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INSTRUCTION MANUAL IM‐139 For Gas Turbine Tensioned Studs and Nuts Fr.9H Turbine GE372A1793P002 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 GE DRAWING NUMBER DATE CHECKED: 373A4004 ISSUED: ...
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13 10.0 Thread Locking 15 11.0 Stud/Nut Removal 15 12.0 Frequently Asked Questions 15 13.0 Revision History 17 Appendix A1 EC Declaration of Conformity 18 Appendix A2 UKCA Declaration of Conformity 19 Appendix B 22‐Bolt Tensioning Pattern Record Sheet 23 CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4004 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 2 of 23 ...
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Instruction Manual IM‐139 1.0 Cautions and Safety Warnings WARNING Improper use and the failure to follow the correct procedures are the primary root causes of tool failures and personal injuries. A lack of training or experience can lead to incorrect hardware installation or incorrect tool use. Only trained persons with careful, deliberate actions should use hydraulic tensioners. Contact Riverhawk 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 tensioner 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. CAUTION ...
Instruction Manual IM‐139 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 the studs and nuts supplied by Riverhawk Company in the flanges at the turbine/coupling connection. This hardware is depicted on the following drawing. This drawing as well as Tooling drawing form part of this manual. HF‐1730 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. □ Test pump. □ Inspect tensioner for any damage. NUT AND STUD PREPARATION □ Inspect stud and nuts for any damage. ...
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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 and install spanner ring onto nut. □ Insert 1/2” hex Allen wrench into the back side of the stud. □ Tighten the puller screw. Then back off puller screw 1/2 a turn. □ Retighten the puller screw and leave tight. DO NOT BACK OFF PULLER SCREW. □ Tighten puller nut and then back nut off two flats or 120 degrees to allow for stud stretch. Bleed the tensioner. Do NOT bleed tensioner off of a stud! Damage to the tool will □ result! □ Tension to 50%. Consult manual for correct pressure. □ Use the pin wrench in spanner ring to tighten nut. CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4004 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 5 of 23 ...
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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. Then back off puller screw 1/2 a turn. □ Retighten the puller screw and leave tight. DO NOT BACK OFF PULLER SCREW. □ Tighten puller nut and then back nut off two flats or 120 degrees to allow for stud stretch. Bleed the tensioner. Do NOT bleed tensioner off of a stud! Damage to the tool will □ result! □ Apply final pressure. □ Loosen nut with the spanner ring and pin wrench. CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4004 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 6 of 23 ...
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Studs and Nuts are interchangeable within sets Do not mix with other sets Save weight certification data supplied with each set for purchase of spare parts. 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. Shipment – coat tensioner with oil and ship in original container CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4004 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 7 of 23 ...
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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. 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. 5.2 Stud Preparation For new installations, the studs should come sealed from the factory and will need no cleaning. CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4004 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 8 of 23 ...
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4. 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. 5. Blow out the threads with compressed air to remove loosened debris. 6. Visually inspect threads for cleanliness. Threads should be bright and shiny. 7. Repeat if any dirt can be seen in the threads. 8. Inspect threads for any damage that may have been caused by previous installation. 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 373A4004 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 9 of 23 ...
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3. Adjust the nut/stud assembly so that the stud protrudes from the face of the cylindrical nut the amount depicted on the hardware drawing (HF‐1730) 0.180/0.200 inches. SETTING THIS PROTRUSION OF STUD TO NUT IS CRITICAL FOR PROPER TENSIONER OPERATION. 4. Hand‐tighten the assembly to a snug fit. 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. Clean puller screw and check for any debris and dents. Puller screw should be free to rotate and move back and forth. Inspect tensioner guard for any signs of damage. Bent guards should be replaced. CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4004 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 10 of 23 ...
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TO AVOID FAILURE, ENSURE SAFETY AND PROPER OPERATION THE TENSIONER ASSEMBLY MUST BE MOUNTED ON THE STUD BEFORE BLEEDING THE SYSTEM AND TENSIONING BEGINS. 1. Mount tensioner on a stud per the assembly instructions of Section 8.0. 2. Make sure the pump is situated below the tensioner assembly. 3. The tensioner assembly has two ports, one for pressurizing and one for bleeding the system. These ports service a common chamber and therefore may be treated interchangeability. The bleed port must always be oriented in the uppermost position. 4. The puller tool is shipped with a 5/8 in. [16 mm] hex coned stem bleeder fitting installed. With this fitting loosened stroke the pump repeatedly until the stream of oil exiting the tool is free of air then retighten the fitting. 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. CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4004 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 11 of 23 ...
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5. Insert the puller screw through the puller tool into the tapered thread of the stud and hand tighten (Ensure that the Puller Nut does not bottom on the Piston when installing the Puller Screw, If it does then the Puller Screw may not be FULLY SEATED) 6. Be sure not to cross‐thread the assembly 7. Tighten the puller screw using Allen wrenches on the puller screw and the stud. 8. Install the puller nut (shown in Figure 3) until it seats snugly on the piston and compresses the piston to it’s original position (This will compress the piston in the tensioner and prevent over stroking and seal damage) and then back‐off 2 flats. This is particularly important for removal because the stud shortens during disassembly and the tensioner may then bind. 9. At this point the Tensioner Assembly MUST BE FREE TO ROTATE. In other words, the puller screw is tight in the stud and the puller nut has been backed‐off the 2 flats. Note: If the tool is not free to rotate it is most likely that the nuts must be repositioned so that the stud may be shifted slightly to the puller tool side of the flange. This can be accomplished as follows: CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4004 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 12 of 23 ...
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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. 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 2.562" 7000 psi Do not measure Turbine to Coupling [65.07 mm] [480 bar] Do not use CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4004 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 13 of 23 ...
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CAUTION DO NOT EXCEED THE MAXIMUM PRESSURE VIBROSCRIBED ON THE PULLER BODY. Excessive pressure can damge the stud and puller screw. Flange Position Stud Size Final Pressure Final Stretch 2.562" 13500 psi 0.026" ‐ 0.029" Turbine to Coupling [65.07 mm] [930 bar] [0.66 mm ‐ 0.77 mm] For the procedures of either Sections 9.1 or 9.3 excessive stretch variations or low stretch values can be corrected by retensioning all or selected studs to the pressure values stated in the above table. Have final stretch values approved by the supervisor responsible for the installation CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4004 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 14 of 23 ...
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11.0 Stud/Nut Removal For those assemblies that have been locked using mechanical lock nuts, 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 nut see Figure 4. 3. Install the appropriate puller tool to the stud as described in Section 8.0. 4. Apply the appropriate hydraulic pressure per the table of Section 9.3 and using the spanner ring and spanner wrenches shown in Figure 3 loosen the nut, then release the pressure and remove the puller tool 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? CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4004 New Hartford, NY 13413 Tel: +1 315 768 4855 ...
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Instruction Manual IM‐139 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. Q: Is there an easier way to support or move the tensioner around the coupling shaft? A: Use two straps. One around the coupling shaft and the other attach to any overhead support. Straps must be slack during mounting tensioner to stud and during tensioning. ...
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Instruction Manual IM‐139 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, 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‐ grip pliers. Be careful to not strip the threads off the tube or hose end. 13.0 Revision History Revision Effective Date Description Letter E May 18, 2022 Updated EC Declaration of Conformity; Added UKCA ...
Instruction Manual IM‐139 ‐ Dec 17, 2001 Released 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 ...
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Instruction Manual IM‐139 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 373A4004 New Hartford, NY 13413 Tel: +1 315 768 4855 ...
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Instruction Manual IM‐139 CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4004 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 20 of 23 ...
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Instruction Manual IM‐139 CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4004 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 21 of 23 ...
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Instruction Manual IM‐139 HT-1746 on GT to Coupling Flange CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4004 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision E Email: info@riverhawk.com Page 22 of 23 ...
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20 10 21 11 22 CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4004 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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