riverhawk IM-139 Manual de usuario
Repairs – Rentals
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INSTRUCTIONMANUALIM‐139
ForGasTurbineTensionedStudsandNuts
Fr.9HTurbineGE372A1793P002
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 FrequentlyAskedQuestions 15
13.0 RevisionHistory 17
AppendixA1 ECDeclarationofConformity 18
AppendixA2 UKCADeclarationofConformity 19
AppendixB 22‐BoltTensioningPatternRecordSheet 23
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1.0CautionsandSafetyWarnings
WARNING
Improperuseandthefailuretofollowthecorrectproceduresaretheprimaryrootcausesof
toolfailuresandpersonalinjuries.Alackoftrainingorexperiencecanleadtoincorrect
hardwareinstallationorincorrecttooluse.Onlytrainedpersonswithcareful,deliberateactions
shouldusehydraulictensioners.ContactRiverhawkwithanytrainingneeds.
WARNING
Riskofhighpressurehydraulicfluidinjection.Riverhawktoolsoperateunderhighpressure.
Thoroughlyinspectallhosesandconnectionsfordamageorleakspriortousingthisequipment.
CAUTION
Personalinjuryandequipmentdamagecanoccurifthepullerscrewisnotsecurelyengaged
withthetaperedthreadofthestud.Properengagementisachievedwhenthepullerscrewis
tightinthestudandtheTensionerAssemblyisfreetorotate.
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
Thisdocumentdescribestheproceduretobeusedtoinstallthestudsandnutssuppliedby
RiverhawkCompanyintheflangesattheturbine/couplingconnection.Thishardwareis
depictedonthefollowingdrawing.ThisdrawingaswellasToolingdrawingformpartofthis
manual.
HF‐1730
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.
□Mountthetensioneronthestudinflangeandinstallspannerringontonut.
□Insert1/2”hexAllenwrenchintothebacksideofthestud.
□Tightenthepullerscrew.Thenbackoffpullerscrew1/2aturn.
□Retightenthepullerscrewandleavetight.DONOTBACKOFFPULLERSCREW.
□Tightenpullernutandthenbacknutofftwoflatsor120degreestoallowforstudstretch.
□Bleedthetensioner.DoNOTbleedtensioneroffofastud!Damagetothetoolwill
result!
□Tensionto50%.Consultmanualforcorrectpressure.
□Usethepinwrenchinspannerringtotightennut.
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□Releasepressure,movetonextstudinpattern.
□Repeatabovestepsatfinalpressure.
□Measurefinalstudlengthandrecordonstretchdatasheets.Calculatestretch.
□Torquenuts'setscrews.
Detensioning(Studremoval)
□Loosennuts'setscrews
□Inspectandcleanstuds'conicalthreads.DonotcontinueuntilALLdebrisisremoved
fromthethreads!Donottrytousethetensionertoremoveadamagedstud!
□Applyalightcoatofcleanturbineoilorspraylubricanttothepullerscrew.DONOTUSE
“NEVERSEIZE”ONTHECONICALTHREADS.
□Slidespannerringoverthepullerscrew.
□Mountthetensioneronthestud.
□Installspannerringintonut.
□Tightenthepullerscrew.Thenbackoffpullerscrew1/2aturn.
□Retightenthepullerscrewandleavetight.DONOTBACKOFFPULLERSCREW.
□Tightenpullernutandthenbacknutofftwoflatsor120degreestoallowforstudstretch.
□Bleedthetensioner.DoNOTbleedtensioneroffofastud!Damagetothetoolwill
result!
□Applyfinalpressure.
□Loosennutwiththespannerringandpinwrench.
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□Movetonextstudinpattern
4.0GeneralPreparations
Readandunderstandallinstructionsbeforeinstallingstuds.
Thisequipmentproducesveryhighhydraulicpressuresandveryhighforces.Operatorsmust
exercisecaution,wearsafetyglassesandhardhatswhenusingthisequipment.High‐pressure
fluidfromtheHydraulicPressureKitsystempressurizesthetensioner,whichgeneratesa
stretchingforcethatactuallystretchesthestud.Asthestudisstretchedthenutliftsoffthe
flange.Thenutisthenreseatedintopositionontheflangebyturninganutdriverbyhand.
Whenthenutistightagainsttheflange,thepressureinthetensionerisreleasedleavingthe
studloadedtoitspredeterminedvalue.
4.1MachinePreparation
Theflangetobetensionedmustbefullyclosedpriortopositioningthestudsintheflanges.
Theremustbeprovisionsforturningtheshaftsoftheturbine,coupling,gearboxandgenerator.
Also,itwillbeadvantageoustoremoveasmanyobstructionsaspossiblefromtheflangearea,
suchasspeedprobesandconduit.
4.2Hardware–Balance
Hardwareissuppliedasweightbalancedsets
StudsandNutsareinterchangeablewithinsets
Donotmixwithothersets
Saveweightcertificationdatasuppliedwitheachsetforpurchaseofspareparts.
4.3Tensioner–CareandHandling
Whennotinuse,thetensionershallbemaintainedinacleanenvironmentandallcapsand
plugsforhydraulicopeningsandfittingsmustbeinplace.
UseISO32gradeoil.
Wheninuse,thetensionershallbeprotectedfromsandandgrit.
Longtermstorage–coattensionerwithoil,returntooriginalcontainer,sealcontainerand
protectfrommoisture.
Shipment–coattensionerwithoilandshipinoriginalcontainer
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4.4 HandTools
Severalhandwrenchesandmicrometerswillberequiredtoperforminstallationand
measurementofthestuds:
5/8”wrench
AsetofAllenWrenches
3’–4’BreakerBar
14”to15”micrometerorcaliper
4.5SpecialTools
HydraulicTensionerKit: HT‐1746HydraulicTensioner
(referenceGE359B2511)
HydraulicPumpKit: AP‐0532Air‐OperatedHydraulicPump
(recommended)
(referenceGE359B2502)
5.0PreparationofHardware
5.1NutPreparation
Fornewinstallationsthenutsshouldcomesealedfromthefactoryandwillneednocleaning.
Previouslyinstallednutsrequirecleaningasfollows:Wirebrushusingapetroleumbased
solventtoremoveanyforeignmaterialontheexternalsurfacesandthreads.
Donotapplythreadlubricantstothethreads.
Finishthecleaningprocessbyrinsinginavolatilesolventsuchasacetoneandallowtodry.
5.2StudPreparation
Fornewinstallations,thestudsshouldcomesealedfromthefactoryandwillneednocleaning.
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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.
Donotapplythreadlubricantstothethreads.
Finishthecleaningprocessbyrinsinginavolatilesolventsuchasacetoneandallowtodry.
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5.3StudLengthMeasurement
Measureandrecordtheinitiallengthofthestuds.Thefollowingsuggestionswillimproveyour
results:
Plantostartandfinishanyflangeinthesameday.
Studsandflangemustbeatthesametemperature
Numbereachstudwithamarker.
Markthelocationofthemeasurementonstudendwithapermanentmarker.
Measureeachstudtonearest0.001inch.
Recordeachmeasurementonthesuppliedcharts.
Donotallowthemeasuringinstrumentstosetinthesun.
6.0StudandNutAssembly
1. Refertothehardwareassemblydrawing(HF‐1730)listedinSection2.0ofthismanual.
Assemblethecylindricalnuttothetaperedthreadend(PullEnd)ofthestud.
2. SlidethestudandcylindricalnutassemblyintotheflangeasshowninFigure1and
installtheothernutonthebackside.
3. Adjustthenut/studassemblysothatthestudprotrudesfromthefaceofthecylindrical
nuttheamountdepictedonthehardwaredrawing(HF‐1730)0.180/0.200inches.
SETTINGTHISPROTRUSIONOFSTUDTONUTISCRITICALFORPROPERTENSIONER
OPERATION.
4. Hand‐tightentheassemblytoasnugfit.
7.0AssemblyofHydraulicTensionerEquipment
7.1KitAssembly
Assemblethehydraulicpumpwithitshosetothepullertoolandbleedthesystemofairper
followinginstructions.
Cleanpullerscrewandcheckforanydebrisanddents.
Pullerscrewshouldbefreetorotateandmovebackandforth.
Inspecttensionerguardforanysignsofdamage.Bentguardsshouldbereplaced.
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