riverhawk IM-150 Manual de usuario
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INSTRUCTIONMANUALIM‐150
ForGas/SteamTurbineTensionedStudsandNuts
Fr.6CTurbineto6A8GeneratorGE381A6851
SteamTurbineto6A8GeneratorGE382A4352
GEPower&Water
GENERALELECTRICCOMPANY
MLI: ____ OF ____
DATE
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GESIGNATURES
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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 PreparationofHardware 9
6.0 NutandStudAssembly 11
7.0 AssemblyofHydraulicTensionerEquipment 11
8.0 AssemblyofTensioneronStud 12
9.0 StudPullingandTensioning 14
10.0 ThreadLocking 16
11.0 Stud/NutRemoval 16
12.0 FrequentlyAskedQuestions 17
13.0 RevisionHistory 19
AppendixA1 ECDeclarationofConformity 20
AppendixA2 UKCADeclarationofConformity 21
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1.0CautionsandSafetyWarnings
WARNING
Impropertooluseandthefailuretofollowthecorrectproceduresaretheprimaryrootcauses
oftoolsfailuresandpersonalinjuries.Alackoftrainingorinexperiencecanleadtoincorrect
hardwareinstallationorincorrecttooluse.Onlytrainedoperatorswithcareful,deliberate
actionsshouldusehydraulictensioners.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
Thisdocumentdescribestheproceduretobeusedtoinstallthestudandnutsetssuppliedby
theRiverhawkCompanyintheflangesattheTurbine/Coupling,Coupling/Gearand
Gear/Generatorconnections.
ThevariousframeconfigurationscoveredinthismanualarelistedinSections2.1through2.2
withdifferencesasrelatedtoconnectivehardwaredefined.Listedalsoarethepertinent
hardwaredrawings(HF‐).Thesedrawingsaswellastoolingdrawings(HT‐)formpartofthis
manual.
2.1Fr.6CTurbineto6A8GeneratorGE381A6851
HF‐2267,HT‐2268,HT‐2286
ThehardwaredrawingdepictsthestudandnutsetforbothTurbinetoLoadCouplingand
CouplingtoGearbox(11/8”[29mm]size,Qty48)aswellasGearboxtoGenerator(15/8”[41
mm]size,Qty40)
2.2SteamTurbineto6A8GeneratorGE382A4352
HF‐2312,HT‐2268
ThehardwaredrawingdepictsthestudandnutsetforbothTurbinetoGenerator(15/8”[41
mm]size,Qty40)
3.0QuickChecklist
ThefollowingchecklistisintendedasasummaryofthestepsneededtousetheRiverhawk‐
suppliedequipment.Newpersonnelorthoseexperiencedpersonnelwhohavenotusedthe
Riverhawkequipmentrecentlyareencouragedtoreadtheentiremanual.
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EQUIPMENTINSPECTION
□Checkoillevelinhydraulicpump.
□Checkairpressureat80psi[5.5bar]minimum.(Forair‐drivenpumps)
□Checkhydraulichosefordamage.
□Testpump.
□Inspecttensionerforanydamage.
NUTANDSTUDPREPARATION
□Inspectstudandnutsforanydamage.
□Measurestudlength.
□Cleanthestudsandnuts.
□Installstudsandnuts(off‐center)intotheflange.
□Setstick‐outdimensiononstudendwiththeinternal,conicalthread.
□Handtightenallstuds.
□Verifystick‐outmeasurement(VERYIMPORTANT)
Tensioning(Boltinstallation)
□Matchthetensionersetuptotheflangejoint.
□Applyalightcoatofcleanturbineoilorspraylubricanttothepullerscrew.DONOTUSE
“NEVERSEIZE”ONTHECONICALTHREADS.
□Slidespannerringoverthepullerscrew.
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□Mountthetensioneronthestudinflangeandinstallspannerringontonut.
□Insert3/8”hexAllenwrenchintothebacksideofthestud.
□Tightenthepullerscrew.Thenbackoffpullerscrew1/2aturn.
□Retightenthepullerscrewandleavetight.DONOTBACKOFFPULLERSCREW.
□Tightenpullernutandthenbacknutofftwoflatsor120degreestoallowforstudstretch.
□Bleedthetensioner.DoNOTbleedtensioneroffofastud!Damagetothetoolwill
result!
□Tensionto50%.Consultmanualforcorrectpressure.
□Usethepinwrenchinspannerringtotightennut.
□Releasepressure,movetonextstudinpattern.
□Repeatabovestepsatfinalpressure.
□Measurefinalstudlengthandrecordonstretchdatasheets.Calculatestretch.
□Torquenuts'setscrews.
Detensioning(Studremoval)
□Loosennuts'setscrews
□Inspectandcleanstuds'conicalthreads.DonotcontinueuntilALLdebrisisremoved
fromthethreads!Donottrytousethetensionertoremoveadamagedstud!
□Applyalightcoatofcleanturbineoilorspraylubricanttothepullerscrew.DONOTUSE
“NEVERSEIZE”ONTHECONICALTHREADS.
□Slidespannerringoverthepullerscrew.
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□Mountthetensioneronthestudandinstallspannerringintonut.
□Tightenthepullerscrew.Thenbackoffpullerscrew1/2aturn.
□Retightenthepullerscrewandleavetight.DONOTBACKOFFPULLERSCREW.
□Tightenpullernutandthenbacknutofftwoflatsor120degreestoallowforstudstretch.
□Bleedthetensioner.DoNOTbleedtensioneroffofastud!Damagetothetoolwill
result!
□Applyfinalpressure.
□Loosennutwiththespannerringandpinwrench.
□Movetonextstudinpattern
4.0GeneralPreparations
Readandunderstandallinstructionsbeforeinstallingandtensioningstuds.
Thisequipmentproducesveryhighhydraulicpressuresandveryhighforces.Operatorsmust
exercisecaution,wearsafetyglassesandhardhatswhenusingthisequipment.
High‐pressurefluidfromtheHydraulicPressureKitsystempressurizesthetensionerwhich
generatesastretchingforcethatactuallystretchesthestud.Asthestudisstretchedthenut
liftsofftheflange.Thenutisthenreseatedintopositionontheflangebyturninganutdriver
byhand.Whenthenutistightagainsttheflange,thepressureinthetensionerisreleased
leavingthestudloadedtoitspredeterminedvalue.
4.1MachinePreparation
Theflangetobetensionedmustbefullyclosedpriortopositioningthestudsintheflanges.
Theremustbeprovisionsforturningtheshaftsoftheturbine,coupling,gearboxandgenerator.
Also,itwillbeadvantageoustoremoveasmanyobstructionsaspossiblefromtheflangearea,
suchasspeedprobesandconduit.
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4.2Hardware–Balance
Hardwareissuppliedinweightbalancedsets
StudsandNutsareinterchangeablewithinsets
Donotmixwithothersets
Saveweightcertificationdatasuppliedwitheachsetforpurchaseofspares
4.3Tensioner–CareandHandling
Whennotinuse,thetensionershallbemaintainedinacleanenvironmentandallcapsand
plugsforhydraulicopeningsandfittingsmustbeinplace.
UseISO32gradeoil.
Wheninuse,thetensionershallbeprotectedfromsandandgrit
Longtermstorage–coattensionerwithoil,returntooriginalcontainer,sealcontainerand
protectfrommoisture.
Shipment–coattensionerwithoilandshipinoriginalcontainer
4.4 HandTools
Severalhandwrenchesandmicrometerswillberequiredtoperforminstallationand
measurementofthestuds:
5/8”openendwrench
15/16"open‐endwrench
1”wrench
AsetofAllenWrenches
3’–4’BreakerBar
5”to6”micrometerorcaliper
6”to7”micrometerorcaliper
4.5SpecialTools
HydraulicTensionerKit: HT‐2268HydraulicTensioner,1‐5/8”
HT‐2286HydraulicTensioner,1‐1/8”
(referenceGE364B3422)
HydraulicPumpKit: MP‐0130ManualHand‐Operated
HydraulicPump
(recommended)
(referenceGE359B2506)
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AP‐0532Air‐OperatedHydraulicPump
(referenceGE359B2502)
5.0PreparationofHardware
5.1NutPreparation
Fornewinstallationsthenutsshouldcomesealedfromthefactoryandwillneednocleaning.
Previouslyinstallednutsrequirecleaningasfollows:Wirebrushusingapetroleumbased
solventtoremoveanyforeignmaterialontheexternalsurfacesandthreads.
Ifpreviousinstallationemployedathreadlockingcompound,whichwillbevisibleasagrayish‐
greenresidue,removeasmuchofthiscompoundaspossible.
Donotapplythreadlubricantstothethreads.
Finishthecleaningprocessbyrinsinginavolatilesolventsuchasacetoneandallowtodry.
5.2StudPreparation
Checkthestudforanyvisibledamage.Ifthereisanyvisibledamage,donotusethestudand
contacttheRiverhawkCompanyforareplacementstud.Pleasebepreparedtosupplythe
turbinenumber,weightcertification,anddigitalphotographsforevaluation.
Theconicalthreadsofeachstudmustbecleanbeforeinstallationorremoval.Thisensuresthe
properseatingofthepullerscrew.
5.2.1StudCleaning‐NewInstallations
Fornewinstallations,thestudsshouldcomesealedfromthefactoryandwillneednocleaning.
5.2.2StudCleaning‐OldInstallations
Previouslyinstalledstudsmayrequirecleaning.Cleanconicalthreadsshouldhaveabrightand
shinyappearance.
Ifcleaningisrequired,followthesesteps:
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1. Blowoutthethreadswithcompressedairtoremoveloosedebrisanddryconical
threads.Donotapplyasolventorothercleaningsolutiontothethreadsasthismay
chemicallyattackthestud.
2. UseStudCleaningKit,GT‐4354orasimilar1/2"diameterBrasspowerbrush.
PictureofBrassPowerBrush
3. Insertthebrushintoanelectricdrillandsetdrilltoruninacounterclockwisedirection
athighspeed.
4. Workthedrillinacircularmotionwhilemovingthebrushinandouttocleanallofthe
threads.Trynottoholdthebrushinoneplacetoolong,soasnottoremovethestud's
protectivecoating.
5. Blowoutthethreadswithcompressedairtoremovelooseneddebris.
6. Visuallyinspectthreadsforcleanliness.Threadsshouldbebrightandshiny.
7. Repeatifanydirtcanbeseeninthethreads.
8. Inspectthreadsforanydamagethatmayhavebeencausedbypreviousinstallation.
Donotapplythreadlubricantstothethreads.
Finishthecleaningprocessbyrinsinginavolatilesolventsuchasacetoneandallowtodry.
5.3StudLengthMeasurement
Measureandrecordtheinitiallengthofthestuds.Thefollowingsuggestionswillimproveyour
results:
Plantostartandfinishanyflangeinthesameday.
Studsandflangemustbeatthesametemperature
Numbereachstudwithamarker.
Markthelocationofthemeasurementonstudendwithapermanentmarker.
Measureeachstudtonearest0.001inch.
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