riverhawk IM-269 Manual de usuario
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INSTRUCTIONMANUALIM‐269
ForGasTurbineTensionedStudsandNuts
Fr.9FATurbinetoHITACHIGeneratorGE102T5689P001
GE102T5689P002
Fr.9FATurbinetoLoadCouplingGE102T5689P004
LoadCouplingtoHITACHIGeneratorGE102T5689P005
GEPower&Water
GENERALELECTRICCOMPANY
MLI: ____ OF ____
DATE
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GESIGNATURES
CHECKED:
TheRiverhawkCompanyreservestherighttomakechangesupdatingthisdocumentwithout
dissemination or notice. The latest revision level may be obtained by contacting Riverhawk
Companydirectlyorvisitourwebsiteatwww.riverhawk.com
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TableofContents
Section Description PageNumber
1.0 CautionsandSafetyWarnings 3
2.0 Scope 3
3.0 QuickCheck‐List 4
4.0 GeneralPreparations 6
5.0 HardwareSetPreparations 8
6.0 StudandNutAssembly 10
7.0 AssemblyofHydraulicTensionerEquipment 12
8.0 AssemblyofTensioneronStud 15
9.0 StudTensioning 20
10.0 ThreadLocking 22
11.0 WindagePlugInstallation 23
12.0 StudandNutRemoval 25
13.0 StorageInstructions 27
14.0 FrequentlyAskedQuestions 29
15.0 RevisionHistory 31
AppendixA1 ECDeclarationofConformity 31
AppendixA2 UKCADeclarationofConformity 32
AppendixB1 TurbineSideStretchRecordSheet 33
AppendixB2 GeneratorSideStretchRecordSheet 34
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1.0CautionsandSafetyWarnings
CAUTION
Personalinjuryandequipmentdamagecanoccurifthepullerscrewisnotsecurelyengagedwith
thetaperedthreadofthestud.Properengagementisachievedwhenthepullerscrewistightin
thestudandtheTensionerAssemblyisfreetorotate.
CAUTION
The “9FA gas turbine to the load coupling” flange uses a different tensioner than the “load
couplingtoHITACHIgenerator”flange.Verifythecorrecttensionerisbeingused.
WARNING
ThesafetycageMUSTbeinplaceandhandskeptoutofdesignatedareasatalltimeswhenthe
tensionerispressurizedotherwisepersonalinjurycanoccur.
CAUTION
DO NOT EXCEED THE MAXIMUM PRESSURE VIBROSCRIBED ON THE PULLER BODY. Excessive
pressurecandamagethestudandthepullerscrew.
CAUTION
DO NOT EXCEED THE MAXIMUM PRESSURE VIBROSCRIBED ON THE PULLER BODY. Excessive
pressurecandamagethestudandpullerscrew
Note:Beforethreadingthepullerscrewintothestud,carefullycheckthecleanlinessofboththe
stud'sandthepullerscrew'sconicalthreads.Besuretoremovealldirtfromtherootofthestuds’
conicalthreads.Applyalightcoatofcleanturbineoiloraspraylubricanttothepullerscrew.Do
notuse“NeverSeize”ontheconicalthreads.Thisprocedurewill ease assembly and assure
positivematingofthethreadsbeforetightening.
2.0 Scope
ThisdocumentdescribestheproceduretobeusedtoinstallstudsandnutssuppliedbyRiverhawk
Company in the flanges at the turbine/coupling and coupling/generatorconnections.This
hardwareisdepictedonthefollowingdrawings.ThesedrawingsaswellasToolingdrawingsform
apartofthismanual.
HardwareSets:
HF‐5376 HF‐5458 HF‐5459
HydraulicTensioners:
HT‐0445 HT‐5407
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3.0QuickChecklist
The following checklist is intended as a summary of the steps needed to use the Riverhawk‐
suppliedequipment. Newpersonnelor thoseexperiencedpersonnelwhohavenot usedthe
Riverhawkequipmentrecentlyareencouragedtoreadtheentiremanual.
EQUIPMENTINSPECTION
□ Checkoillevelinhydraulicpump.
□ Checkairpressureat80psi[5.5bar]minimum.(Forair‐drivenpumps)
□ Checkhydraulichosefordamage.
□ Testpump.
□ Inspecttensionerforanydamage.
NUTANDSTUDPREPARATION
□ Inspectstudandnutsforanydamage.
□ Measurestudlength.
□ Cleanthestudsandnuts.
□ Installstudsandnuts(off‐center)intotheflange.
□ Setstick‐outdimensiononthecouplingsideoftheflange.
□ Handtightenallstuds.
□ Verifystick‐outmeasurement(VERYIMPORTANT)
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Tensioning(Boltinstallation)
□ Matchthetensionersetuptotheflangejoint.
□ Applyalightcoatofcleanturbineoilorspraylubricanttothepullerscrew.DONOTUSE
“NEVERSEIZE”ONTHECONICALTHREADS.
□ Slidespannerringoverthepullerscrew.
□ Mountthetensioneronthestudinflange.
□ Installspannerringontonut.
□ Insert1/2”hexAllenwrenchintothebacksideofthestud.
□ Tightenthepullerscrew.
□ Backoffpullerscrew1/2turn.
□ Retightenthepullerscrewandleavetight.DONOTBACKOFFPULLERSCREW.
□ Bleedthetensioner.DoNOTbleedtensioneroffofastud!Damagetothetoolwill
result!
□ Tensionto50%.Consultmanualforcorrectpressure.
□ Usethepinwrenchinspannerringtotightennut.
□ Releasepressure,movetonextstudinpattern.
□ Repeatabovestepsatfinalpressure.
□ Measurefinalstudlengthandrecordonstretchdatasheets.Calculatestretch.
□ Torquenuts'setscrews.
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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.
□ Loosennutwiththespannerringandpinwrench.
□ Movetonextstudinpattern
4.0GeneralPreparations
Readandunderstandallinstructionsbeforeinstallingandtensioningstuds.
Thisequipmentproducesveryhighhydraulicpressuresandveryhighforces.Operatorsmust
exercisecaution,wearsafetyglassesandhardhatswhenusingthisequipment.
HighpressurefluidfromtheHydraulicPressureKitsystempressurizesthetensionerwhich
generatesastretchingforcethatactuallystretchesthestud.Asthestudisstretchedthenut
liftsofftheflange.Thenutisthenreseatedintopositionontheflangebyturninganutdriver
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byhand.Whenthenutistightagainsttheflange,thepressureinthetensionerisreleased
leavingthestudloadedtoitspredeterminedvalue.
4.1MachinePreparation
Theflangetobetensionedmustbefullyclosedpriortopositioningthestudsintheflanges.
Also,itwillbeadvantageoustoremoveasmanyobstructionsaspossiblefromtheflangearea,
suchasspeedprobesandconduit.
4.2Hardware–Balance
Hardwareissuppliedasweightbalancedsets
Studsandnutsareinterchangeablewithinsets
Donotintermixwithothersets
Saveweightcertificationsuppliedwitheachsetforthepurchaseofspareparts
4.3Tensioner–CareandHandling
Whennotinuse,thetensionershallbemaintainedinacleanenvironmentandallcapsand
plugsforhydraulicopeningsandfittingsmustbeinplace.
Wheninuse,thetensionershallbeprotectedfromsandandgrit.
Longtermstorage–coattensionerwithoil,returntooriginalcontainer,sealcontainerand
protectfrommoisture.DONOTSTOREOUTSIDE
Shipment–coattensionerwithoilandshipinoriginalcontainer.
4.4 HandTools
Severalhandwrenchesandmicrometerswillberequiredtoperforminstallationand
measurementofthestuds:
5/8”wrench
1"wrench
1”SocketandImpactWrench
AsetofAllenWrenches
3’–4’BreakerBar
12”to13”micrometerorcaliper
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4.5SpecialTools
HydraulicTensionerKit: HT‐0445HydraulicTensioner
GASTURBINESIDEONLY
(referenceGE359B2507)
HT‐5407HydraulicTensioner
GENERATORSIDEONLY
(referenceGE269B8709)
HydraulicPumpKit: AP‐0532Air‐OperatedHydraulicPump
(recommended)
(referenceGE359B2502)
MP‐0130ManualHand‐Operated
HydraulicPump
(referenceGE359B2506)
5.0HardwareSetPreparations
5.1NutPreparation
Fornewinstallations,thenutsshouldcomesealedfromthefactoryandwillneednocleaning.
Previouslyinstallednutsrequirecleaning:Wirebrushusingapetroleum‐basedsolventto
removeanyforeignmaterialontheexternalsurfacesandthreads.
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
Studmeasurementwillrequireamicrometerorcaliper,whichwillmeasure12”to13”(304.8
mmto330.2mm).
Measureandrecordtheinitiallengthofthestuds.Thefollowingsuggestionswillimproveyour
results:
Plantostartandfinishanyflangeinthesameday.
Studsandflangemustbeatthesametemperature.
Numbereachstudwithamarker.
Markthelocationofmeasurementonstudendwithapermanentmarker.
Measureeachstudtonearest0.001”(.02mm).
Recordeachmeasurementonthesuppliedcharts.
Donotallowthemicrometertosetinthesun.
6.0 Stud and Nut Assembly
RefertoHardwareAssemblyDrawing(HF‐)listedinSection2.0ofthismanual.
1. Beforethreadingthenutontothestudchecktobecertainthatthesetscrewsarefree
toturn.
2. Assemblefront‐sidenuttothetaperedthreadend(PullEnd)ofthestud.Pleasenote
thatthefrontandbacksidenutsaredifferent.
3. Slidethestudandnutassemblyintotheflangefromthecouplingsideasshownin
Figures1and2.
4. Installthenutontheback‐sideoftheflange.Pleasenotethatthefrontandbackside
nutsaredifferent.
5. Adjustthenut/studassemblysothatthestudprotrudesfromthefaceofthe
cylindricalnutbytheamountdepictedonthehardwaredrawing(fromsection2)and
showninFigures1and2.SETTINGTHISPROTRUSION(orstick‐out)OFSTUDTONUT
ISCRITICALFORPROPERTENSIONEROPERATION.Ametalstick‐outgageisprovided
withthetensionertoassisttheoperatorinsettingtheprotrusiondimension(See
Figure3forthisandothermethods).
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