riverhawk IM-116 Manual de usuario
Repairs – Rentals
Field Service
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INSTRUCTIONMANUALIM‐116
ForGasTurbineTensionedStudsandNuts
Fr.9ETurbineto9A3ELINGeneratorGE358A7202P022
GEPower&Water
GENERALELECTRICCOMPANY
MLI: ____ OF ____
DATE
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GESIGNATURES
CHECKED:
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TableofContents
Section Description PageNumber
1.0 CautionsandSafetyWarnings 3
2.0 Scope 4
3.0 QuickCheck‐List 4
4.0 GeneralPreparations 7
5.0 HardwareSetPreparations 8
6.0 StudandNutAssembly 10
7.0 AssemblyofHydraulicTensionerEquipment 10
8.0 AssemblyofTensioneronStud 12
9.0 StudPullingandTensioning 13
10.0 ThreadLocking 15
11.0 Stud/NutRemoval 15
12.0 FrequentAskedQuestions 16
13.0 RevisionHistory 18
AppendixA1 ECDeclarationofConformity 19
AppendixA2 UKCADeclarationofConformity 20
AppendixB 16‐BoltTensioningPatternRecordSheet 29
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1.0CautionsandSafetyWarnings
WARNING
Impropertooluseandthefailuretofollowthecorrectproceduresaretheprimaryrootcauses
oftoolfailuresandpersonalinjuries.Alackoftrainingorexperiencecanleadtoincorrect
hardwareinstallationorincorrecttooluse,onlytrainedoperatorswithcareful,deliberate
actionshouldusehydraulictensioners.ContactRiverhawkCompanywithanytrainingneeds.
CAUTION
Personalinjuryandequipmentdamagecanoccurifthepullerscrewisnotsecurelyengaged
withthetaperedthreadofthestud.Properengagementisachievedwhenthepullerscrewis
tightinthestudandtheTensionerAssemblyisfreetorotate.
WARNING
Riskofhighpressurehydraulicfluidinjection.Riverhawktoolsoperateunderhighpressure.
Thoroughlyinspectallhosesandconnectionsfordamageorleakspriortousingthisequipment.
WARNING
Theproperpersonalprotectiveequipmentmustbewornatalltimes.Riverhawkrecommends
ataminimum,safetyglasses,longsleeveshirt,hardhat,heavyworkgloves,andsteeltoe
shoes.
WARNING
ThesafetycageMUSTbeinplaceandhandskeptoutofdesignatedareasatalltimeswhenthe
tensionerispressurizedotherwisepersonalinjurycanoccur.
CAUTION
DONOTEXCEEDTHEMAXIMUMPRESSUREVIBROSCRIBEDONTHEPULLERBODY.Excessive
pressurecandamagethestudandthepullerscrew.
WARNING
FireHazard!DONOTheatwhenthepullerassemblyisinplace.Personalinjuryorequipment
damagemayoccur.UseofanOxy‐Acetylenetorchisnotrecommended.
NOTICE
DonotusemorethreadlockingcompoundthanspecifiedorthenutmaybeVERYdifficultto
removeatdisassembly.
CAUTION
DONOTEXCEEDTHEMAXIMUMPRESSUREVIBROSCRIBEDONTHEPULLERBODY.Excessive
pressurecandamagethestudandpullerscrew
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Note:Beforethreadingthepullerscrewintothestud,carefullycheckthecleanlinessofboth
thestud'sandthepullerscrew'sconicalthreads.Applyalightcoatofcleanturbineoilora
spraylubricanttothepullerscrew.Donotuse“NeverSeize”ontheconicalthreads.This
procedurewilleaseassemblyandassurepositivematingofthethreadsbeforetightening.
2.0 Scope
Thisdocumentdescribestheproceduretobeusedtoinstallstudsandnutssuppliedby
RiverhawkCompanyintheflangesattheturbine/couplingandcoupling/generatorconnections.
ThishardwareisdepictedonthefollowingdrawingsThesedrawingsaswellasthetooling
drawingsformapartofthismanual.
HF‐0813
3.0QuickChecklist
ThefollowingchecklistisintendedasasummaryofthestepsneededtousetheRiverhawk‐
suppliedequipment.Newpersonnelorthoseexperiencedpersonnelwhohavenotusedthe
Riverhawkequipmentrecentlyareencouragedtoreadtheentiremanual.
EQUIPMENTINSPECTION
□Checkoillevelinhydraulicpump.
□Checkairpressureat80psi[5.5bar]minimum.(Forair‐drivenpumps)
□Checkhydraulichosefordamage.
□Testpump.
□Inspecttensionerforanydamage.
NUTANDSTUDPREPARATION
□Inspectstudandnutsforanydamage.
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□Measurestudlength.
□Cleanthestudsandnuts.
□Installstudsandnuts(off‐center)intotheflange.
□Setstick‐outdimensiononthecouplingsideoftheflange.
□Handtightenallstuds.
□Verifystick‐outmeasurement(VERYIMPORTANT)
Tensioning(Boltinstallation)
□Matchthetensionersetuptotheflangejoint.
□Applyalightcoatofcleanturbineoilorspraylubricanttothepullerscrew.DONOTUSE
“NEVERSEIZE”ONTHECONICALTHREADS.
□Slidespannerringoverthepullerscrew.
□Mountthetensioneronthestudinflange.
□Installspannerringontonut.
□Insert1/2”hexAllenwrenchintothebacksideofthestud.
□Tightenthepullerscrew.
□Backoffpullerscrew1/2turn.
□Retightenthepullerscrewandleavetight.DONOTBACKOFFPULLERSCREW.
□Bleedthetensioner.DoNOTbleedtensioneroffofastud!Damagetothetoolwill
result!
□Tensionto50%.Consultmanualforcorrectpressure.
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□Usethepinwrenchinspannerringtotightennut.
□Releasepressure,movetonextstudinpattern.
□Repeatabovestepsatfinalpressure.
□Measurefinalstudlengthandrecordonstretchdatasheets.Calculatestretch.
□Torquenuts'setscrews.
Detensioning(Studremoval)
□Loosennuts'setscrews
□Inspectandcleanstuds'conicalthreads.DonotcontinueuntilALLdebrisisremoved
fromthethreads!Donottrytousethetensionertoremoveadamagedstud!
□Applyalightcoatofcleanturbineoilorspraylubricanttothepullerscrew.DONOTUSE
“NEVERSEIZE”ONTHECONICALTHREADS.
□Slidespannerringoverthepullerscrew.
□Mountthetensioneronthestud.
□Installspannerringintonut.
□Tightenthepullerscrew.
□Backoffpullerscrew1/2aturn.
□Retightenthepullerscrewandleavetight.DONOTBACKOFFPULLERSCREW.
□Bleedthetensioner.DoNOTbleedtensioneroffofastud!Damagetothetoolwill
result!
□Applyfinalpressure.
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□Loosennutwiththespannerringandpinwrench.
□Movetonextstudinpattern
4.0GeneralPreparations
Readandunderstandallinstructionsbeforeinstallingstuds.
Thisequipmentproducesveryhighhydraulicpressuresandveryhighforces.Operatorsmust
exercisecaution,wearsafetyglassesandhardhatswhenusingthisequipment.
HighpressurefluidfromtheHydraulicPressureKitsystempressurizesthetensionerwhich
generatesastretchingforcethatactuallystretchesthestud.Asthestudisstretchedthenut
liftsofftheflange.Thenutisthenreseatedintopositionontheflangebyturninganutdriver
byhand.Whenthenutistightagainsttheflange,thepressureinthetensionerisreleased
leavingthestudloadedtoitspredeterminedvalue.
4.1MachinePreparation
Theflangetobetensionedmustbefullyclosedpriortopositioningofstudsintheflanges.
Theremustbeprovisiontoturntheshaftsoftheturbineandthegenerator.Also,itwillbe
advantageoustoremoveasmanyobstructionsaspossiblefromtheflangearea,suchasspeed
probesandconduit.
4.2Hardware–Balance
Hardwareissuppliedasweightbalancedsets
StudsandNutsareinterchangeablewithinsets
Donotmixwithothersets
Saveweightcertificationforthepurchaseofspares
4.3Tensioner–CareandHandling
Whennotinuse,thetensionershallbemaintainedinacleanenvironmentandallcapsand
plugsforhydraulicopeningsandfittingsmustbeinplace.
UseISO32gradeoil.
Wheninuse,thetensionershallbeprotectedfromsandandgrit
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Longtermstorage–coattensionerwithoil,returntooriginalcontainer,sealcontainerand
protectfrommoisture
Shipment–coattensionerwithoilandshipinoriginalcontainer
4.4 HandTools
Severalhandwrenchesandmicrometerswillberequiredtoperforminstallationand
measurementofthestuds:
5/8”wrench
1"wrench
1”socketandimpactwrench
AsetofAllenWrenches
3’–4’BreakerBar
9”to10”micrometerorcaliper
10”to11”micrometerorcaliper
4.5SpecialTools
HydraulicTensionerKit: HT‐0814HydraulicTensioner
HydraulicPumpKit: AP‐0532Air‐OperatedHydraulicPump
(recommended)
(referenceGE359B2502)
MP‐0130ManualHand‐Operated
HydraulicPump
(referenceGE359B2506)
5.0HardwareSetPreparations
5.1NutPreparation
Fornewinstallations,thenutsshouldcomesealedfromthefactoryandwillneednocleaning.
Previouslyinstallednutsrequirecleaningasfollows:Wirebrushusingapetroleum‐based
solventtoremoveanyforeignmaterialontheexternalsurfacesandthreads.
Ifpreviousinstallationsemployedathreadlockingcompound,whichwillbevisibleasagrayish‐
greenresidue,removeasmuchofthiscompoundaspossible.
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Donotapplythreadlubricantstothethreads.
Finishthecleaningprocessbyrinsinginavolatilesolventsuchasacetoneandallowtodry.
5.2StudPreparation
Fornewinstallations,thestudsshouldcomesealedfromthefactoryandwillneednocleaning.
5.2.1StudCleaning‐OldInstallations
Previouslyinstalledstudsmayrequirecleaning.Cleanconicalthreadsshouldhaveabrightand
shinyappearance.
Ifcleaningisrequired,followthesesteps:
1. Blowoutthethreadswithcompressedairtoremoveloosedebrisanddryconical
threads.Donotapplyasolventorothercleaningsolutiontothethreadsasthismay
chemicallyattackthestud.
2. UseStudCleaningKit,GT‐4253orasimilar1"diameterBrasspowerbrush.
PictureofBrassPowerBrush
3. Insertthebrushintoanelectricdrillandsetdrilltoruninacounterclockwisedirection
athighspeed.
4. Workthedrillinacircularmotionwhilemovingthebrushinandouttocleanallofthe
threads.Trynottoholdthebrushinoneplacetoolong,soasnottoremovethestud's
protectivecoating.
5. Blowoutthethreadswithcompressedairtoremovelooseneddebris.
6. Visuallyinspectthreadsforcleanliness.Threadsshouldbebrightandshiny.
7. Repeatifanydirtcanbeseeninthethreads.
8. Inspectthreadsforanydamagethatmayhavebeencausedbypreviousinstallation.
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Donotapplythreadlubricantstothethreads.
Finishthecleaningprocessbyrinsinginavolatilesolventsuchasacetoneandallowtodry.
5.3StudLengthMeasurement
Measureandrecordtheinitiallengthsofthestuds.Thefollowingrecommendationswill
improveyourresults.
Plantostartandfinishanyflangeinthesameday.
Studsandflangemustbeatthesametemperature.
Numbereachstudwithamarker.
Markthelocationofmeasurementonstudendwithapermanentmarker.
Measureeachstudtonearest0.001inch.
Recordeachmeasurementonthesuppliedcharts.
Donotallowthemeasuringinstrumentstosetinthesun.
6.0StudandNutAssembly
Refertohardwareassemblydrawing(HF‐0813)listedinSection2.0ofthismanual.
1. Assemblecylindricalnuttothetaperedthreadend(PullEnd)ofthestud.
2. SlidethestudandcylindricalnutassemblyintotheflangeasshowninFigures1&2and
installtheothernutonthebackside.
3. Adjustthenut/studassemblysothatthestudprotrudesfromthefaceofthe
cylindricalnuttheamountasdepictedonthehardwaredrawing(HF‐0813).SETTING
THISPROTRUSIONOFSTUDTONUTISCRITICALFORPROPERTENSIONEROPERATION.
4. Hand‐tightentheassemblytoasnugfit.Seephotos1&2forviewofstudsinflange
priortotensioning.
7.0AssemblyofHydraulicTensionerEquipment
7.1KitAssembly
Assemblethehydraulicpumpwithitshosetothepullertoolandbleedthesystemofairper
followinginstructions.Photo4showshoseconnectedtomanifoldoftensioner.
Cleanpullerscrewandcheckforanydebrisanddents.
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