riverhawk IM-186 Manual de usuario
Repairs – Rentals
Field Service
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INSTRUCTIONMANUALIM‐186
ForGasTurbineTensionedStudsandNuts
Fr.7HTurbinetoLoadCouplingGE372A1793P003,P004
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 8
6.0 NutandStudAssembly 10
7.0 AssemblyofHydraulicTensionerEquipment 10
8.0 AssemblyofTensioneronStud 11
9.0 StudPullingandTensioning 13
10.0 ThreadLocking 14
11.0 Stud/NutRemoval 15
12.0 FrequentlyAskedQuestions 16
13.0 RevisionHistory 18
AppendixA1 ECDeclarationofConformity 19
AppendixA2 UKCADeclarationofConformity 20
FiguresandIllustrations 21
20‐BoltTensioningPatternRecordSheet 23
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1.0CautionsandSafetyWarnings
WARNING
Impropertooluseandthefailuretofollowthecorrectproceduresaretheprimaryrootcauses
oftoolsfailuresandpersonalinjuries.Alackoftrainingorexperiencecanleadtoincorrect
hardwareinstallationorincorrecttooluse.Onlytrainedoperatorswithcareful,deliberate
actionsshouldusehydraulictensioners.ContactRiverhawkCompanywithanytrainingneeds.
WARNING
Riskofhighpressurehydraulicfluidinjection.Riverhawktoolsoperateunderhighpressure.
Thoroughlyinspectallhosesandconnectionsfordamageorleakspriortousingthisequipment.
CAUTION
Personalinjuryandequipmentdamagecanoccurifthepullerscrewisnotsecurelyengaged
withthetaperedthreadofthestud.Properengagementisachievedwhenthepullerscrewis
tightinthestudandtheTensionerAssemblyisfreetorotate.
WARNING
Theproperpersonalprotectiveequipmentmustbewornatalltimes.Riverhawkrecommends
ataminimum,safetyglasses,longsleeveshirt,hardhat,heavyworkgloves,andsteeltoe
shoes.
WARNING
ThesafetycageMUSTbeinplaceandhandskeptoutofdesignatedareasatalltimeswhenthe
pullertoolispressurizedotherwisepersonalinjurycanoccur.
CAUTION
DONOTEXCEEDTHEMAXIMUMPRESSUREVIBROSCRIBEDONTHEPULLERBODY.Excessive
pressurecandamagethestudandthepullerscrew.
WARNING
FireHazard;DONOTheatwhenthepullerassemblyisinplace.Personalinjuryorequipment
damagemayoccur.UseofanOxy‐Acetylenetorchisnotrecommended.
NOTICE
DonotusemorethreadlockingcompoundthanspecifiedorthenutmaybeVERYdifficultto
removeatdisassembly.
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CAUTION
DONOTEXCEEDTHEMAXIMUMPRESSUREVIBROSCRIBEDONTHEPULLERBODY.Excessive
pressurecandamagethestudandpullerscrew
Note:Donotoverextendthestud.Overextensioncancausethepistontolooseitssealand
leakoil.
Note:Beforethreadingthepullerscrewintothestud,carefullycheckthecleanlinessofboth
thestud'sandthepullerscrew'sconicalthreads.Applyalightcoatofcleanturbineoilora
spraylubricanttothepullerscrew.Donotuse“NeverSeize”ontheconicalthreads.This
procedurewilleaseassemblyandassurepositivematingofthethreadsbeforetightening.
2.0 Scope
Thisdocumentdescribestheproceduretobeusedtoinstallstudsandnutssuppliedby
RiverhawkCompanyintheflangesattheturbine/couplingandcoupling/generatorconnections.
Thishardwareisdepictedonthefollowingdrawingsthesedrawingsaswellasthetooling
drawingsformapartofthismanual.
HF‐1554
3.0QuickChecklist
ThefollowingchecklistisintendedasasummaryofthestepsneededtousetheRiverhawk‐
suppliedequipment.Newpersonnelorthoseexperiencedpersonnelwhohavenotusedthe
Riverhawkequipmentrecentlyareencouragedtoreadtheentiremanual.
EQUIPMENTINSPECTION
□ Checkoillevelinhydraulicpump.
□ Checkairpressureat80psi[5.5bar]minimum.(Forair‐drivenpumps)
□ Checkhydraulichosefordamage.
□ Testpump.
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□Inspecttensionerforanydamage.
NUTANDSTUDPREPARATION
□Inspectstudandnutsforanydamage.
□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.
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□Retightenthepullerscrewandleavetight.DONOTBACKOFFPULLERSCREW.
□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.
□ Mountthetensioneronthestud.
□ Installspannerringintonut.
□ Tightenthepullerscrew.
□ Backoffpullerscrew1/2aturn.
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□ Retightenthepullerscrewandleavetight.DONOTBACKOFFPULLERSCREW.
□ Bleedthetensioner.DoNOTbleedtensioneroffofastud!Damagetothetoolwill
result!
□ Applyfinalpressure.
□Loosennutwiththespannerringandpinwrench.
□Movetonextstudinpattern
4.0GeneralPreparations
Readandunderstandallinstructionsbeforeinstallingandtensioningstuds
4.1MachinePreparation
Theflangetobetensionedmustbefullyclosedpriortopositioningofstudsintheflanges.
Turningtheshaftsoftheturbineandthegeneratorarenotrequired,butmaybeuseful.Also,it
willbeadvantageoustoremoveasmanyobstructionsaspossiblefromtheflangearea,suchas
speedprobes,shippingplates,andconduit.
4.2Hardware–Balance
Hardwareissuppliedasweightbalancedsets
StudsandNutsareinterchangeablewithinsets
Donotintermixsets
Saveweightcertificationsuppliedwitheachsetforthepurchaseofspares
4.3Tensioner–CareandHandling
Whennotinuse,thetensionershallbemaintainedinacleanenvironmentandallcaps
andplugsforhydraulicopeningsandfittingsmustbeinplace.
UseISO32gradeoil.
Wheninuse,thetensionershallbeprotectedfromsandandgrit.
Longtermstorage–coattensionerwithoil,returntooriginalcontainer,sealcontainer
andprotectfrommoisture.
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Shipment–coattensionerwithoilandshipinoriginalcontainer.
4.4 HandTools
Severalhandwrenchesandmicrometerswillberequiredtoperforminstallationand
measurementofthestuds:
5/8”wrench
1"wrench
1"Socket&ImpactWrench
AsetofAllenWrenches
3’–4’BreakerBar
14”to15”micrometerorcaliper
4.5SpecialTools
HydraulicTensionerKit: HT‐2981HydraulicTensioner
(referenceGE359B2589)
HydraulicPumpKit: AP‐0532Air‐operatedHydraulicPump
(recommended)
(referenceGE359B2502)
5.0PreparationofHardware
5.1NutPreparation
Fornewinstallations,thenutsshouldcomesealedfromthefactoryandwillneednocleaning.
Previouslyinstallednutsrequirecleaning:asfollows:Wirebrushusingapetroleumbased
solventtoremoveanyforeignmaterialontheexternalsurfacesandthreads.
Ifpreviousinstallationsemployedathread‐lockingcompound,whichwillbevisibleasagrayish‐
greenresidue,removeasmuchofthiscompoundaspossible.
Donotapplythreadlubricantstothethreads.
Finishthecleaningprocessbyrinsinginavolatilesolventsuchasacetoneandallowtodry.
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5.2StudPreparation
Fornewinstallations,thestudsshouldcomesealedfromthefactoryandwillneednocleaning
5.2.1StudCleaning‐OldInstallations
Previouslyinstalledstudsmayrequirecleaning.Cleanconicalthreadsshouldhaveabrightand
shinyappearance.
Ifcleaningisrequired,followthesesteps:
1. Blowoutthethreadswithcompressedairtoremoveloosedebrisanddryconical
threads.Donotapplyasolventorothercleaningsolutiontothethreadsasthismaychemically
attackthestud.
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.
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Finishthecleaningprocessbyrinsinginavolatilesolventsuchasacetoneandallowtodry.
5.3StudLengthMeasurement
Measureandrecordtheinitiallengthsofthestuds.Thefollowingrecommendationswill
improveyourresults.
Plantostartandfinishanyflangeinthesameday.
Studsandflangemustbeatthesametemperature.
Numbereachstudwithamarker.
Markthelocationofmeasurementonstudendwithapermanentmarker.
Measureeachstudtonearest0.001inch.
Recordeachmeasurementonthesuppliedcharts.
Donotallowthemicrometertosetinthesun
6.0StudandNutAssembly
RefertoHardwareAssemblyDrawing(HF‐1554)listedinSect.2.0ofthismanual.
1. Assemblecylindricalnuttothetaperedthreadend(PullEnd)ofthestud.
2. SlidetheassemblyintotheflangefromthecouplingsideasshowninFigures1&2then
installtheotherCylindricalnutonthebackside(thecylindricalnutsareidentical).
3. Adjustthestud/nutassemblysothatthestudprotrudesfromthefaceofthe
cylindricalnuttheamountdepictedonthehardwaredrawing(HF‐1554)TYPICALLY
0.250”TURBINEEND.SETTINGTHISPROTRUSIONOFSTUDTONUTISCRITICALFOR
PROPERTENSIONEROPERATION.Handtightentheassemblytoasnugfit.SeePhotos1
&2foraviewoftheassemblyofstudsandnutsintheflangepriortotensioning.
7.0AssemblyofHydraulicTensionerEquipment
7.1KitAssembly
Assemblethehydraulicpumpwithitshosetothepullertoolandbleedthesystemofairper
followinginstructionsinparagraph6.3(MUSTBEONASTUD).Photo3showshoseconnected
tomanifoldoftensioner.
7.1.1Fittings
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