendixx B1 STRETCH H RECORD SH HEET FOR THE HPIP P TO LP TURBINEE NUMBER: DATE: TECHNIC CIAN: SUPERVISSOR: HOLE NUMBER STARTING G MEASUREMEENT FINAL MEASSUREMENT FINAL GAUGE READIN NG 1 9 5 13 15 7 3 11 8 16 12 4 10 2 6 14 215 Clintton Road New Hartford, NY 13413 15 768 4855 Tel: +1 31 Fax: +1 315 768 4941 Email: inffo@riverhawk.com m GE DRAWING NU UMBER REV 100A14 467 Page 3 36 of 36
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