IM 377 9FA HSIG Tensioner

INSTRUCTION MANUAL IM-377
For Gas Turbine

Tensioned Studs and Nuts
Applicable Bolting Connections
Fr. 9FA Gas Turbine to Load Coupling
Load Coupling to 324 Generator
Applicable GE Ordering Sheet Part Numbers

101T6386P001
106T9921P001
106T9921P002
106T9921P003
106T9921P004
106T9921P005
106T9921P007
107T7526P0001
107T7526P0002
107T7526P0003
107T7526P0004
107T7526P0005
107T7526P0007
361A6162P002
361A6162P007
361A6162P008
361A6162P010
361A6162P011
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
REV
CHECKED:
ISSUED:
373A4085
The Riverhawk Company reserves the right to update this document without dissemination or notice.
The latest revision may be obtained by contacting Riverhawk Company or thru www.riverhawk.com.
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Email: [email protected]
Instruction Manual IM-377
Table of Contents
1.0 Cautions and Safety Warnings .................................................................................................. 3
2.0 Scope ......................................................................................................................................... 5
3.0 Quick Checklist .......................................................................................................................... 6
4.0 General Preparations ................................................................................................................ 9
5.0 Hardware Set Preparations ..................................................................................................... 11
6.0 Stud and Nut Assembly ........................................................................................................... 13
7.0 Hydraulic Tensioner Equipment Assembly ............................................................................. 15
8.0 Assembly of Tensioner on a Stud............................................................................................ 16
9.0 Stud Tensioning....................................................................................................................... 20
10.0 Thread Locking and Windage Plug Installation ..................................................................... 22
11.0 Stud and Nut Removal .......................................................................................................... 24
12.0 Storage Instructions .............................................................................................................. 25
13.0 Frequently Asked Questions ................................................................................................. 27
14.0 Revision History .................................................................................................................... 29
Appendix A1 - EC Declaration of Conformity ................................................................................ 30
Appendix B1 Puller Screw Release Tape Installation ................................................................. 31
Appendix B2 - Hydraulic Fittings ................................................................................................... 32
Appendix B3 - Hydraulic Tensioners Rupture Disc Replacement ................................................ 33
Appendix C1 - Record Sheet 18 Colt Circle ................................................................................... 34
Appendix C2 - Record Sheet 16 Colt Circle ................................................................................... 35

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1.0 Cautions and Safety Warnings
WARNING
Improper tool 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 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 proper health and safety codes and
procedures are not followed. Contact the sites health and safety office to determine all
applicable safety rules and regulations.
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.
CAUTION
It is especially important to check the condition of the conical thread used to tension the stud.
Thread damage from previous abuse can lead to failure of the stud or tensioning equipment
CAUTION
Riverhawk recommends that the tensioner should be returned to Riverhawk for periodic
inspections. Replacement of obsolete tensioners is recommended. Functional upgrades are also
recommended. The Riverhawk Service Returns Coordinator should be notified 3-6 months prior
to a planned outage to schedule an inspection service.
WARNING
A damaged burst disc must be replaced with a with a burst disc of the same design and
pressure rating. Do not substitute a damaged burst disc with a different disc type, a different
pressure rating, or a foreign object.

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WARNING
To avoid failure, ensure safety, and proper operation, the tensioner assembly must be installed
on a stud in the flange before bleeding and pressurizing the tensioner. Do not use the tensioner
at any pressure unless the tool is installed on a stud in a flange.
CAUTION
Do not over extend the tensioner. Over extension may cause the piston to lose its seal and leak
oil.
CAUTION
Personal injury and equipment damage can occur if the puller screw is not securely engaged
with the tapered threads of the stud. Proper engagement is achieved when the puller screw is
tight in the stud and the tensioner assembly is free to turn.
WARNING
The safety interlock guard must be in place at all times. When the tensioner is pressurized
hands must be kept out of designated areas to avoid any potential for personal injury.
CAUTION
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. This procedure will ease assembly and assure positive mating of
the threads before tightening. Do not use Never Seize on the conical threads.
CAUTION
Do not tighten the nut while the tool is coming up to pressure; wait until pressure is achieved
before attempting to tighten the nut with the spanner ring. If the tool is not properly installed,
the tool could jump off the stud while coming up to pressure.
CAUTION
Do not exceed the maximum pressure marked on the tensioner. Excessive pressure can damage
the stud and puller screw.
WARNING
FIRE HAZARD: DO NOT heat when puller assembly is in place. Personal injury or equipment
damage may occur. Use of an Oxy-Acetylene torch is not recommended

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2.0 Scope
This document describes the procedure to be used to install the stud and nut sets supplied by
the Riverhawk Company in the flanges at the Turbine/Coupling, and Coupling/Generator.
The various frame configurations covered in this manual are listed in Sections 2.1 through 2.5
with differences as related to connective hardware defined. Listed also are the pertinent
hardware drawings (HF-xxxx). These drawings as well as tooling drawings (HT-xxxx) form part of
this manual.
2.1 Frame 9FA Gas Turbine to 324 Generator
GE Part Number
101T6386P001
106T9921P001
106T9921P002
361A6162P008
361A6162P002
Riverhawk P/N
HF-3234
HF-3234
HF-3234
HF-3234
HF-3234
GE VENDOC P/N
GE 359B2580
GE 359B2580
GE 359B2580
GE 359B2580
GE 359B2580
The hydraulic tooling used for installation and removal is Riverhawk HT-6749.
These hardware drawings depict the complete stud and nut package for the Gas Turbine to
Load Coupling (3 size, Qty 18) as well as the Load Coupling to Generator (2-3/4 size, Qty 16).
The drawing also depicts the windage plugs (Qty 34) used to enclose the conical thread of each
stud.
2.2 Frame 9FA Gas Turbine to Load Coupling
GE Part Number
106T9921P004
106T9921P007
361A6162P010
361A6162P007
Riverhawk P/N
HF-3821
HF-3821
HF-3821
HF-3821
GE VENDOC P/N
GE 359B2594
GE 359B2594
GE 359B2594
GE 359B2594
These hardware drawings depict the complete stud and nut package for the Gas Turbine to
Load Coupling (3 size, Qty 18). The drawing also depicts the windage plugs (Qty 18) used to
enclose the conical thread of each stud.

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2.3 Load Coupling to 324 Generator

GE Part Number
106T9921P003
Riverhawk P/N
HF-3820
GE VENDOC P/N
GE 359B2595
These hardware drawings depict the complete stud and nut package for the Load Coupling to
Generator (2-3/4 size, Qty 16). The drawing also depicts the windage plugs (Qty 16) used to
enclose the conical thread of each stud.
2.4 Hydraulic Tooling
GE Part Number
106T9921P005
361A6162P011
Riverhawk P/N
HT-6749
AP-0532
HT-6749
AP-0532
GE VENDOC P/N
GE 101B0653
GE 359B2502
GE 101B0653
GE 359B2502
3.0 Quick Checklist

The following checklist is intended as a summary of the steps needed to use the Riverhawksupplied 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 80psi [5.5 bar] minimum. (For air-driven pumps)
Check hydraulic hose for damage.
Test the pump.
Inspect tensioner for any damage.

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NUT AND STUD PREPARATION
Inspect studs and nuts for any damage.
Clean the studs and nuts.
Measure stud lengths. (VERY IMPORTANT)
Lubricate the studs threads with clean turbine oil or spray lubricant. Lubricate the nuts
threads and nut face with clean turbine oil or spray lubricant.
Install studs and nuts into the flange.
Set stick-out dimension on the coupling side of the flange.
Hand tighten nuts on turbine / generator side of flange.
Verify stick-out measurement (VERY IMPORTANT)
TENSIONING (Bolt Installation)
Check tensioner drawing for correct parts and part numbers.
Apply a light coat of clean turbine oil or spray lubricant to the puller screw. DO NOT USE NEVER
SEIZE ON THE CONICAL THREADS.
Install the spanner ring onto the nut.
Install one puller screw release tape strip into stud. (Appendix B1)
Install the tensioner on the stud in flange.
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.

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Place the guard over the tensioner positioning the guide pin into the backside of the stud and
the tensioner handle into the locating slot in the guard.
Tighten the guards knurled clamping screw by hand until it presses firmly against tensioner the
puller screw.
Push interlock knob to insert interlock screw into port on the tensioner and tighten firmly.
Tension to 50%. Consult manual for correct pressure.
Use the pin wrench in spanner ring to tighten nut.
Release pressure, move to next stud in pattern.
Repeat above steps at final pressure.
Measure final stud length and record on stretch datasheets. Calculate stretch.
Torque the nuts' set screws.
Install the windage plugs (if included) and torque their set screws.
DETENSIONING (Stud Removal)
Loosen the windage plugs (if included) set screws and remove the windage plugs from
the studs
Loosen nuts' set screws
Inspect and clean studs' conical threads. Do not continue until ALL debris is removed
from the threads! See instruction manual IM-220. 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 onto nut.
Install the tensioner on the stud in flange.

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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.
Place the guard over the tensioner positioning the guide pin into the backside of the
stud and the tensioner handle into the locating slot in the guard.
Push interlock knob to insert interlock screw into port on the tensioner and tighten
firmly.
Apply final pressure.
Loosen nut with the spanner ring and pin wrench.
Move to next stud in pattern
4.0 General Preparations

Read and understand all instructions before installing and tensioning studs.
Operators should be trained or have previous experience using Riverhawk tensioning
equipment. Training will minimize the chance of improper use of the equipment.
The hydraulic tooling including the hydraulic hoses should be inspected prior to use. Inspection
guidelines are listed in the following sub-sections.
This equipment produces very high hydraulic pressures and very high forces. Operators must
exercise caution and wear the appropriate personal protective equipment when handling and
operating the hydraulic tooling.
High-pressure oil from the hydraulic pump pressurizes the tensioner which generates a very
large force that actually stretches the stud. As the stud is stretched the nut lifts off the flange.
The nut is then turned by hand using the supplied spanner ring. Once the nut is tight against the
flange, the pressure in the tensioner is released. The hardware is now clamping the flange
together.

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4.1 Machine Preparation

The flange to be tensioned must be fully closed prior to positioning of studs in the flanges.
Turning the turbine and generator shafts is not required, but may be useful. Also, it will be
advantageous to remove as many obstructions as possible from the flange area, such as speed
probes, shipping plates, and conduit.
4.2 Hardware Balance
Hardware is supplied as weight balanced sets. Studs and Nuts are interchangeable within sets.
Do not intermix sets.
Save the weight certification supplied with each set. It will be needed for the purchase of
replacement hardware.
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.
See section 12 for long term storage requirements.
4.4 Hand Tools
Several hand wrenches and micrometers will be required to perform installation and
measurement of the studs:
5/8 Wrench
1/2 Drive Ratchet
3 to 4 Breaker Bar
A set of Allen Wrenches
12 to 13 Micrometer

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4.5 Special Tools

Hydraulic Tensioner Kit:
HT-6749 Hydraulic Tensioner, 2-3/4, 3

(reference GE VENDOC 101B0653)
Hydraulic Pump Kit:
AP-0532 Air-Operated Hydraulic Pump

(recommended)
MP-0130 Manual Hand-Operated Hydraulic Pump
CAUTION
Riverhawk recommends that the tensioners be returned to Riverhawk for periodic
inspections. Replacement of obsolete tensioners is recommended. Functional upgrades are
also recommended. The Riverhawk Service Returns Coordinator should be notified 3-6
months prior to a planned outage to schedule an inspection service.
5.0 Hardware Set Preparations
5.1 Nut Preparation
(2) Locking
Set Screws
(2) Spanner
Ring Holes
Picture 5A - Riverhawk Locknut

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If there is any visible damage on a nut, do not use the nut and contact the Riverhawk Company
for a replacement nut. Please be prepared to supply the turbine number, weight certification,
and digital photographs for evaluation.
5.1.1 Nut Cleaning - New Installations
For new installations, the nuts should come sealed from the factory and will need no cleaning.
5.1.2 Nut Cleaning - Old Installations
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.
5.2 Stud Preparation
Check the stud for any visible damage. If there is any visible damage, do not use the stud and
contact the Riverhawk Company for a replacement stud. Please be prepared to supply the
turbine number, weight certification, and digital photographs for evaluation.
CAUTION
It is especially important to check the condition of the conical thread used to tension the
stud. Thread damage from previous abuse can lead to failure of the stud or tensioning
equipment.
The conical threads of each stud must be clean of grit and dirt before installation or removal.
This ensures the proper seating of the puller screw.
5.2.1 Stud Cleaning - New Installations
For new installations, the studs should come sealed from the factory and will need no cleaning.
5.2.2 Stud Cleaning - Old Installations
Previously installed studs may require cleaning using Riverhawk Stud Cleaning Kit #GT-4253
(GE VENDOCS 373A4026). Clean internal conical threads should have a bright and shiny
appearance.
Follow instruction manual IM-220 (GE VENDOCS 373A4025) for cleaning procedure of the
conical threads on Riverhawk studs using a brass power brush. The latest revision may be
obtained by contacting Riverhawk Company or thru www.riverhawk.com.

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Picture 5B - Brass Power Brush

5.3 Stud Length Measurement
Measure and record the initial lengths of the studs. The following suggestions will improve your
results.
Plan to start and finish any flange in the same day.
Studs and flange must be at the same temperature.
Number each stud with a marker for later stretch measurement tracking.
Mark the location of measurement on stud end with a permanent marker.
Measure each stud to nearest 0.001 inch (.01 mm).
Record each measurement on the supplied record sheets.
Do not allow the measuring instruments to sit in the sun.
The same person should make all measurements.
6.0 Stud and Nut Assembly
Refer to the hardware assembly drawing (HF-xxxx) listed in Section 2.0 of this manual.
1. Assemble the cylindrical nut to the internal, conical thread end of the stud.
2. Slide the stud and cylindrical nut assembly into the flange as shown in Figure 6A and 6B.
Nut
Hex Drive
Stud
Nut
Tensioning
Conical Thread
* Set Stud Stick-out
on this side only
Load Coupling
Gas Turbine
Flange
Figure 6A Cross-section View of Gas Turbine to

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Load Coupling Bolted Flange Connection
Tensioning
Conical Thread
Tall Nut
Stud
Short Nut
Hex Drive
* Set Stud Stick-out

on this side only
Load Coupling
Flange
Generator
Flange
Figure 6B Cross-section View of Load Coupling

to Generator Bolted Flange Connection
3. Install the other nut on the backside.
4. Adjust the nut/stud assembly so that the stud protrudes (or sticks out) from the face of
the cylindrical nut the distance specified on the hardware drawing (HF-xxxx). SETTING
THIS PROTRUSION OF STUD TO NUT IS CRITICAL FOR PROPER TENSIONER OPERATION.
A metal stick-out gage is provided with the tensioner to assist the operator in setting the
protrusion dimension
Picture 6C Use of Stick-Out Gage on Load Coupling to Generator Bolted Flange Connection

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5. Hand tighten the assembly to a snug fit.

6. Recheck the stud stick-out length. If the stick-out length does not match the hardware
drawing, adjust the nuts as necessary.
7.0 Hydraulic Tensioner Equipment Assembly
7.1 Hydraulic Equipment Inspection
7.1.1 Hydraulic Tensioner Inspection
CAUTION
Riverhawk recommends that the tensioner be returned to Riverhawk for periodic inspections.
Replacement of obsolete tensioners is recommended. Functional upgrades are also
recommended. The Riverhawk Service Returns Coordinator should be notified 3-6 months
prior to a planned outage to schedule an inspection service.
WARNING
To avoid failure, ensure safety, and proper operation, the tensioner assembly must be
installed on a stud in the flange before pressurizing the tensioner. Do not use the tensioner at
any pressure unless the tool is installed on a stud in a flange.
Check puller screw usage life with Riverhawk service bulletin SB-08001.
Clean puller screw and check for any debris and dents.
Puller screw should be free to rotate and move back and forth.
Seam between cylinders closed tightly.
Inspect the tensioner guard for any signs of damage including cracked welds. Any guards
modified in the field should be replaced. Bent guards should be replaced.
Inspect the outside of the tensioner for discoloration patterns that may indicate submersion
and internal damage.
Perform an inventory of the loose equipment supplied with the tensioner. An inventory list is
provided on the tensioners technical drawing (for example Riverhawk HT-xxxx). Replacement
parts are available from Riverhawk.

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7.1.2 Hydraulic Pump Kit Inspection

Refer to the Hydraulic Pump Kit Instruction Manual, IM-293 (GE VENDOC 373A4058). The latest
revision may be obtained by contacting Riverhawk Company or thru www.riverhawk.com.
8.0 Assembly of Tensioner on a Stud
8.1 Handling of the Tensioner
A strap can be placed around the cylinder lifting handle on the hydraulic connection side only to
help the operator support the tensioner during installation. The lifting strap must be loose
during tensioning.
8.2 Kit Assembly
Refer to the hardware assembly drawing (HF-xxxx) listed in Section 2.0 of this manual and the
tensioner assembly drawing (HT-xxxx) listed in Section 4.5 of this manual to determine which
side of the flange the tensioner must be located on in order to use the tensioner properly.
Pin Wrench
Generator
Flange
Safety
Guard
Tensioner
Cylinder
Hose
Connection
Clamping
Screw
Load
Coupling
Picture 8A Features of the Hydraulic Tensioner HT-6749

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Safety
Guard
Pin Wrench
Interlock
Screw
Generator
Flange
Clamping
Screw
Load
Coupling
Picture 8B Features of the Hydraulic Tensioner HT-6749
Interlock
Port
Tensioner
Cylinder
Puller
Screw
Safety
Guard
Clamping
Screw
Guide Pin
Load
Coupling
Generator
Flange
Picture 8C Cutaway view of Hydraulic Tensioner HT-6749

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.

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Assembly sequence is as follows:

1. Open the hydraulic return valve on the pump to allow hydraulic fluid to be pushed back
from the puller tool into the pump reservoir. (This is automatic on the air-operated
hydraulic pump)
2. Place the spanner ring on the nut aligning the pins in the spanner ring with the holes on
the nut.
3. 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.
4. Install one puller screw release tape strip into end of stud. (Appendix B1)
5. Place and hold the tensioner assembly over the end of the stud to be tightened.
6. Slide the puller screw in to the tapered thread of the stud and hand tighten. Be sure not
to cross thread assembly.
7. Hold the stud steady with a 1/2 hex key wrench and using 1/2 drive ratchet wrench on
end of puller screw. Tighten the puller screw into the conical thread of the stud with
the ratchet wrench.
8. Back off the puller screw 1/2 a turn.
9. Retighten the puller screw.
10. At this point the Tensioner Assembly MUST BE FREE TO ROTATE, the puller screw must
be tight in the stud. DO NOT BACK OFF PULLER SCREW.
11. Place guard assembly over top of cylinder and flange and position the guide pin into the
hole in the backside of the stud.
12. Tighten the knurled clamping screw until it firmly presses against the tensioner puller
screw with the screw pin inside of the 1/2 drive hole.
13. Align the interlock screw with the port on the cylinder. Tighten to firmly seat internal
interlock valve.

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Align with
interlock port
Push interlock
screw into port and
tighten by hand
Picture 8D Activation of Safety Interlock

14. Connect the hydraulic pump to the tensioner. The tensioner should be completely
assembled and ready for use.
If the tensioner is not free to rotate when the puller screw is tight then, either (1) the stud is
not properly positioned in the flange and recheck the stick-out length and reposition the nuts,
or (2) The tensioner is damaged and must be returned for repair.
CAUTION
Do not over extend the stud. Over extension can cause the piston to lose its seal and leak oil.
CAUTION
Personal injury and equipment damage can occur if the puller screw is not securely engaged
with the tapered threads of the stud. Proper engagement is achieved when the puller screw is
tight in the stud and the tensioner assembly is free to turn.
8.3 Bleeding Hydraulic System
Bleeding of the hydraulic system is not necessary with this tensioner design.

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9.0 Stud Tensioning

The studs will be tensioned in two steps, at 50% pressure and at final pressure. Follow the
tensioning sequence for each flange joint as defined on the record sheets found at the end of
this manual.
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.
WARNING
The safety guard must be in place at all times. Keep hands out of designated areas at all times
when the tensioner is pressurized otherwise personal injury can occur.
CAUTION
CAUTION
Do not exceed the maximum pressure marked on the tensioner. Excessive pressure can
damage the stud and puller screw.
CAUTION
before attempting to tighten the nut with the spanner ring. If the tool is not properly
installed, the tool could jump off the stud while coming up to pressure.
Flange Position
Stud Size
50% Pressure
50% Stretch
Turbine to Coupling
3"
[76 mm]
10000 psi
[690 bar]
Do not measure
Do not use
Coupling to Generator
2-3/4"
[71 mm]
10000 psi
[690 bar]
Do not measure
Do not use

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9.1.1 Tightening of 3 and 2-3/4 nuts

Turn the cylindrical nut using the spanner ring and pin wrench until it bottoms firmly on the
flange.
9.2 Removing the Tensioner from an Installed Stud
The tensioner removal is accomplished by the follows steps:
1. Release the hydraulic pressure by either releasing the hand switch on the AP-0532
Pump Kit or by opening the valve on the MP-0130 Manual Pump Kit and leave the valve
open.
2. Wait for the tensioner to fully retract and the tensioner is free to rotate.
3. Unscrew the hydraulic interlock knob until the screw is disconnected from the cylinder.
4. Unscrew the knurled clamping screw and remove the guard from the tensioner.
5. Unscrew the puller screw using a wrench and breaker bar. Do not use an impact wrench
as this can damage the tensioner.
6. Remove the spanner ring from the nut.
7. Move the tool to the next bolt hole following the tensioning pattern from the stretched
record sheets at the end of this manual.
9.3 Tensioning at Final Pressure
Repeat the pulling and tightening procedure stated above at full pressure. After all of the studs
have been tensioned, measure the final stud length. The final pressure and required stretch
values are listed in the following table.
WARNING
The safety guard must be in place at all times. Keep hands out of designated areas at all times
when the tensioner is pressurized otherwise personal injury can occur.
CAUTION
CAUTION
Do not exceed the maximum pressure marked on the tensioner. Excessive pressure can
damage the stud and puller screw.

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CAUTION
before attempting to tighten the nut with the spanner ring. If the tool is not properly
installed, the tool could jump off the stud while coming up to pressure.
Flange Position
Stud Size
Final Pressure
Final Stretch
Turbine to Coupling
3"
[76 mm]
18000 psi
[1240 bar]
0.020" - 0.022"
[0.51 mm - 0.56 mm]
2-3/4"
[71 mm]
19000 psi
[1310 bar]
0.025" - 0.027"
[0.64 mm - 0.69 mm]
Incorrect stretch values can be corrected by uninstalling some or all of the selected studs. Remeasure the initial length of the studs and repeat the installation instructions studs. Excessive
stretch variations can also be corrected by the same method.
Have final stretch values approved by the supervisor responsible for the installation.
10.0 Thread Locking and Windage Plug Installation
10.1 Thread Locking
(2) Locking
Set Screws
(2) Spanner
Ring Holes
Picture 10A - Riverhawk Locknut

Mechanical lock nuts have two set screws located in the top face. Before threading the nut
onto the stud check to be certain the set screws are free to turn. Once the nut is seated torque

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the set screws to the values specified in the following table. When seated and torqued to the
values specified the load created by the set screw displaces the thread of the nut in the area of
the web creating the desired locking action.
Stud Size
Set Screw Size
Torque
3
[76 mm]
3/8-24 UN
200 inlbs 250 inlbs

[22.6 Nm 28.2 Nm]
2-3/4
[71 mm]
3/8-24 UN
200 inlbs 250 inlbs

[22.6 Nm 28.2 Nm]
10.2 Windage Plug Installation

Refer to the hardware assembly drawing (HF-xxxx) listed in Section 2.0 of this manual to
determine if windage plugs are required for the installation.
Nut
Windage Plug
Stud
Locking Set Screws
Figure 10B Windage Plug Installation

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Assembly sequence is as follows:

1.
2.
3.
4.
5.
Verify the studs internal threads are clean and free from oil.
Fully insert Windage Plug by threading it into the studs internal thread.
Torque the windage plug to 200-250 inlbs (22.6 28.2 Nm).
Tighten the windage plugs set screws to 80-90 inlbs (9.0 10.1 Nm).
Check the distance the plug is inside of the stud. The plug should be at a minimum of
.06 (1.5mm) below the face of the stud.
11.0 Stud and Nut Removal

11.1 Handling of the Tensioner
A strap can be placed around the cylinder lifting handle on the hydraulic connection side only to
help the operator support the tensioner during installation. The lifting strap must be loose
during tensioning.
11.2 Stud and Nut Removal
Removal is accomplished as follows:
If present, remove the windage plugs from the studs by reversing the installation
instructions from section 10.2. It may be necessary to use two Allen wrenches: one to
stop the windage plug from rotating, one to remove the set screws. Do not misplace the
set screws.
Using a wire brush, GT-4253, and shop air clean the internal tapered thread of the stud
to remove any debris/deposits which may have accumulated during service as described
in section 5.2.2.
With an Allen-wrench loosen the two locking set screws but do not remove from the
nut.
Picture 11A - Loosening of a nut's set screws

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Install the appropriate tensioner to the stud as described in Section 8.0.

Apply the appropriate hydraulic pressure per this table. DO NOT BACK OFF THE PULLER
SCREW.
Flange Position
Stud Size
Removal Pressure
Turbine to Coupling
3"
[76 mm]
18000 psi
[1240 bar]
2-3/4"
[71 mm]
19000 psi
[1310 bar]
Using the spanner ring and spanner/pin wrenches, loosen the nut, then release the
pressure.
11.3.1 Removing the Tensioner from a Stud

The tensioner removal is accomplished by the follows steps:
1. Release the hydraulic pressure by either releasing the hand switch on the AP-0532 Pump Kit
or by opening the valve on the MP-0130 Manual Pump Kit and leave the valve open.
2. Wait for the tensioner to fully retract and the tensioner is free to rotate.
3. Unscrew the hydraulic interlock knob until the screw is disconnected from the cylinder.
4. Unscrew the knurled clamping screw and remove the guard from the tensioner.
5. Unscrew the puller screw using a wrench and breaker bar. Do not use an impact wrench as
this can damage the tensioner.
6. Remove the spanner ring from the nut.
7. Move the tool to the next bolt hole following the tensioning pattern from the stretched
record sheets at the end of this manual.
12.0 Storage Instructions
Follow these directions to properly store your hydraulic tensioner and hydraulic pump kit for
long term storage and shipment.
If any damage is observed, contact the Riverhawk Company to schedule a maintenance
inspection.

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12.1 Hydraulic Pump Kit Storage

Refer to the Hydraulic Pump Kit Instruction Manual, IM-293 (GE VENDOC 373A4058). The latest
revision may be obtained by contacting Riverhawk Company or thru www.riverhawk.com.
12.2 Hydraulic Tensioner Storage
Check the tensioner for any damage
1. Clean puller screw and check for any debris and dents.
2. Puller screw should be free to rotate and move back and forth.
3. Seam between cylinders closed tightly.
4. Inspect tensioner guard for any signs of damage. Bent guards should be replaced.
If any damage is observed, contact the Riverhawk Company to schedule a maintenance
inspection.
Place protective red plastic cap into the hydraulic port.
Coat the hydraulic tensioner with a light coat of oil and place the tensioner into the original
shipping container.
12.3 Store shipping container
Secure the hydraulic pump and hydraulic tensioner into the original shipping containers using
the supplied wood braces.
Seal the original shipping container and store under shelter and protected from moisture, sand,
and grit.

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13.0 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:
Can I rent a hydraulic tensioner kit?
A:
Yes, Riverhawk has rental tensioner kits available for most of our hydraulic tensioners.
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 and must be removed
from the work area. 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. Leaving a damaged
stud in place will lead to a safety hazard on future outages.
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.
If a stud must be left in place, paint the damaged stud with a generous amount of
indelible, bright-colored paint. Notify the appropriate GE Safety and Service personnel.
Note the location of the damaged stud in the services notes for the machine.
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 pressure 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.

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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 pump is set to the right
pressure. Re-measure the stud's initial length then try to install the stud again.
Q:
The tensioner is at its final pressure, but the nut cannot be loosened.
A:
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 5.2.2
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 as shown in Appendix B2, 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.

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Q:
The hydraulic hose has a collar on it that can't be moved by hand
A:
The hydraulic fitting is shown in Appendix B2. 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.
14.0 Revision History

Revision
Letter
Effective Date
Description
Sept. 21, 2015
Released

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Appendix A1 - EC Declaration of Conformity
EC Declaration of Conformity
Manufacturer:
Address:
Riverhawk Company
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, and ISO 4414.
Furthermore, this equipment has been manufactured under the Riverhawk quality system per
EN ISO 9001:2008
Consult the Declaration of Conformance included with the shipment of this equipment that
identifies the authorized Riverhawk representative, applicable serial numbers, and appropriate
signature.

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Appendix B1 Puller Screw Release Tape Installation

Reference: GT-6516 (GE 373A4080)
Caution
Apply a light coat of clean turbine oil or a spray lubricant to the puller screw. This procedure
will ease assembly and assure positive mating of the threads before tightening. Do not use
Never Seize on the conical threads.
To use puller screw release tape
-During tensioner assembly
1. Following steps in the tensioner installation manual, before inserting the puller screw
into the stud.
2. Insert a single puller screw release tape onto the internal thread of the stud leaving
approximately 1/8 [3mm] sticking out of the end of the stud. (see picture below)
3. Insert puller screw into stud, per instruction manual and continue assembly of the
tensioner.
-After tensioning and removal of tensioner from stud
1. Follow appropriate tensioner installation manual for disassembly of the tensioner.
2. Once tensioner is removed, clean studs internal thread and puller screw external thread
to remove all debris left behind by puller screw release tape using brass power brush
(GT-4253)
Release Tape
-Release tape should only be used for stud installation; puller screw engagement does not
require the use of release tape during de-tensioning of the studs.
-Do not substitute for Riverhawk release tape, contact Riverhawk for support (+1) 315-7684855 or www.Riverhawk.com

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Appendix B2 - Hydraulic Fittings

Riverhawk tensioners use a 1/4 High Pressure port
to connect its hydraulic hoses. The hose connector is
made from a three piece assembly: a gland nut, a
collar, and a 1/4 tube or 1/4 hose end. (See
Illustration 1)
To assembly the fitting, slide the gland nut over the
1/4 tube or 1/4 hose end. Turn the collar counterclockwise (left hand thread) on to the tube or hose
end as shown in Illustration 1.
Illustration 1
The collar should be placed .125 (3.2 mm) from the

tip of the cone. (See Illustration 2) 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.
Illustration 2
Slide the gland nut down over the collar. (See
Illustration 3) Insert the 1/4 tube or 1/4 hose end
into tensioner or hydraulic pump. While firmly
holding the tube or hose end to stop it from rotating,
turn the gland nut clockwise (right hand thread) and
torque the gland nut to 25 FT-LBS (34 N-m).
Illustration 3
Tips:
Make sure all parts are clean and free from
debris.
Protect the cone on the end of the 1/4 tube or
1/4 hose end from scratches as this is the
sealing surface.
Replace red plastic caps when finished to protect
the threads and cone.

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Appendix B3 - Hydraulic Tensioners Rupture Disc Replacement

The hydraulic tensioners rupture disc is a key element in the overall safe use of the hydraulic
tensioner.
Each tensioner is shipped from our factory with one rupture disc already installed in the
tensioner and with another spare disc for field replacement. Extra rupture discs are available
from Riverhawk for replacement purposes.
To replace a damaged rupture disc:
1. Remove the hydraulic ports dispersion nut, compression ring, and damaged rupture
disc.
2. Discard the damaged rupture disc.
3. Clean the dispersion nut, compression ring, new rupture disc, and the hydraulic port
with a solvent to ensure a dirt-free installation.
4. Reassemble new rupture disc, compression ring, and dispersion nut into the same
hydraulic port.
Warning
A damaged rupture disc must be replaced with a with a rupture disc of the same design and
pressure rating. Do not substitute a damaged rupture disc with a different disc type, a
different pressure rating, or a foreign object.

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Appendix C1 - Record Sheet 18 Colt Circle

STRETCH RECORD SHEET FORTHE
GAS TURBINE TO LOAD COUPLING
TURBINE NUMBER:
DATE:
TECHNICIAN:
SUPERVISOR:
HOLE NUMBER
STARTING LENGTH
FINAL LENGTH
FINAL STRETCH
1
10
2
11
3
12
4
13
5
14
6
15
7
16
8
17
9
18

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Appendix C2 - Record Sheet 16 Colt Circle

STRETCH RECORD SHEET FORTHE
LOAD COUPLING TO GENERATOR
TURBINE NUMBER:
DATE:
TECHNICIAN:
SUPERVISOR:
HOLE NUMBER
STARTING LENGTH
FINAL LENGTH
FINAL STRETCH
1
9
2
10
3
11
4
12
5
13
6
14
7
15
8
16

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INSTRUCTION MANUAL IM-377

For Gas Turbine

Applicable GE Ordering Sheet Part Numbers

CUSTOMER'S INFORMATION BOX

GE Power & Water

GENERAL ELECTRIC COMPANY

215 Clinton Road

Instruction Manual IM-377

CUSTOMER'S INFORMATION BOX

Instruction Manual IM-377

1.0 Cautions and Safety Warnings

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Instruction Manual IM-377

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Instruction Manual IM-377

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Instruction Manual IM-377

2.3 Load Coupling to 324 Generator

3.0 Quick Checklist

Check oil level in hydraulic pump.

Check hydraulic hose for damage.

Test the pump.

Inspect tensioner for any damage.

CUSTOMER'S INFORMATION BOX

Instruction Manual IM-377

NUT AND STUD PREPARATION

Inspect studs and nuts for any damage.

Clean the studs and nuts.

Measure stud lengths. (VERY IMPORTANT)

Install studs and nuts into the flange.

Set stick-out dimension on the coupling side of the flange.

Hand tighten nuts on turbine / generator side of flange.

Verify stick-out measurement (VERY IMPORTANT)

TENSIONING (Bolt Installation)

Check tensioner drawing for correct parts and part numbers.

Install the spanner ring onto the nut.

Install the tensioner on the stud in flange.

CUSTOMER'S INFORMATION BOX

Instruction Manual IM-377

Tension to 50%. Consult manual for correct pressure.

Use the pin wrench in spanner ring to tighten nut.

Release pressure, move to next stud in pattern.

Repeat above steps at final pressure.

Torque the nuts' set screws.

DETENSIONING (Stud Removal)

Loosen nuts' set screws

Slide spanner ring onto nut.

Install the tensioner on the stud in flange.

CUSTOMER'S INFORMATION BOX

Instruction Manual IM-377

Apply final pressure.

Loosen nut with the spanner ring and pin wrench.

Move to next stud in pattern

4.0 General Preparations

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Instruction Manual IM-377

4.1 Machine Preparation

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