riverhawk IM-255 Manual de usuario
Repairs – Rentals
Field Service
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WARNING: THIS MANUAL IS ONLY FOR
HYDRAULIC TENSIONERS WITH
THE ORANGE SAFETY GUARD.
DO NOT USE IF THE GUARD
IS A DIFFERENT COLOR.
INSTRUCTIONMANUALIM‐255
ForSyngasTurbineTensionedStudsandNuts
ApplicableBoltingConnections
7FBSyngasTurbinetoLoadCoupling
7FBSyngasLoadCouplingtoGenerator
ApplicableGEOrderingSheetPartNumbers
101T4503P001
101T4503P002
101T4503P003
101T4503P004
101T4503P005
101T4503P006
101T4503P007
GEPower&Water
GENERALELECTRICCOMPANY
MLI: ____ OF ____
DATE
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ISSUED:
THISDOCUMENTSHALLBEREVISEDINITSENTIRETY.ALLSHEETSOFTHISDOCUMENTARE
THESAMEREVISIONLEVELASINDICATEDINTHISVENDORSUPPLIEDDRAWINGAPPLIQUE.
REV
373A4038
GEDRAWINGNUMBER
VENDORSUPPLIED
THISDOCUMENTISFILEDUNDERTHEGEDRAWINGNUMBER.
GENOTTOREVISE.GEREVISIONLEVELISSHOWNONTHISAPPLIQUE.
GESIGNATURES
CHECKED:
TheRiverhawkCompanyreservestherighttomakechangesupdatingthisdocumentwithoutdisseminationornotice.
The latest revision level may be obtained by contacting Riverhawk Company directly or at our website
www.riverhawk.com.
Instruction Manual IM-255
For Gas Turbine Tensioned Studs & Nuts
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TableofContents
Section Description Page
Number
1.0 CautionsandSafetyWarnings 3
2.0 ScopeandGEPartNumberCross‐Reference 4
3.0 QuickCheck‐List 5
4.0 GeneralPreparations 13
5.0 HardwareSetPreparations 15
6.0 NutandStudAssembly 17
7.0 HydraulicEquipmentPreparations 20
8.0 AssemblyofTensioneronStud 22
9.0 StudPullingandTensioning 26
10.0 ThreadLocking 29
11.0 Stud/NutRemoval 30
12.0 Storage 31
13.0 FrequentlyAskedQuestions 32
14.0 RevisionHistory 34
AppendixA1 ECDeclarationofConformity 35
AppendixA2 UKCADeclarationofConformity 36
AppendixB1 HydraulicFittings 37
AppendixB2 PullerScrewReleaseTape 38
AppendixB3 HydraulicTensioner’sBurstDiscReplacement 39
Instruction Manual IM-255
For Gas Turbine Tensioned Studs & Nuts
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AppendixC1 18‐BoltTensioningPattern(GT‐LC)RecordSheet 40
AppendixC2 16‐BoltTensioningPattern(LC‐GEN)RecordSheet 41
1.0CautionsandSafetyWarnings
NOTICE
Asofsummer2011,thismanualistobeusedinrelationtotheinterlockingstyletensioner.This
new tensioner can be identified buy its ORANGE safety guard. Note: yellow guarded tensioner
requirestheuseofdifferentsetofinstructions,consultRiverhawkforassistance
TOAVOIDFAILURE,ENSURESAFETYANDPROPEROPERATIONTHETENSIONERANDINERLOCK
SAFETYGUARDMUSTINSTALLEDONTHEFLANGEBEFORETENSIONINGBEGINS.DONOTUSETHE
TENSIONERASSEMBLYATANYPRESSUREUNLESSTHETOOLISINSTALLEDONTHEFLANGE.
WARNING
Impropertooluseandthefailuretofollowthecorrectproceduresaretheprimaryrootcausesoftool
failuresandpersonalinjuries.Alackoftrainingorexperiencecanleadtoincorrecthardware
installationorincorrecttooluse.Onlytrainedoperatorswithcareful,deliberateactionsshoulduse
hydraulictensioners.ContactRiverhawkCompanywithanytrainingneeds.
WARNING
Riskofhighpressurefluidinjection.Riverhawktoolsoperateunderhighpressure.Thoroughlyinspect
allhosesandconnectionsfordamageorleakspriortousingthisequipment.
CAUTION
Personalinjuryandequipmentdamagecanoccurifthepullerscrewisnotsecurelyengagedwith
theconicalthreadofthestud.Properengagementisachievedwhenthepullerscrewistightinthe
studandisnotcross‐threadedintotheconicalthread.
WARNING
Theproperpersonalprotectiveequipmentmustbewornatalltimes.Riverhawkrecommendsata
minimum,safetyglasses,longsleeveshirt,hardhat,heavyworkgloves,andsteeltoeshoes.
WARNING
ThesafetyguardMUSTbeinplaceandhandskeptoutofdesignatedareasatalltimeswhenthe
tensionerispressurizedotherwisepersonalinjurycanoccur.
Instruction Manual IM-255
For Gas Turbine Tensioned Studs & Nuts
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CAUTION
DONOTEXCEEDTHEMAXIMUMPRESSUREMARKEDONTHETENSIONER.Excessivepressurecan
damagethestudandthepullerscrew.
WARNING:
Keephandsclearofthetoolwhilethepressureisbuildingup.Thisincludesthepinwrenchfor
tighteningthespannerring(nut).Oncethetoolisstabilizedatpressurethenandonlythencanthe
nutbetightened.Thisreducesthepotentialofpersonalinjury.
Note:Beforethreadingthepullerscrewintothestud,carefullycheckthecleanlinessofboththe
stud's and the puller screw's conical threads. Apply a light coat of clean turbine oil or a spray
lubricanttothepullerscrew.Donotuse“NeverSeize”ontheconicalthreads.Thisprocedurewill
easeassemblyandassurepositivematingofthethreadsbeforetightening.
2.0Scope
Thisdocumentdescribesthestepstoinstallasetofhardwarecontainingthestudsandnutssupplied
byRiverhawkCompanyattheturbine/couplingandcoupling/generatorconnections.Thishardware
isdepictedonthefollowingdrawings.Thesedrawingsaswellastoolingdrawingsformpartofthis
manual.
GEOrderingSheet
PartNumber
GEDrawing
Numberfor
HardwareSet
Riverhawk
HardwareSet
PartNumber HardwareSetDescription
101T4503P001
101T4503P002#359B2514 HF‐0771
2‐1/4"and2‐3/4"Hardware
Setfor7F(bothendsofload
coupling)
101T4503P003# n/a n/a
2‐1/4”and2‐3/4”Installation
toolingonly(includesHydraulic
pump)
101T4503P004 359B2539 HF‐2447 2‐1/4"HardwareSetfor7F
(turbineendofloadcoupling)
Instruction Manual IM-255
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101T4503P005 359B2520 HF‐0803
2‐3/4"HardwareSetfor7F
(generatorendofload
coupling)
101T4503P006# n/a n/a
HydraulicTensionerfor2‐1/4”
hardware(Hydraulicpumpand
hardwaresetarenotincluded
withthispart)
101T4503P007# n/a n/a
HydraulicTensionerfor2‐3/4”
hardware(Hydraulicpumpand
hardwaresetarenotincluded
withthispart)
#denotesGEpartnumbersthatincludeinstallationtooling
3.0QuickChecklist
ThefollowingchecklistisintendedasasummaryofthestepsneededtousetheRiverhawk‐supplied
equipment. New personnel or those experienced personnel who have not used the Riverhawk
equipmentrecentlyareencouragedtoreadtheentiremanual.
EQUIPMENTINSPECTION
□ Checkoillevelinhydraulicpump.
□ Checkairpressureat80psi[5.5bar]minimum.(Forair‐drivenpumps)
□ Checkhydraulichoseforanydamage.
□ Testpump.
□ Inspecttensionerforanydamage.
NUTANDSTUDPREPARATION
□ Inspectstudsandnutsforanydamage.
□ Cleanthestudsandnuts.
Instruction Manual IM-255
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□ Measurestudlengths.(VERYIMPORTANT)
□ Installstudsandnutsintotheflange.
□ Setstick‐outdimensiononthecouplingsideoftheflange.
□ Handtightennutsongeneratorsideofflange.
□ Verifystick‐outmeasurement(VERYIMPORTANT)
Tensioning(StudInstallationGASTURBINEEND)
□ Checktensioner’sdrawingforcorrectpartsandpartnumbers.
□Applyalightcoatofcleanturbineoilorspraylubricanttothepullerscrew.DONOTUSE
“NEVERSEIZE”ONTHECONICALTHREADS.
□Installspannerringontothenut.
□ Installonepullerscrewreleasetapestripintostud.(AppendixB2)
□Threadpullerscrewontothestud.
□InsertAllenwrenchintothebacksideofthestudtostopthestudfromrotatingwhen
installingthepullerscrew.
□UsinganAllenwrench,tightenthepullerscrew.Thenbackoffpullerscrew1/2aturn.
□Retightenpullerscrewbyhanduntilitisfullyinserted.DONOTBACKOFFPULLERSCREW.
□Slidefootoverthepullerscrewandorientateintoposition.
□Threadthetensionerontopullerscrew.Lightlyturnthetensionerontothepullerscrew
untilitstops.Thegapbetweenthefootandtensionerisabout1/16”to3/16”
□Placeguardovertensionerandpositionguidepinintotheholeinthebacksideofthestud.
Instruction Manual IM-255
For Gas Turbine Tensioned Studs & Nuts
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□Tightenknurledinterlockfittingbyhanduntilitpressesfirmlyagainsttensioner.(nogap)
□Slideandengagecustomerconnectorfromrearofguardtolocktensionerintoplace.
□Tensionto50%.Consultmanualforcorrectpressure.
□Usethepinwrenchinthespannerringtotightennut.
□Releasepressureandallowthetensionertofullyretract.
□Disconnectthehosefromthetensioner.
□Loosentheknurledfittingandremovethesafetyguard.
□
Unscrewthetensionerfromthepullerscrew.Usecautiontoensurethathandsarenot
betweenthetensionerandthecouplingwhenthetensionerbecomesdisengagedfrom
thepullerscrew.
□Removethefoot.
□Removethepullerscrewfromthestud.
□Removethespannerringfromthenutandmovetothenextstudinthepattern.
□Tensionallstudsto50%beforeproceedingtofinalpressure.
□ Repeattheabovestepsatthefinalpressure.
□ Measurethefinalstudlengthandrecordonthestretchdatasheets.Calculatethestretch
andverifypersection9.2
□ Torquethenuts’setscrewspersection10
Instruction Manual IM-255
For Gas Turbine Tensioned Studs & Nuts
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Tensioning(StudInstallationGENERATOREND)
□ Checktensioner’sdrawingforcorrectpartsandpartnumbers.
□Applyalightcoatofcleanturbineoilorspraylubricanttothepullerscrew.DONOTUSE
“NEVERSEIZE”ONTHECONICALTHREADS.
□Installspannerringontothenut.
□ Installonepullerscrewreleasetapestripintostud.(AppendixB2)
□Threadpullerscrewontothestud.
□InsertAllenwrenchintothebacksideofthestudtostopthestudfromrotatingwhen
installingthepullerscrew.
□UsinganAllenwrench,tightenthepullerscrew.Thenbackoffpullerscrew1/2aturn.
□Retightenpullerscrewbyhanduntilitisfullyinserted.DONOTBACKOFFPULLERSCREW.
□ Installretentionstudsintoadjacentstuds,bothsidesofthepullerscrew.
□ Installbacksideguardcoveringstudtobetensioned,andlightlythreadedintobacksideof
adjacentstuds.
□Slidefootoverthepullerscrewandorientateintoposition.
□Threadthetensionerontopullerscrew.Lightlyturnthetensionerontothepullerscrew
untilitstops.Thegapbetweenthefootandtensionerisabout1/16”to3/16”
□Placeguardovertensionerandpositionlocatingcutoutsontoretentionstuds.
□Tightenknurledinterlockfittingbyhanduntilitpressesfirmlyagainsttensioner(nogap).
Thiswillalsoseatretentionstudsintoguard’slocatingcutouts.
□Slideandengagecustomerconnectorfromrearofguardtolocktensionerintoplace.
Instruction Manual IM-255
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□Tensionto50%.Consultmanualforcorrectpressure.
□Usethepinwrenchinthespannerringtotightennut.
□Releasepressureandallowthetensionertofullyretract.
□Disconnectthehosefromthetensioner.
□Loosentheknurledfittingandremovethesafetyguard.
□
Unscrewthetensionerfromthepullerscrew.Usecautiontoensurethathandsarenot
betweenthetensionerandthecouplingwhenthetensionerbecomesdisengagedfrom
thepullerscrew.
□Removethefootfrompullerscrew.
□Removethepullerscrewfromthestudandretentionstuds.
□Removethespannerringfromthenutandmovetothenextstudinthepattern.
□Tensionallstudsto50%beforeproceedingtofinalpressure.
□ Repeattheabovestepsatthefinalpressure.
□ Measurethefinalstudlengthandrecordonthestretchdatasheets.Calculatethestretch
andverifypersection9.2
□ Torquethenuts’setscrewspersection10
Detensioning(StudRemovalGASTURBINEEND)
□ Loosenthenuts’setscrews
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□
Inspectandcleanstuds’conicalthreads.DonotcontinueuntilALLdebrisisremoved
fromthethreads!RefertoinstructionmanualIM‐220.Donottrytousethetensionerto
removeadamagedstud!
□Applyalightcoatofcleanturbineoilorspraylubricanttothepullerscrew.DONOTUSE
“NEVERSEIZE”ONTHECONICALTHREADS.
□Installthespannerringontothenut.
□Threadthepullerscrewontothestud.
□UsinganAllenwrench,tightenthepullerscrew.Thenbackoffthepullerscrew1/2aturn.
□Lightlyretightenthepullerscrewbyhanduntilitisfullyinserted.DONOTBACKOFFTHE
PULLERSCREW.
□Slidethefootoverthepullerscrewandorientateintoposition.
□Threadthetensionerontothepullerscrew.Lightlyturnthetensionerontothepuller
screwuntilitstops.Thegapbetweenthefootandtensionerisabout1/16”to3/16”.
□Placethesafetyguardoverthetensionerandpositiontheguidepinintotheholeinthe
backsideofthestud.
□Tightentheknurledinterlockfittingbyhanduntilitfirmlypressesagainstthetensioner.
(nogap).
□Slideandengagethecustomconnectorfromtherearofthesafetyguardtolockthe
tensionerintoplace.
□Applythefinalpressure.
□Loosenthenutwiththespannerringandpinwrench.
□Releasethehydraulicpressureandallowthetensionertofullyretract.
□Disconnectthehosefromthetensioner.
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