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Fr.7H Turbine to Load Coupling GE372A1793P003, P004
MLI:
CHECKED:
ISSUED:
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INSTRUCTION MANUAL IM‐186
For Gas Turbine Tensioned Studs and Nuts
CUSTOMER'S INFORMATION BOX
CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL
GE Power & Water
VENDOR SUPPLIED
GE NOT TO REVISE. GE REVISION LEVEL IS SHOWN ON THIS APPLIQUE.
THIS DOCUMENT IS FILED UNDER THE GE DRAWING NUMBER.
THIS DOCUMENT SHALL BE REVISED IN ITS ENTIRETY. ALL SHEETS OF THIS DOCUMENT ARE
THE SAME REVISION LEVEL AS INDICATED IN THIS VENDOR SUPPLIED DRAWING APPLIQUE.
GE SIGNATURES
DATE
215 Clinton Road
New Hartford, NY 13413
Tel: +1 315 768 4855
Fax: +1 315 768 4941
Email: info@riverhawk.com
GENERAL ELECTRIC COMPANY
____ OF ____
GE DRAWING NUMBER
373A4016
REV
Revision E
Page 1 of 23
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Summary of Contents for riverhawk IM-186
- Page 1 INSTRUCTION MANUAL IM‐186 For Gas Turbine Tensioned Studs and Nuts Fr.7H Turbine to Load Coupling GE372A1793P003, P004 CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE Power & Water GENERAL ELECTRIC COMPANY VENDOR SUPPLIED GE NOT TO REVISE. GE REVISION LEVEL IS SHOWN ON THIS APPLIQUE. THIS DOCUMENT IS FILED UNDER THE GE DRAWING NUMBER. THIS DOCUMENT SHALL BE REVISED IN ITS ENTIRETY. ALL SHEETS OF THIS DOCUMENT ARE THE SAME REVISION LEVEL AS INDICATED IN THIS VENDOR SUPPLIED DRAWING APPLIQUE. MLI: ____ OF ____ GE SIGNATURES DATE GE DRAWING NUMBER CHECKED: 373A4016 ISSUED: ...
- Page 2 11.0 Stud/Nut Removal 15 12.0 Frequently Asked Questions 16 13.0 Revision History 18 Appendix A1 EC Declaration of Conformity 19 Appendix A2 UKCA Declaration of Conformity 20 Figures and Illustrations 21 20‐Bolt Tensioning Pattern Record Sheet 23 CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4016 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 2 of 23 ...
- Page 3 Instruction Manual IM‐186 1.0 Cautions and Safety Warnings WARNING Improper tool use and the failure to follow the correct procedures are the primary root causes of tools failures and personal injuries. A lack of training or experience can lead to incorrect hardware installation or incorrect tool use. Only trained operators with careful, deliberate actions should use hydraulic tensioners. Contact Riverhawk Company with any training needs. WARNING Risk of high pressure hydraulic fluid injection. Riverhawk tools operate under high pressure. Thoroughly inspect all hoses and connections for damage or leaks prior to using this equipment. CAUTION Personal injury and equipment damage can occur if the puller screw is not securely engaged with the tapered thread of the stud. Proper engagement is achieved when the puller screw is tight in the stud and the Tensioner Assembly is free to rotate. WARNING The proper personal protective equipment must be worn at all times. Riverhawk recommends at a minimum, safety glasses, long sleeve shirt, hard hat, heavy work gloves, and steel toe shoes. WARNING The safety cage MUST be in place and hands kept out of designated areas at all times when the puller tool is pressurized otherwise personal injury can occur. CAUTION DO NOT EXCEED THE MAXIMUM PRESSURE VIBROSCRIBED ON THE PULLER BODY. Excessive pressure can damage the stud and the puller screw. WARNING Fire Hazard; DO NOT heat when the puller assembly is in place. Personal injury or equipment damage may occur. Use of an Oxy‐Acetylene torch is not recommended. NOTICE Do not use more thread locking compound than specified or the nut may be VERY difficult to remove at disassembly. CUSTOMER'S INFORMATION BOX ...
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Page 4: Equipment Inspection
Instruction Manual IM‐186 CAUTION DO NOT EXCEED THE MAXIMUM PRESSURE VIBROSCRIBED ON THE PULLER BODY. Excessive pressure can damage the stud and puller screw Note: Do not over extend the stud. Over extension can cause the piston to loose its seal and leak oil. Note: Before threading the puller screw into the stud, carefully check the cleanliness of both the stud's and the puller screw's conical threads. Apply a light coat of clean turbine oil or a spray lubricant to the puller screw. Do not use “Never Seize” on the conical threads. This procedure will ease assembly and assure positive mating of the threads before tightening. 2.0 Scope This document describes the procedure to be used to install studs and nuts supplied by Riverhawk Company in the flanges at the turbine/coupling and coupling/generator connections. This hardware is depicted on the following drawings these drawings as well as the tooling drawings form a part of this manual. HF‐1554 3.0 Quick Checklist The following checklist is intended as a summary of the steps needed to use the Riverhawk‐ supplied equipment. New personnel or those experienced personnel who have not used the Riverhawk equipment recently are encouraged to read the entire manual. EQUIPMENT INSPECTION □ Check oil level in hydraulic pump. □ Check air pressure at 80 psi [5.5 bar] minimum. (For air‐driven pumps) □ Check hydraulic hose for damage. ... - Page 5 Hand tighten all studs. □ Verify stick‐out measurement (VERY IMPORTANT) Tensioning (Bolt installation) □ Match the tensioner setup to the flange joint. Apply a light coat of clean turbine oil or spray lubricant to the puller screw. DO NOT USE □ “NEVER SEIZE” ON THE CONICAL THREADS. □ Slide spanner ring over the puller screw. □ Mount the tensioner on the stud in flange. □ Install spanner ring onto nut. □ Insert 1/2” hex Allen wrench into the back side of the stud. □ Tighten the puller screw. □ Back off puller screw 1/2 turn. CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4016 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 5 of 23 ...
- Page 6 □ Torque nuts' set screws. Detensioning (Stud removal) □ Loosen nuts' set screws Inspect and clean studs' conical threads. Do not continue until ALL debris is removed □ from the threads! Do not try to use the tensioner to remove a damaged stud! Apply a light coat of clean turbine oil or spray lubricant to the puller screw. DO NOT USE □ “NEVER SEIZE” ON THE CONICAL THREADS. □ Slide spanner ring over the puller screw. □ Mount the tensioner on the stud. □ Install spanner ring into nut. □ Tighten the puller screw. □ Back off puller screw 1/2 a turn. CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4016 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 6 of 23 ...
- Page 7 Hardware is supplied as weight balanced sets Studs and Nuts are interchangeable within sets Do not intermix sets Save weight certification supplied with each set for the purchase of spares 4.3 Tensioner – Care and Handling When not in use, the tensioner shall be maintained in a clean environment and all caps and plugs for hydraulic openings and fittings must be in place. Use ISO 32 grade oil. When in use, the tensioner shall be protected from sand and grit. Long term storage – coat tensioner with oil, return to original container, seal container and protect from moisture. CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4016 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 7 of 23 ...
- Page 8 Hydraulic Pump Kit: AP‐0532 Air‐operated Hydraulic Pump (recommended) (reference GE 359B2502) 5.0 Preparation of Hardware 5.1 Nut Preparation For new installations, the nuts should come sealed from the factory and will need no cleaning. Previously installed nuts require cleaning: as follows: Wire brush using a petroleum based solvent to remove any foreign material on the external surfaces and threads. If previous installations employed a thread‐locking compound, which will be visible as a grayish‐ green residue, remove as much of this compound as possible. Do not apply thread lubricants to the threads. Finish the cleaning process by rinsing in a volatile solvent such as acetone and allow to dry. CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4016 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 8 of 23 ...
- Page 9 Use Stud Cleaning Kit, GT‐4253 or a similar 1" diameter Brass power brush. Picture of Brass Power Brush Insert the brush into an electric drill and set drill to run in a counterclockwise direction at high speed. Work the drill in a circular motion while moving the brush in and out to clean all of the threads. Try not to hold the brush in one place too long, so as not to remove the stud's protective coating. Blow out the threads with compressed air to remove loosened debris. Visually inspect threads for cleanliness. Threads should be bright and shiny. Repeat if any dirt can be seen in the threads. Inspect threads for any damage that may have been caused by previous installation. Do not apply thread lubricants to the threads. CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4016 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 9 of 23 ...
- Page 10 1. Assemble cylindrical nut to the tapered thread end (Pull End) of the stud. 2. Slide the assembly into the flange from the coupling side as shown in Figures 1 & 2 then install the other Cylindrical nut on the backside (the cylindrical nuts are identical). 3. Adjust the stud/nut assembly so that the stud protrudes from the face of the cylindrical nut the amount depicted on the hardware drawing (HF‐1554) TYPICALLY 0.250” TURBINE END. SETTING THIS PROTRUSION OF STUD TO NUT IS CRITICAL FOR PROPER TENSIONER OPERATION. Hand tighten the assembly to a snug fit. See Photos 1 & 2 for a view of the assembly of studs and nuts in the flange prior to tensioning. 7.0 Assembly of Hydraulic Tensioner Equipment 7.1 Kit Assembly Assemble the hydraulic pump with its hose to the puller tool and bleed the system of air per following instructions in paragraph 6.3 (MUST BE ON A STUD). Photo 3 shows hose connected to manifold of tensioner. 7.1.1 Fittings CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4016 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 10 of 23 ...
- Page 11 TO AVOID FAILURE, ENSURE SAFETY AND PROPER OPERATION THE TENSIONER ASSEMBLY MUST BE MOUNTED ON THE STUD BEFORE BLEEDING THE SYSTEM AND TENSIONING BEGINS. The tensioner has four ports see Fig. 3, one for pressurizing, two for bleeding the system and a fourth pressure relief port. To facilitate bleeding, start by first mounting the tensioner at the 9 o’clock stud position, which will critically place the bleed ports in their uppermost position. In addition, make sure that the pump is always situated below the tensioner assembly. The puller tool is equipped with 5/8” [16 mm] hex coned stem bleeder fittings installed in the bleeder ports. With these two fittings loosened simultaneously, stroke the pump repeatedly until the streams of oil exiting the tool from each port are free of air, then retighten the fittings. Note: The hose is stiff; use of this tooling can be simplified by temporarily mounting the puller tool on one stud prior to final tightening of fittings. This will reduce the tendency for the fittings to loosen during use. 8.0 Assembly of Tensioner on Stud 8.1 Handling of the Tensioner Note: Before threading the puller screw into the stud, carefully check the cleanliness of both the stud's and the puller screw's conical threads. Apply a light coat of clean turbine oil or a CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4016 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 11 of 23 ...
- Page 12 2. Apply a light coat of clean turbine oil or a spray lubricant to the puller screw. Do not use “Never Seize” on the conical threads. 3. Place and hold the tensioner assembly over the end of the stud to be tightened. See photos 3 &4. 4. Hold the stud steady with a 1/2” hex key wrench and lightly tighten the puller screw into the conical thread of the stud with a wrench. 5. Slide the puller screw in to the tapered thread of the stud and hand tighten. Be sure not to cross thread assembly. 6. Place the spanner ring pins into the cylindrical nut located on the stud. 7. At this point the Tensioner Assembly MUST BE FREE TO ROTATE, the puller screw must be tight in the stud. If the puller tool is not free to rotate when the puller screw is tight then, either (1) the stud is not properly positioned in the flange and the nuts must be repositioned so that the stud is shifted slightly more on the puller tool side, or (2) The tensioner is damaged and must be returned for repair. CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4016 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 12 of 23 ...
- Page 13 9.1 Tensioning at 50% pressure After the tensioner is properly installed apply hydraulic pressure to the tool. Bring the pressure to the 50% level in accordance with the following table. Flange Position Stud Size 50% Pressure 50% Stretch 2.246" 9000 psi Do not measure Turbine to Coupling [57.05 mm] [620 bar] Do not use Turn the cylindrical nut using the appropriate spanner ring and pin wrench as depicted in Figure 3 until it bottoms on the flange. CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4016 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 13 of 23 ...
- Page 14 [57.05 mm] [1170 bar] [0.86 mm ‐ 0.91 mm] Note: Before threading the puller screw into the stud, carefully check the cleanliness of both the stud's and the puller screw's conical threads. Apply a light coat of clean turbine oil or a spray lubricant to the puller screw. Do not use “Never Seize” on the conical threads. This procedure will ease assembly and assure positive mating of the threads before tightening. CAUTION DO NOT EXCEED THE MAXIMUM PRESSURE VIBROSCRIBED ON THE PULLER BODY. Excessive pressure can damage the stud and puller screw. Excessive stretch variation or low stretch values can be corrected by retensioning all or selected studs to the pressure values stated above. Have final stretch values approved by the supervisor responsible for the installation. 10.0 Thread Locking Once pulling and tensioning is completed all stud nuts must be locked in position. CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4016 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 14 of 23 ...
- Page 15 For those assemblies which have been locked using mechanical locknuts, removal is accomplished as follows: 1. Using a wire brush and shop air clean the internal tapered thread of the stud to remove any debris/deposits which may have accumulated during service. (see section 5.2.1) 2. With an Allen‐wrench loosen the two locking set screws but do not remove from the nut see Figure 6. 3. Install the puller tool to the stud as described in Section 6.0. Apply the appropriate hydraulic pressure per the Table below and using the spanner ring and spanner/pin wrenches shown in Figure 7 loosen the nut, then release the pressure and remove the puller tool. Flange Stud Size Pressure Turbine/Coupling 2.246 in. 17,000 psi [57.05 mm] [1170 bar] CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4016 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 15 of 23 ...
- Page 16 Instruction Manual IM‐186 12.0 Frequently Asked Questions This section contains some frequently asked questions and problems. If the steps listed here do not solve your problem, contact the Riverhawk Company thru our website, email, or phone call. Q: A tensioner has pulled itself out of the stud's conical threads. Can I continue using a tensioner on this stud? A: No. Both the tensioner and the stud may have been damaged. If the stud is tensioned, a Nut Buster repair kit, from Riverhawk, must be used to remove the damaged stud by drilling out the nut. Riverhawk can supply a replacement stud and nut based on the initial weight certification supplied with the hardware set (see section 4.2). The damaged tensioner should also be returned to Riverhawk for inspection and repair. Q: The hydraulic tensioner has been taken up to its final pressure. The final stretch length is short of the final stretch target. What is the next step? A: Do not increase the hydraulic pressure. Check if the hydraulic pump is set to the right pressure. Install the tensioner and re‐pressurize the tensioner to the final p ressure then recheck the stretch measurement. If the stretch value is still short, remove the stud from the hole and re‐measure the stud's initial length then try to install the stud again. Q: The hydraulic tensioner has been taken up to its final pressure. The final stretch length is larger than the final stretch target. What is the next step? A: Remove the stud from the bolt hole. Check if the hydraulic p ump is set to the right pressure. Re‐measure the stud's initial length then try to install the stud again. ...
- Page 17 If the nuts cannot be loosened at the final pressure, continually increasing the pressure will not help and can be dangerous and in some cases make it harder to remove the nut. Check the nut to see if its set screws have been loosened. Check for and remove any corrosion around the nut's threads. Q: How do I clean the conical threads on a stud? A: The conical threads are best cleaned using a spiral wound brass brush in a drill as described in section 5.2.1 Q: During the initial steps of removing a tensioned stud, the stick‐out length is found to be wrong. A: Do not proceed. Contact Riverhawk for assistance. With the wrong stick‐out length, the hydraulic tensioner has a limited stroke and may not work properly and can be damaged. Q: The hydraulic pump appears to be leaking. A: Check the hose connection to the hydraulic pump. If the 1/4" high pressure fitting is not assembled correctly it may look like the pump is leaking. If the problem continues, it may be necessary to open the pump kit. Contact Riverhawk for guidance. Q: The hydraulic hose has a collar on it that can't be moved by hand A: The collar is sometimes held in place with a thread locking compound. This prevents the collar from moving too easily. It may be necessary to adjust this collar with a set of vise‐...
- Page 18 Updated EC Declaration of Conformity; Added UKCA Declaration of Conformity D Jan 15, 2015 Updated section 1.0, 4.3, and 15.0 C Jun 13, 2014 Added EC Declaration of Conformity B Jun 10, 2009 Added turbine oil and removed “Never Seize” from sections 1.0, 3.0, 8.1, and 9.3 A Mar 25, 2009 Added sections 3 and 13 ‐ Mar 16, 2006 Released CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4016 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 18 of 23 ...
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Page 19: Ec Declaration Of Conformity
Instruction Manual IM‐186 Appendix A1 EC Declaration of Conformity Manufacturer: Riverhawk Company Address: 215 Clinton Road New Hartford, NY 13413, USA The hydraulic pump and bolt tensioning tool described in this manual are used for installing and applying tension to large bolts that are specifically designed by Riverhawk Company to be tensioned hydraulically. All applicable sections of European Directive 2006/42/EC for machinery have been applied and fulfilled in the design and manufacture of the hydraulic pump and bolt tensioning tool described in this manual. Reference also ISO 12100:2010, ISO 4413:2010, and ISO 4414:2010. Furthermore, this equipment has been manufactured under the Riverhawk quality system per EN ISO 9001:2015 Consult the Declaration of Conformance included with the shipment of this equipment that identifies the authorized Riverhawk representative, applicable serial numbers, and appropriate signature. CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4016 New Hartford, NY 13413 Tel: +1 315 768 4855 ... - Page 20 Instruction Manual IM‐186 Appendix A2 UKCA Declaration of Conformity Manufacturer: Riverhawk Company Address: 215 Clinton Road New Hartford, NY 13413, USA The hydraulic pump and bolt tensioning tool described in this manual are used for installing and applying tension to large bolts that are specifically designed by Riverhawk Company to be tensioned hydraulically. All applicable sections of Supply of Machinery (Safety) 2008 have been applied and fulfilled in the design and manufacture of the hydraulic pump and bolt tensioning tool described in this manual. Reference also ISO 12100:2010, ISO 4413:2010, and ISO 4414:2010. Furthermore, this equipment has been manufactured under the Riverhawk quality system per EN ISO 9001:2015 Consult the Declaration of Conformance included with the shipment of this equipment that identifies the authorized Riverhawk representative, applicable serial numbers, and appropriate signature. CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4016 New Hartford, NY 13413 Tel: +1 315 768 4855 ...
- Page 21 Instruction Manual IM‐186 CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4016 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 21 of 23 ...
- Page 22 Instruction Manual IM‐186 PULLER SCREW INTEGRAL SAFETY GAGE BLEED PORTS 5/8” HEX PRESSURE RELIEF PORT ADAPTER FOOT SPANNER RING CYLINDRICAL NUT CYLINDRICAL NUT CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4016 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 22 of 23 ...
- Page 23 Instruction Manual IM‐186 CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4016 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 23 of 23 ...
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