Chapter 2 Installation INTRODUCTION Proper installation of the machinery will contribute to long trouble-free operating life with minimum

maintenance. To aid in making a proper installation, this chapter describes a detailed procedure that has proven successful for installing numerous turbines and the associated e uipment. The following chapter contains the installation methods recommended by !"P#-"lliott Company. $ther procedures do e%ist which can provide a satisfactory installation& however, prior to using any of these alternate procedures, it is recommended that the purchaser carefully investigate both the procedure and the ability of workers to produce a permanent and satisfactory installation. !"P#-"lliott 'ervice (epresentatives are e%perienced in installation procedures and can assist in providing a good installation. The installation procedures contained in this chapter are as specific as possible but cannot possibly cover all variations in field conditions. Therefore, the !"P#- "lliott 'ervice (epresentative may sometimes deviate slightly from the published procedures. This is done to give a better installation by using procedures to fit specific field and service conditions. (egardless of the procedure used, first class materials and uality workmanship should be employed. The procedure recommended by !"P#- "lliott involves the following items) *. 2. -. /. 0. 1. 2. +oundation Chock ,locks .routing 'etting the e uipment on foundation 'haft alignment Coupling Installation Piping (ecommendations

Included in this chapter is a detailed procedure for making 3cold alignment3 as well as methods for making machine 3hot alignment3 checks.

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2-*

Chapter 2 Installation 7hile many aspects of an installation are the responsibility of the purchaser or his engineer, some suggestions are offered which may contribute to suitable installation. $ne such e%ample is whether to install the machine outdoors under only a roof, or in a completely enclosed building. 7hile this class of e uipment can generally be installed outdoors, local conditions may suggest alternate arrangements. +ree8ing or low ambient temperatures around machinery can create difficulties during start-ups and shutdowns& for e%ample, lubricating oil must be warm before starting e uipment. 7ater and steam e uipment must be drained completely or heated during shutdown. 9lternately, in tropical areas, direct sun on one side of the foundation might cause e%pansions which, when coupled with other factors in the system, could create unacceptable alignment. In addition to operating considerations, maintenance and e uipment inspections will be re uired - sometimes scheduled and occasionally unscheduled. (egardless of which, weather conditions may not always cooperate. (ain, snow, wind and low or high temperatures generally e%tend maintenance and inspection when workers are e%posed directly to these elements. In addition, uality of workmanship may be lowered to a point where work accomplished is futile. +or inspection and maintenance, a permanent overhead crane or hoist is recommended. Casing top halves and rotors have close clearances which must be protected, therefore, moves must be slow and positive. This is seldom achievable with crawler or wheelmounted cranes. Installation of the machinery may be on either steel soleplates or a self-supporting fabricated steel baseplate. The functional purpose of these intermediate supports is to provide a permanent mounting plate for the machine feet that can be shimmed. 7hen the foundation support is not continuous or is mounted directly on columns, a self-supporting fabricated steel baseplate must be designed that will minimi8e deflections between contact supports. 'oleplates usually provide support for only one machine or smaller e uipment strings. In most cases, a baseplate is made to support larger e uipment strings. 'ome baseplates are also designed to contain or support lubrication and seal system piping and instrumentation in addition to the machinery. ,aseplates with the lubrication system built in may re uire less space and have lower installation cost, but are generally more difficult to maintain. Installations of a self-supporting baseplate on a reinforced concrete foundation should follow the guidelines presented with only the sections indicated on the outline drawing left unsupported. 7hen the installation of a self-supporting baseplate is on structural steel or columns, care must be e%ercised to insure that the mounting surfaces are machined level :from end to end and side to side there should be less that 5, 1; slope< and flat :each pad must be flat within .55-= :.521mm<<. +ull contact between the mounting surfaces is re uired without the use of step shimming. 7ith this installation arrangement, grouting is not used to fill in gaps, but other procedures presented in this chapter should be followed. 'ee +igure 2-*.

2-2

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Chapter 2 Installation
">?IP@"AT ,9'"P#9T"

+$?AB9TI$A ,$#T

,9'"P#9T" P9B 'CI@' 'T(?CT?(" P9B P#9AT '?PP$(TIA. 'T(?CT?("

FIGURE 2-1 TYPICAL BASEPLATE MOUNTING ARRANGEMENT ON STRUCTURAL STEEL FOUNDATION The principle function of the foundation is to provide a permanently rigid, non-warping support for the machinery. In meeting these re uirements, the foundation should) hold machines in proper alignment under all operating conditions support the machineDs weight and load, and distribute it uniformly and evenly to the soil or main support structure maintain established e uipment locations minimi8e transmission of vibration to or from the machines. 7hile the responsibility for a successful foundation rests with the purchaser, the following suggestions are offered for assistance and consideration) *. The outline drawing provides e uipment mounting surface areas, anchor bolt locations, main piping connections, and other information necessary in designing a foundation. 9 foundation of reinforced concrete should be of ample si8e and proportion for ade uate support of the machinery, as well as piping forces such as inlet and discharge piping. Provision should be made in the foundation design for accessibility to all parts of the machine or its au%iliaries during operation, inspection and maintenance. 2--

2.

-.

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Chapter 2 Installation /. The foundation should rest entirely on natural rock or entirely on solid earth. 9 foundation resting partly on one or partly on another may warp due to settling of part of the foundation support. Bistortion may also occur due to une ual pressures created by differences in ground water level. +oundations supported on pilings should have a rigid continuous cap over the pilings on which the foundation rests. Temperature surrounding the foundation should be uniform. Temperature differences between the top slab and mat, for instance, can create substantial bending stresses in columns. Care must be taken to reduce thermal distortion from radiation or uneven heating and cooling. Birect sunlight on outdoor tropical installations is to be avoided. 'team lines passing close to the foundation should also be avoided& but when unavoidable, the lines should be insulated and the foundation shielded. +oundation should be isolated from all other structures and arranged so that outside vibrations are not transmitted to it. 7here foundations must be supported by floor beams, a vibration dampening material should be interposed between the beams and the foundation. Besign of foundation structure should avoid resonant fre uencies of operating speed, /5F to 05F of operating speed, rotor critical speeds, and two times operating speeds. It is recommended that concrete foundations be allowed to cure for appro%imately 2E days before loading. This will allow for development of strength and reduction in shrinkage rate. Curing procedure should be in accordance with 9merican Concrete Institute recommendations.

0. 1.

2.

E.

G.

*5. (ecommended si8e of foundation anchor bolts and proHection above foundation is shown on the outline drawing. 'uggested installation of the anchor bolt is as shown in +igure 2-2. ?se of a pipe sleeve around anchor bolt allows for some shifting of the anchor bolt if found necessary during installation of e uipment. It allows for increased stretch length of anchor bolts. **. 7hen establishing the top elevation for the foundation, allow appro%imately 5.0 inch :*2 mm< for removal of top crust of concrete by chipping. (einforcing rods, ties, or steel members should be sufficiently below the surface to permit chipping away of appro%imately *.55 inch :20 mm< of concrete without making contact. 9 minimum space of *.55 inch :20 mm< should be provided between foundation and chock block to provide ade uate room for insertion of grout. The ma%imum distance between the foundation and soleplate or baseplate should not e%ceed /.55 inches :*55 mm<. +igure 2-- is a cross-sectional view showing the location of a soleplate with chock blocks, chock block grout and final grout. +igure 2-/ is similar but shows the location of a baseplate with chock blocks, chock block grout and final grout.

2-/

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Chapter 2 Installation

,9'"P#9T" ,$I,"9@

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FIGURE 2-2 SUGGESTED ANCHOR BOLT ARRANGEMENT

">?IP@"AT '$#"P#9T" 'CI@' CC$C! ,#$C! C$#B B$7A 'C("7 +$?AB9TI$A ,$#T PIP" '#""L"

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FIGURE 2-3 TYPICAL SOLEPLATE MOUNTING ARRANGEMENT

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2-0

Chapter 2 Installation Foundation P !"a ation 7hen the foundation is constructed of reinforced concrete, it is not practical to pour the concrete block with the necessary precision to permit setting the machinery directly onto the block. Therefore, the soleplate or baseplate is set with a void between it and the foundation. 9fter the soleplate or baseplate is positioned, machinery placed and cold alignment check made, the soleplate or baseplate is cemented or grouted to the foundation. This procedure essentially creates one continuous support for the machinery.

+$?AB9TI$A ,$#T

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FIGURE 2-# TYPICAL BASEPLATE MOUNTING ARRANGEMENT In order to obtain good bonding surfaces for the grout, all defective concrete, laitance, dirt, oil, wa%, grease and loose material must be removed from the mating surfaces. This can best be accomplished by chipping, bush hammering or by other means until sound, clean surfaces are obtained. (emoval of appro%imately 5.0 inch :*2 mm< of the top concrete surface should provide a strong, laitance-free surface for bonding and anchoring of the grout.

2-1

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Chapter 2 Installation CHOC$ BLOC$S In this manual, the term 3chock block3 is used to describe steel or grout blocks that serve to level and support the soleplate or baseplate prior to full grouting. The si8e of a steel chock block may vary, but the two si8es shown in +igure 2-0 will generally satisfy most all conditions. 7hen steel chock blocks are furnished by "lliott Company, the blocks will conform to the information provided in +igure 2-0 or when desired this figure can be used to make chock blocks. To provide for ease of installation and leveling, four Hackscrews are furnished in the chock block. 9 screw anchor in the center of the block is used to anchor the chock block securely until grouting in of the blocks. C%o&' B(o&' *. 2. -. @aterial carbon steel plate @achine both top and bottom flat ,reak all corners and chamfer all holes
*.5 in. 20 mm

5.0 in. *- mm

E.55 in. $( *2.55 in. 25- mm $( -50 mm

/.55 in. *5* mm

5.20 in. *G mm

/ - '"T 'C("7' *623 - *- % *-*623 #$A. $L9# P$IAT $( ">?IL9#"AT @9CCIA" 'C("7 *6/3 - 25 % -3 #$A. +#9T C"9B $( ">?IL9#"AT 'C("7 9ACC$( 'CI"#B T$ @9TCC @9CCIA" 'C("7

FIGURE 2-) TYPICAL CHOC$ BLOC$

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2-2

Chapter 2 Installation "po%y grout chock blocks can also be used in place of steel chock blocks. 7hen using epo%y grout chock blocks, small forms should be positioned at each anchor bolt Hust as suggested for steel chock blocks. The top surface of each form should be level and at essentially the same elevation as all other chock block forms. +orms should be anchored, coated with wa% and sealed around the bottom. 7hen pouring grout, forms should be completely filled. This will minimi8e need for shimming between chock and baseplate or soleplate. ?se of chock blocks allows the installation workmen to easily make a change in elevation at a soleplate or baseplate support pad. The chock blocks also distribute the machinery weight and hold down nut force so that deflections of the soleplate or baseplate due to these forces are minimi8ed. 7ith chock blocks, the soleplate or baseplate can be easily shifted hori8ontally without disturbing established elevations. +or ma%imum effectiveness, two chock blocks should be positioned at each foundation anchor bolt as shown in +igure 2-1. @achines mounted on baseplates generally have the foundation anchor bolts spread out and close to only one edge& therefore, placement of chock blocks can usually be accomplished as shown in +igure 2-1. +or machines mounted on soleplates, the number of foundation anchor bolts increases while available surface area decreases, therefore making effective placement of chock blocks more difficult.
9ACC$( ,$#T CC$C! ,#$C!

9PP($II@9T"#4 /.553 :*55 mm<

,9'"P#9T" $( '$#"P#9T"

FIGURE 2-* PREFERRED LOCATION OF CHOC$ BLOC$S

2-E

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Chapter 2 Installation +igure 2-2 shows a preferred arrangement when space is available, while +igure 2-E illustrates an alternate arrangement that may be used. The arrangement used should provide ma%imum support and minimi8e deflection or warping to the soleplate or baseplate during installation work.
-1.55 in. :G55 mm<

*2.55 in :-55 mm<

CC$C! ,#$C!'

FIGURE 2-+ PREFERRED LOCATION OF CHOC$ BLOC$S

25.55 in :055 mm<

G.55 in :-25 mm<

T7$ CC$C! ,#$C!'

FIGURE 2-, ALTERNATE LOCATION OF CHOC$ BLOC$S +igure 2-G illustrates a typical arrangement with chock blocks positioned on either side of the foundation anchor bolt. 9s described earlier, the foundation surface must be prepared by chipping or other means prior to setting the chock blocks. The chock block surfaces, where a bond with the grout is desired, must also be cleaned prior to setting. 'urfaces must be free of oil, dirt and o%idation. If the chock blocks have been coated with a cataly8ed epo%y primer, the surface coating should not be removed but surfaces should be cleaned with solvent to remove any oil or dirt prior to setting.
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2-G

Chapter 2 Installation
+oundation anchor bolt Temporary plug 'eal Chock block #eveling screws Chock block grout +orm 'ea l Chipped foundation surface $btain this dimension from the certified outline drawing

*.55 in :20mm< min. 'crew anchor Cold down screw

(einforcement rods

FIGURE 2-TYPICAL CHOC$ BLOC$ ARRANGEMENT The chock block surfaces should be sandblasted if coated with rust or some other surface coating. 'andblasting is best, but a disk grinder or other mechanical method can be used. If chock blocks will be immediately grouted after setting, no further surface treatment is re uired. 9 clean, sandblasted surface will provide a good bonding surface. If grouting in of the chock blocks will be delayed after cleaning, the cleaned surfaces should be coated with an epo%y primer or surface coating recommended by grout supplier. To set a chock block, determine the chock block anchor screw locations on the foundation and drill 5.0-inch :*2 mm< diameter by *.55-inch :20 mm< deep holes :if screw anchor shield is other than that shown, appropriate drilling should be used< in the concrete. Position the chock block and engage the screw anchor as shown in +igure 2-G. #evel the individual blocks using the four setscrews provided. 9ll blocks must be level and appro%imately at the same elevation. It is desirable to maintain all chock block elevations within a few thousandths of an inch or a few hundredths of a millimeter. This makes final installation and shimming of the e uipment much easier. $n installations where overall length of the e uipment is short, elevation of the chock blocks can best be set by use of a straight edge and precision level. $n installations where the overall length of the e uipment is large, use of a precision tilting level may be advantageous. (egardless of the method used, shimming should be used between the chock blocks and soleplate or baseplate to correct any elevation variations re uired. NOTE ,efore making a check of chock block level and elevation, be sure anchor screw is tight and all four leveling screws are making contact with the foundation.

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Chapter 2 Installation GROUTING The procedure to be followed for grouting in of chock blocks, soleplates or baseplates is the same e%cept for uantity of grout placed. "lliott recommends that the grout used be a good uality epo%y grout system from a reliable manufacturer of heavy machinery grouts. "po%y grouts consist of an epo%y resin, hardener and graded silica aggregate. The resin and hardener serve as the adhesive while the aggregate serves as a filler to reduce cost, improve thermal e%pansion compatibility and absorb heat released by curing. 7ith proper application, an epo%y grout should provide a permanent, reliable installation. ?se of sandcement grout or sand-cement grout with various additives may also provide an ade uate installation, however both are generally lower in strength, have more tendencies to shrink unevenly and are generally more susceptible to chemical attack and deterioration by oils. The prime purpose of grouting is to) +ill all voids between the foundation and the soleplate or baseplate. Provide a permanent bond between the foundation and the soleplate or baseplate. To assist the foundation anchor bolts in preventing lateral movement. Provide a solid, level base to which the machine can be anchored by the foundation anchor bolts to prevent vertical movement. @ake the soleplate or baseplate more or less an integral part of the concrete foundation. 9s anchor bolts are designed for hold down purposes, it is desirable to provide for some stretching of the anchor bolt between the bottom of the sleeve and the bottom of the nut. Therefore, it is recommended that the sleeve be filled with a pliable material such as silicone rubber, prior to final grouting. ?se of epo%y grouts re uires some installation procedures that differ from those used for sand-cement grouts. The procedure that follows provides a general guide for use with epo%y grout& but for more specific details, consult the grout supplierDs bulletins or labels. This is particularly important in regard to safety precautions.

-79(AIA.MOST EPO.Y GROUT IS FLAMMABLE/ TO.IC/ POISONOUS/ AND CORROSI0E1 THEREFORE/ MATERIAL SHOULD BE $EPT A2AY FROM OPEN FLAME/ HIGH HEAT SOURCES OR SPAR$S1 IT SHOULD BE MI.ED IN A 2ELL-0ENTILATED AREA1 2OR$MAN SHOULD 2EAR EYE PROTECTION AT ALL TIMES DURING MI.ING OF GROUT AND HARDENER AND ALSO 2HEN APPLYING MI.ED GROUT1 GLO0ES AND PROTECTI0E CLOTHING SHOULD BE 2ORN AT ALL TIMES1 7hen grouting in baseplates, thermal e%pansion rates between sand-cement grout and steel or an aggregate filled epo%y grout and steel generally can become significant. Therefore e%pansion Hoints should be installed when stretches greater than appro%imately three feet are encountered. 9fter the foundation has been dressed, the surface of the e%pansion Hoint should be sealed with silicone rubber. 2-**

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Chapter 2 Installation Timing and proper mi%ing are the secrets to successful grouting. ,efore mi%ing the components together, everything else should be ready - surfaces cleaned and dry, forms completed and sealed, pushing tools, rags, cleaning solvents available and ade uate manpower. ,ecause of epo%y groutDs higher compressive and tensile strengths and its readiness to bond to metals, the top of the grout should be brought up along the side of the soleplate or baseplate to give some protection against lateral movement. .rout forms should be built of materials of ade uate strength and should be securely anchored and shored to withstand the pressure of the grout under working conditions. +or epo%y grout, the forms must be wa%ed to keep them from becoming bonded to the grout. +or chock block grouting, the anchor bolt sleeve should be sealed and the form height sufficient to provide a grout height appro%imately half way up the chock block. ,ecause the epo%y grout will flow through even the smallest holes, the forms must be fit together as tightly as possible. Putty can be used as caulking for small cracks or holes. To permit easy cleanup, wa% or cover all surfaces where grout may splash. +or outdoor installation, the foundation should be protected from rain since it is important that the foundation be clean and dry at the time of grouting. Aormal grouting temperature should be between /5M and G5M+ :/M and -2MC<. Bue to the accelerated rate of curing at high temperatures, shade the foundation from summer sunlight for at least 2/ hours before and /E hours after grouting. In the hot summer weather, place the grout during the afternoon so the initial cure will occur during the cooler evening hours. In cold weather, the grout materials should be stored in a warm place. #ow temperatures make the grout stiff and hard to handle. +or best results, ingredients should have an actual temperature of 25M+ :2*MC< or higher. (efer to instructions for the particular grout mi% being used for allowable working time at various ambient temperatures. +low grade epo%y grouts can generally be handled with the same methods and tools that are used with flow grade sand-cement grouts. @i%ing can be done in small mortar mi%ers. ?se of a purchased grout with all the ingredients accurately measured into convenient batches reduces the chance of error. The actual placing of the material can be accomplished by several means. 'ome contractors prefer to force the materials into place while others through years of e%perience, prefer to place the materials by other methods. The material is very viscous& however, it will flow and seek its own level given time and an ambient temperature within a given range. .enerally, it is best to start at one end of the baseplate and work toward the other end, forcing the air out to eliminate voids as the material moves along. Plywood strips, sheet metal strips, wires and rods can be used to flow the grout completely under the soleplate or baseplate. NOTE Check the forms fre uently for leaks. #eaks do not selfseal. If not stopped, leaks will cause voids. +orms should be left in place until the grout is hard enough throughout that it cannot flow. This usually occurs overnight but can be longer in cold weather.

2-*2

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Chapter 2 Installation SETTING THE E3UIPMENT ON FOUNDATION $nce the chock block grout has cured sufficiently to withstand static load, installation of the e uipment on the foundation may proceed. If the soleplates or baseplates have been coated with a cataly8ed primer, the surface coating should not be removed but only the oil and dirt removed with solvent. If the surfaces that will come in contact with the grout are coated with some other material or rust, the surfaces should be sandblasted. 7hile sandblasting is best, a disk grinder or some other mechanical method may be used. The cleaned surface should be coated with epo%y primer or surface coating recommended by the grout supplier. Prior to placing the soleplate or baseplate on the chock blocks, clean chock block contact surfaces and install appro%imately 5.*20 inch :-.5 mm< thick shim pack having an assortment of shim thicknesses on each chock block. 'him pack should be full si8e, clean, smooth and rust free. This will provide a means of lowering any portion of the machine or baseplate that re uires adHustment during leveling. 'et the baseplate or soleplates on the shimmed chock blocks and tighten down all the foundation bolts. Check for level and make necessary adHustments by adding or removing shims. Aormally, it is best to start at the middle and work towards the ends. 9ll soleplate or baseplate leveling should be done using the machined support foot surfaces. ,efore mounting the e uipment on the soleplates or baseplate, place a 5.*20 inch :-.5 mm< thick stainless steel shim pack having an assortment of shim thicknesses on each machine support. 9 stainless steel shim pack is generally preferred. +ull si8e shims are preferred when setting machinery or when making elevation changes during alignment. NOTE 'hims and contact surfaces should be kept smooth, free of burrs and clean to prevent erroneous alignment readings. Check that coupling hubs have been mounted on their respective shaft ends before setting machinery on soleplate or baseplate. If not, refer to coupling installation procedure in this chapter and the coupling manufacturerDs literature. 9fter machinery has been placed on soleplates or baseplate, install and tighten hold down bolts. Check for a 3soft foot3 by loosening each hold down bolt in turn while measuring with a dial indicator movement between machine foot and soleplate or baseplate. If movement on loosening a nut e%ceeds appro%imately 5.552 inch :5.50 mm< at any foot, shim changes to eliminate the 3soft foot3 should be made before proceeding. 7ith soleplates or baseplate set and leveled, machinery mounted and rough aligned, remove all temporary shipping braces.

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Chapter 2 Installation NOTE The Hournal bearings on the turbine have been fitted with plastic inserts for protection during shipment. These plastic inserts must be removed before the rotor is turned. If the machine is to be reshipped, the plastic inserts must be reinstalled for transit to final Hobsite. Then clean the bearings and bearing housings. 9ll clearances should then be checked. (efer to clearance table and drawings. Thoroughly oil all bearings and reassemble bearing housings. (efer to appropriate sections in Chapter /. The machinery is now ready to be 3cold aligned3. The 3cold alignment3 method to use is dependent on the distance between the coupling hubs. +or greatest accuracy, the method suggested should be used whenever possible. Initial cold alignment should be obtained prior to grouting in soleplates or baseplate. In order to provide ma%imum fle%ibility and minimum confusion, the cold alignment should be completed with all piping disconnected from the machinery. 9%ial coupling separation indicated on outline drawing must be maintained during cold alignment. COUPLING INSTALLATION 9 fle%ible coupling is used between the turbine and the driven e uipment. This type of coupling can be manufactured for use with either straight or tapered shaft ends. Individual preferences or certain operating conditions may dictate using different types of couplings. Therefore, it is advisable to refer to the manufacturerDs instructions for specific details pertaining to the coupling. In4ta((in5 A St ai5%t Bo ! Cou"(in5 *. 2. -. Clean and de-burr the coupling hub and shaft end. Place the coupling sleeve :if applicable< on the e uipment shaft with the bolting flange positioned toward the shaft end. Check the key fit in the coupling hub and the shaft keyways. The key must have a side clearance of .55* inch to .55- inch :5.5- mm to 5.52 mm< between the key and coupling keyway. The fit between the key and shaft keyway must be .555 inch to .552-inch :5.5 mm to 5.50 mm< interference. The key must be fitted to provide .550 inch to .5*--inch :5.*- mm to 5.-- mm< top clearance in the coupling keyway. 9fter the key has been fitted to provide the proper clearances, insert it in the shaft keyway. 9pply a light coat of suitable anti-galling lubricant on the mounting surface of the shaft. Ceat the coupling hub in oil or in an oven to appro%imately -55M+ :*05MC<. The coupling should not be heated with an open flame or be allowed to e%ceed 155M+ :-*0MC<.

/. 0. 1.

2-*/

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Chapter 2 Installation

-79(AIA.HEAT-RESISTANT GLO0ES SHOULD BE 2ORN 2HEN HANDLING THE HEATED COUPLING1

,$#TIA. +#9A." '#""L" !"4794 #$C!A?T TC("9B"B 'C9+T "AB

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FIGURE 2-16 FLE.IBLE COUPLINGS7TAPERED AND STRAIGHT BORE 2. Place the coupling hub on the shaft and position it so that the hub face is flush with the shaft end. CAUTION Do not d i8! t%! &ou"(in5 on o o99 t%! 4%a9t :it% a %a;;! 1 T%! 9o &! o9 t%! %a;;! :i(( !4u(t in int! na( !<ui";!nt da;a5!1 In4ta((in5 a Ta"! !d Bo ! Cou"(in5 *. 2. -. /. Clean and de-burr the coupling hub and shaft end. 9pply a light coating of Prussian blue to the rotor shaft. Place the coupling hub on the shaft. (emove the coupling and check the contact with the shaft. 2-*0

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Chapter 2 Installation CAUTION Hand (a""in5 t%! &ou"(in5 %u= on t%! oto 4%a9t ;a> 9o ; a id5! t%at :i(( a99!&t t%! &ou"(in5 &onta&t :%!n "u((!d u"1 Co !&t t%! &onta&t => (i5%t(> 4tonin5 an> id5!4/ =u 4 o %i5% 4"ot41 0. Check the key fit in the coupling hub and the shaft keyways. The key must have a side clearance of .55* inch to .55- inch :5.5- mm to 5.52 mm< between the key and coupling keyway. The fit between the key and shaft keyway must be .555 inch to .552 inch :5.5 mm to 5.50 mm< interference. The key must be fitted to provide .550 inch to .5*- inch :5.*- mm to 5.-- mm< top clearance in the coupling keyway. 9fter the key has been fitted to provide the proper clearances and the coupling contact is determined to be satisfactory, insert the key in the shaft keyway. Place the coupling sleeve :if applicable< on the shaft. toward the shaft end. +it the coupling hub on the shaft :at room temperature<. Take a reference dimension from the hub to a fi%ed part on the machine case or a shaft shoulder. @ake certain the shaft is seated against either of the thrust bearings. Position the bolting flange

1. 2. E. G.

*5. Put a small amount of thread lubricant on the drive nut. **. Tighten the shaft locknut to obtain an interference fit between the coupling and shaft. 'ee the Turbine $utline drawing in Chapter *5 for specifications on coupling pull up. *2. (echeck referenced dimension :step G< and record for future use. *-. #ock drive nut. CAUTION Do not d i8! t%! &ou"(in5 on o o99 t%! 4%a9t :it% a %a;;! 1 T%! 9o &! o9 t%! %a;;! :i(( !4u(t in int! na( !<ui";!nt da;a5!1

SHAFT ALIGNMENT The turbine and the driven e uipment are normally connected by fle%ible couplings. +le%ible couplings are used because changes in temperature and loadings during normal operation, start-up or shutdown can cause one shaft end to move relative to its companion shaft end. +or high-speed, high-performance applications such as between compressors and turbines, the coupling is usually the gear, disk or diafram type.

2-*1

,4( P".ch52.5165/652

Chapter 2 Installation 9ll fle%ible couplings have limits within operation without failure or undue wear. "ven when operating within the design limits, these couplings generate some resistance to fle%ing. The force usually increases as the misalignment increases, thereby increasing or decreasing bearing load fluctuations as the shaft rotates. +urthermore, operating with collinear shafts at normal operating conditions minimi8es tooth-sliding velocity or diafram fle%ure while providing the ma%imum reserve for movement in any direction should it be re uired. "%perience indicates that e%cessive vibration of compressors and their drivers is often caused by improper shaft alignment. +re uently, high or unusual bearing and seal wear can be traced to improper shaft alignment. In e%treme cases, poor alignment can precipitate a coupling, bearing or shaft failure. +or smooth operation and long trouble-free runs, good shaft alignment procedures are essential and cannot be over-emphasi8ed. 9n understanding of good shaft alignment techni ues must begin with a few basic definitions. 3Cold or ambient alignment3 is the procedure that involves positioning the frames or casings of compressors and other rotating machines while at standstill and ambient conditions. The 3cold shaft alignment3 is normally accomplished using dial indicators, feeler gauges, micrometers or a combination of these instruments. This positioning should allow for thermal growth and material deflections that will occur between ambient conditions and stabili8ed operating temperatures. The incremental movement used to establish the cold shaft alignment may be actual measurements made during start-up or shutdown, growths estimated by the machinery manufacturer or estimates made by the installation man. To calculate thermal e%pansion or contraction, multiply original length :generally distance from machine shaft centerline to top of baseplate or soleplate< times e%pansion coefficient :5.5555512 for steel< times temperature change in degrees +ahrenheit. :"%pansion coefficient is 5.5555*2 for steel and temperature change in degrees Celsius.< # :change in length< N # :length< % 5.5555512 % T :change in temp. M+< # :change in length< N # :length< % 5.5555*2 % T :change in temp. MC< A$T") # and # in same units. Aormally, the vertical movement is minimi8ed by use of a bolted Hoint where the support foot attaches to the casing. Therefore, the average temperature of the support foot may be considerably lower than the average of adHacent casing temperature to foot temperature. 9 good 3hot shaft alignment3 will either verify or suggest alternate growth figures to use. 3Cot shaft alignment3 also known as operating shaft alignment or service alignment is a procedure for monitoring the change in shaft alignment from cold or ambient conditions to normal operating conditions. !nowing the 3cold shaft alignment3 and measuring the change, provides a method for determining if the shaft alignment becomes collinear at normal operating conditions. This method is indirect, but if properly done, provides the most reliable and acceptable method available.
,4( P" *55 .ch52.5165/62552

2-*2

Chapter 2 Installation

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FIGURE 2-11 TYPES OF SHAFT MISALIGNMENT 9. Collinear alignment - In +igure 2-** part 9& the two machine shaft ends are considered to be 3collinear aligned3 when the two shaft ends rotate about the same straight line :no misalignment<. 9ll machinery shafts have some deflection& therefore, this reference is limited to the center of rotation of one shaft end relative to the opposite shaft end. "ach coupling must be analy8ed individually. ,. 9ngular or +ace displacement - In +igure 2-** part ,& indicates the amount of angular misalignment at a shaft end. Aormally, angular displacement is measured in mils of offset per inch :in mm of offset per meter< of coupling diameter or a%ial separation. C. Parallel offset - In +igure 2-** part C& indicates the amount of parallel misalignment between the centerlines of two adHacent shaft ends. +igure 2-** part C, shows two shafts with only parallel offset. 39%ial separation3. 7hen the coupling connecting two shaft ends is a gear type, an a%ial separation of plus or minus .5120 inch :*.15 mm< tolerance is usually acceptable. 7hen the coupling connecting the two shaft ends is a disk or diafram type, an a%ial separation as shown in +igure 2-** of less than plus or minus .5*0 inch :5./5 mm< tolerance is usually re uired. Check coupling drawing and coupling instructions for precise limits.

2-*E

,4( P".ch52.5165/652

Chapter 2 Installation 7hen aligning disk or diafram type couplings, the dimension information shown on the coupling drawings must be adhered too. @easurements should be taken with the e uipment in normal thrust position :turbine rotor toward e%haust<. ?sually, the critical dimension is a coupling flange face dimension as shown in +igure 2-*-. +or further information on a%ial separation, refer to coupling vendor drawing and installation procedure.
9II9# '"P9(9TI$A

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FIGURE 2-12 A.IAL SEPARATION

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FIGURE 2-13 A.IAL SEPARATION - DIAFRAM COUPLING There are two similar procedures available for measuring parallel offset and angular displacement. The most accurate measurements are obtained when one of the following recommended methods is used. The 3(im and +ace @ethod3 is the preferred procedure when the distance between the two adHacent shaft ends is less than one-half the coupling diameter :this assumes face readings are taken near outside diameter<. This procedure is also known as the 3Cub and +ace @ethod3 or 3Two Indicator @ethod.3 The 3(everse Indicator @ethod3 is the preferred procedure when the distance between the adHacent shaft ends is greater than one-half the coupling diameter.

,4( P" *55 .ch52.5165/62552

2-*G

Chapter 2 Installation S%a9t A(i5n;!nt Ma" In4t u&tion4 Preparation and use of a 3'haft alignment map3 for each installation is recommended. 9 typical shaft alignment map is shown in +igure 2-*/. ?se of a shaft alignment map provides a convenient form on which to record indicator readings and calculate e uipment moves. @aintaining this information for comparison during maintenance inspections or for reference, should problems develop, can provide valuable diagnostic information. 9 blank form for your use is provided in +igure 2-*2. In addition to providing machine identification information, date and shaft alignment method used, the shaft alignment map provides a plan :top< and vertical :side< elevation of the machine shafts, complete with all the important reference points identified. The hori8ontal or abscissa coordinate should be scaled using some convenient scale such as *.55 or 2.55 inches per division :20 or 05 millimeters per division<. 9ll support feet and coupling faces should be located. 7hen more than two machines are involved, a larger map or graph may be advantageous. The vertical or ordinate coordinate should be an e%panded scale such as * mil :5.52 millimeters< per division in order to clearly identify misalignment. @ark Aorth compass direction in plan view and corresponding compass directions in indicator reading circles so no confusion develops during measurements. 7hen making shaft alignment corrections, it is usually advantageous to hold one machine in a fi%ed position and align other machine or machines to the fi%ed machine. 'ome guidelines to determine the best machine to hold stationary are as follows. *. 2. -. If the e uipment consists of turbine driven compressor, it is generally preferred to level turbine and move compressor into desired cold alignment. If a gear is present, level and s uare the gear to the foundation or baseplate and move the other machinery into alignment with the gear. If the e uipment string consists of three or more pieces of e uipment, level the machine nearest the center, s uare it to the foundation or baseplate, and move the other machinery into alignment with the selected machine.

The solid, dark, heavy lines on the shaft alignment map represent the desired hot shaft alignment& i.e., collinear alignment. Plot historical or calculated thermal e%pansion or contraction change for each support location on shaft alignment map. Connect points plotted for each machine with a dashed line. ?se dashed line for desired 3cold alignment setting3. (ead off differences between the two dashed lines in vertical plane and record desired readings in circles so marked. Plan or hori8ontal alignment usually remains unchanged from ambient :cold< of bottom reading. If system has a gear, the gear case is usually doweled or keyed under the pinion and allowed to e%pand toward bull gear shaft thus re uiring alignment allowances in plan view at bull gear or low speed shaft end. NOTE :+or 9ll (im @easurements< 9ctual measurement is *62 TI( :Total Indicator (eading<& therefore, value of measurement shown on indicator reading circle should be twice the distance indicated on plot. $ffset value is plus :J< if proHected centerline of machine that indicator is attached to is above coupling mark of the machine that indicator is riding on. 2-25
,4( P".ch52.5165/652

SHAFT ALIGNMENT MAP

?'"( 9,C Company @P *0'"(LIC" Propane (efrigeration #?," 9#I.A@"AT @"TC$B .rease ">?IP. A$. 9@,I"AT T"@P. C05E%%% 6 C05-2%% 15 + 9#I.A@"AT ,9( '9. B9T" A9@" Aegligible @I#'6@@ *5 6 G0

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(everse Indicator

*< 'how Aorth in Plan view of sketch. 2< @ark compass direction in circles. -< If offset value is plus, proHected center line of machine that the indicator was attached to will be above the coupling mark of the opposite machine. /< If offset value is minus, proHected center line of machine that the indicator was attached to will be below the coupling mark of the opposite machine. LEFT 6 COMP -121) 2 TO E TURB -2) 6 COMP -16 2 TO E -# TURB -1# @+ -121) @16 RIGHT LEFT 6 TURB 2 TO E COMP @26 6 TURB 2 TO E COMP @1* @ACTUAL COLD READING @16 DESIRED COLD READING -*/ 5 C6T 9CT RIGHT

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2-21

Chapter 2 Installation

'ometimes the work descriptions such as used on an alignment map can be confusing. +igure 2-*0 is a pictorial view of Aote - on alignment map. It reads) 3If offset value is plus, proHected centerline of machine that the indicator was attached to will be above the coupling mark of the opposite machine.3

FIGURE 2-1) PICTORIAL OF NOTE 3 ON ALIGNMENT MAP +igure 2-*1 is a pictorial view of Aote / on alignment map. It reads) 3If offset value is minus, proHected centerline of machine that the indicator was attached to will be below the coupling mark of the opposite machine.3

FIGURE 2-1* PICTORIAL OF NOTE # ON ALIGNMENT MAP

2-22

*55 .ch52.5*6*16255-

'C9+T 9#I.A@"AT @9P

?'"( C$?P#IA. T4P" NOTES? *< 'how Aorth in Plan view of sketch. 2< @ark compass direction in circles. -< If offset value is plus, proHected center line of machine that the indicator was attached to will be above the coupling mark of the opposite machine. /< If offset value is minus, proHected center line of machine that the indicator was attached to will be below the coupling mark of the opposite machine. TO TO LEFT RIGHT LEFT RIGHT '"(LIC" #?," 9#I.A@"AT @"TC$B ">?IP. A$. 9@,I"AT T"@P. 9#I.A@"AT ,9( '9. B9T" A9@" @I#'6@@

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2-23

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Chapter 2 Installation Ri; and Fa&! M!t%od o9 A(i5n;!nt *. 2. -. /. ?se (im and +ace @ethod when distance between the two adHacent shaft ends is less than one-half the coupling diameter. #ubricate bearings before rotating shafts. @ark both coupling hubs at four locations G5 apart so that their position is evident at all times during alignment work. 9ll piping strain must be removed from machine. +or initial alignment work during installation, all piping should be left unconnected from machinery. 9fter cold alignment has been secured, arrange dial indicators between shaft ends, or between foundation and machine case such that any movement of machine can be detected. Connect one flange at a time and observe indicator readings continuously. 'hould movement e%ceed 2 mils :5.50 mm<, piping strain is considered e%cessive. (eason for strain should be investigated and condition corrected before proceeding with alignment. 'hift rotors to running position and determine that coupling spacer distance is as specified on coupling drawing. @ount dial indicator so indicator button rides near center of rotation. (otate shaft against which button rests to measure a%ial wobble. If unable to maintain a%ial wobble to less than 5.55* inch :.520 mm< on either shaft, use of two face indicators *E5M apart or multiple measurements is recommended. NOTE 9%ial shaft movement during face reading measurements can cause false readings. Two dial indicators mounted *E5M apart should be used when a%ial float cannot be easily controlled. 7hen using this setup, set dial indicators at 5M and *E5M position and 8ero indicators. Bial indicator at 5M should be tagged prime dial indicator. 9t each interval, subtract second dial indicatorDs reading from prime dial indicator reading. Bivide this result by two and record result in primeDs location. ,e sure to retain proper plus or minus signs. 2. @easure angular misalignment with inside micrometer, feeler gauges or dial indicator such as shown in +igure 2-*E. This is best accomplished by marking measurement point at 5M and recording readings or change in readings between 5M point and points at G5M, *E5M, 225M and -15M. $n return to 5M position, indicator should return to 8ero or repeat measurement. Take several sets of readings, to be sure no mistake has been made or something has moved that shouldnDt have. 7hen taking measurements, rotate both shafts e ual amounts to cancel out eccentricity and surface imperfections.

0. 1.

2-2/

*55 .ch52.5165162552

Chapter 2 Installation
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FIGURE 2-1, MEASURING ANGULAR MISALIGNMENT E. (eadings observed in step 2, above should be recorded on alignment map. 9s face readings provide the slope of shaft on which dial indicator is mounted relative to coupling face of the opposite machine :'ee +igure 2-*G<, use an indicator recording circle for an a%ial location e ual to the 3face reading measurement diameter3 away from the hub on which the indicator button is riding.
9 ,

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FIGURE 2-1ANGULAR DISPLACEMENT G. To measure Parallel $ffset, attach the dial indicator to bracket mounted on machine that will be moved. 'et the indicator button to contact periphery of opposite coupling hub at top appro%imately 5.20 inch :1 mm< from edge :as shown in +igure 2-25<. 'et the indicator to 8ero at top, rotate both shafts together and record dial readings on alignment map for G5M, *E5M, 225M. $n return to top position, the indicator should return to 8ero. (epeat this procedure several times to be sure no mistake has been made or something moved. These four readings will be TI( :Total Indicator (eadings<, and actual parallel offset is one-half of indicator :TI(< readings.

*55 .ch52.5165162552

2-20

Chapter 2 Installation
o

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FIGURE 2-26 MEASURING PARALLEL OFFSET *5. (eadings observed in 'tep G should be recorded on alignment map in indicator recording circle corresponding to same a%ial location as dial indicator measuring location :fi%ed machines coupling<. **. Lertical offset :Lo< and hori8ontal offset :Co< for proHected centerline of machine to be moved at fi%ed machineDs coupling face can be determined by using alignment map Aote - or /. *2. 'lope of machineDs shaft to be moved relative to fi%ed machine is determined by :a< drawing a line thorough point determined in 'tep ** and parallel to fi%ed machineDs centerline, :b< applying alignment map Aote - of / to face readings at the a%ial location previously determined in 'tep E above. *-. In each view, draw a straight line through points located in 'tep ** and *2 with line e%tended to intersect both supports of machine to be moved. (ead off distance between line Hust completed and desired cold shaft position :dashed line< at each support for component to be moved. This measurement represents movement necessary to obtain correct cold alignment. */. @ake adHustments indicated in 'tep *-. *0. (epeat 'teps 2 through */ to verify adHustments made in 'tep */ correct. *1. ?nless otherwise noted, a final hot alignment should provide for an angular displacement between machine coupling hub centerline and coupling spacer centerline of appro%imately 5.20 mil per inch :5.20 mm per m< at the coupling gear teeth or fle% elements. This angular displacement is not a limit, but a suggested alignment goal. (efer to coupling literature for more information on ma%imum allowable misalignment. 2-21
*55 .ch52.5165162552

Chapter 2 Installation R!8! 4! Indi&ato M!t%od o9 S%a9t A(i5n;!nt *. ?se the reverse indicator method of shaft alignment when distance between two adHacent shaft ends is greater than one half the coupling diameter. Not! +or alignment purposes, the effective distance between shaft ends can be increased by spanning the shaft end to obtain a dial indicator location inboard of actual shaft ends. !ey factor is to spread two indicators as far apart as practical with negligible bracket sag. :9s spread increases, so does possibilities for bracket sag.< The reverse indicator method of shaft alignment eliminates the need for taking face readings. 2. The reverse indicator method involves taking readings from one shaft to the rim surface on the hub of the adHoining shaft and vice versa as shown in +igure 2-2*.

("9B C"(" 'C9+T 393

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FIGURE 2-21 RE0ERSE INDICATOR READINGS -. /. #ubricate bearings before rotating shaft. @ark both the coupling hubs at four locations G5M apart so that their position can easily be seen at all times during the alignment work.

*55 .ch52.5165162552

2-22

Chapter 2 Installation 0. 9ll piping strain must be removed from machine. +or initial alignment work during installation, all piping should be left unconnected from machinery. 9fter cold alignment has been secured, arrange dial indicators between shaft ends or between foundation and machine case such that any movement of machine can be detected. Connect one flange at a time and observe indicator readings continuously. 'hould movement e%ceed 2 mils :5.50 mm<, piping strain is considered e%cessive. (eason for strain should be investigated and condition corrected before proceeding with alignment. 7hen spanning the coupling gap with an indicator rig or bracket, 8ero sag is impractical to achieve& therefore, the actual amount of sag should be determined and recorded on the alignment map. The bracket should be sturdily constructed to minimi8e shifting and sag during use. NOTE +or purposes of this e%planation, the fi%ed machine is called shaft 393. The shaft of machine to be aligned to shaft 393 will be called shaft 3,3. Therefore, shaft 3,3 belongs to machine that will be moved. 2. E. 9ttach the indicator bracket to shaft 393. 9ttach the dial indicator to the bracket so that the button will rest on the outer rim of coupling hub 3,3. The indicator button should contact in about 5.20 inch :1 mm< from the hub face. Position dial indicator at top dead center, in line with 5 marking on coupling 3,3 and 8ero indicator.

1.

G.

*5. (otate both shafts together and record dial readings on alignment map at G5M, *E5M and 225M positions. $n return to top position, the indicator should return to 8ero. (epeat this step several times to be sure no mistake has been made or something moved. **. The accuracy of the readings may be verified by algebraically adding the side readings and comparing this sum to bottom reading. The readings should be e ual to or within * mil :.20 mm<. *2. (emove the bracket from shaft 393 and install on shaft 3,3. ?sing the same procedure obtain indicator readings from shaft 3,3 to the rim of coupling hub 393. *-. ?sing the two e uations shown on the suggested shaft alignment map, calculate the vertical offset :Lo< and the hori8ontal or plan view offset :Co<. Plot these results in the proper view and in the a%ial location where indicator readings were taken. Aote or / on the alignment map can assist in determining the shaft location above or below other shaft. 7hen making this determination, it is sometimes helpful to locate centerline of shaft end 3,3 first that is shaft end of machine to be moved, and then the proHected centerline of shaft end 3,3 at shaft end 393. In this e%planation shaft end 393 is fi%ed and therefore shaft 3,3 must be located relative to shaft 393.

2-2E

*55 .ch52.5165162552

Chapter 2 Installation NOTE Correct the bottom reading for sag in the bracket by algebraically adding to bottom indicator reading. Ao correction is needed on the side readings since it is negative on both sides and will cancel out. */. In each view draw a straight line through points located in 'tep *-, e%tending the line to intersect both supports of machine 3,3. (ead off distance between line Hust completed and desired cold shaft position :dashed line< at each support for machine 3,3. This measurement represents movement necessary to obtain correct cold alignment. *0. @ake adHustments indicated in 'tep */. *1. (epeat 'teps 2 through */ to verify adHustments made in 'tep *0 were correct. *2. ?nless otherwise noted, a final hot alignment should provide for an angular displacement between machine coupling hub centerlines and coupling spacer centerline of appro%imately 5.20 mil per inch 5.20 mm6m< at the coupling gear teeth or fle% elements. This angular displacement is not a limit but a suggested alignment goal. (efer to coupling literature for more information on ma%imum allowable misalignment. 9fter cold alignment has been made, the soleplates or baseplates must then be grouted& refer to previous section titled 3.routing3. 9fter final grouting is completed, cold alignment should be checked and adHusted if necessary. Hot A(i5n;!nt C%!&' 9 hot alignment check should be made after the e uipment string has operated with full load for several hours and stable operating temperatures have been reached. This check will indicate any final adHustments necessary to achieve collinear alignment of the turbine and driven e uipment under operating conditions. The purpose of the hot alignment procedure is to measure the movement of one shaft end relative to the opposite shaft end. 9s the shaft rotates, it is not practical to measure the actual position of one shaft end relative to its companion with dial indicators or similar instruments, as was the case during the cold alignment procedure. Therefore, most Cot 9lignment procedures make the assumption that the machine casing and bearing housing e%pand uniformly in a radial direction from the shaft center of rotation and maintain this relationship to the shaft center regardless of the casing temperature. This basic assumption appears to be valid as compressors and turbines are nearly symmetrical about the shaft& therefore, distortions are minimi8ed. ?sing this principle, one of the following methods should be used to make a hot alignment check. The 3mechanical hot alignment3 method uses accurate measurements between fi%ed reference points on the foundation or base and the machinery bearing housings to indicate shaft movement between ambient and normal operating conditions. This method assumes that the fi%ed reference points do not move between cold alignment conditions and machinery operation. In general, this is a good assumption provided one side or area of the foundation is not e%posed to direct sun when the other is not. ?nprotected hot steam and process lines passing in close pro%imity to the foundation can also contribute to uncertainty in incremental movements.
*55 .ch52.5165162552

2-2G

Chapter 2 Installation This method eliminates the re uirement for alignment brackets or bars by using permanent reference points :called benchmarks< that are affi%ed directly to the foundation and to the bearing housing as shown in +igure 2-22. 9ll four reference points should lie in a plane perpendicular to the centerline of the machine shaft. 'imilarly mounted reference points should be established at each bearing housing in the train. 'uggested benchmarks for this techni ue are 5.0-inch :*2.2 mm< diameter precision balls. ,ecause these benchmarks become an integral part of the installation and the accuracy of alignment records over the long term are dependent upon these references, it is recommended that the balls be made of stainless steel to prevent corrosion and mounted solidly to avoid inadvertent movement. It is also recommended that the benchmarks be protected with covers when not in use.

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9 C$#B

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FIGURE 2-22 TYPICAL DISPLACEMENT OF BENCHMAR$S ON FOUNDATION AND BEARING HOUSING NOTE 9cculign, Inc markets a tool kit designed specifically for the purpose of conducting hot alignment checks by this method. +ollowing cold alignment of the e uipment string, reference dimensions 9 and , and angles and are determined at each bearing housing and recorded. #ubrication system should be operating and oil supply temperature near design to minimi8e effect of bearing housing growth. 9fter the machine is brought to normal stabili8ed operating conditions, dimensions 9D and ,D are measured at each position. 7ith these two sets of data, the vertical and hori8ontal movement of each bearing housing of the machines in the train can be determined relative to the foundation.

2--5

*55 .ch52.5165162552

Chapter 2 Installation 'ee +igure 2-2-. ?sing common grid paper :0 % 0 grid is usually a convenient si8e<, lay out reference vectors 9 and , at angles and , having these vectors cross at one of the grid intersections. The intersection of these vectors represents the centerline of the machine shaft in the cold position. Aow refer to the cold and hot measurements previously made :9, 9D, ,, and ,D< and determine the movement of the bearing housing along vectors 9 and , by taking the differences between cold and hot measurements : 9 and ,< for each location. #ay out the movements along vectors 9 and , using any convenient scale, say 5.20 inch e uals 5.55* inch :2 mm e uals 5.5* mm<, to establish points a and b.

L"CT$( ,

C +IA9# 'C9+T P$'ITI$A a b G5 , 9

L"CT$( 9 G5 L

IAITI9# 'C9+T P$'ITI$A

FIGURE 2-23 GRAPHICAL DETERMINATION OF SHAFT IN HOT POSITION RELATI0E TO COLD POSITION Aow draw lines through a and b perpendicular to vectors 9 and ,. These lines represent arcs of radii 9D and ,D drawn from the foundation benchmarks. The intersection of these lines defines the position of the machine shaft centerline in the hot position relative to the cold position. To determine the movement in vertical and hori8ontal directions, it is necessary only to scale off the dimensions referred to as C and L, using the same scale as used in plotting 9 and ,. 9 similar plot for the data secured at each bearing housing can be compared to the alignment map information for validity of the original estimates. 7here differences e%ist, corrections should be made to the original estimates used on alignment map and the machinery realigned. 7ith the permanent benchmark installed and the desired cold alignment reference dimensions recorded, this information can also be used for resetting machines uickly or for maintenance checks. 9nother hot alignment check is the 3reverse hot alignment3 method that uses the same basic principles as the reverse indicator method of shaft alignment. (ather than mounting brackets off the coupling, the brackets are mounted permanently off the bearing housing or casing.

*55 .ch52.5165162552

2--*

Chapter 2 Installation (egardless of the measurement method used, several things should be kept in mind when making a setup. *. The probes and indicating blocks should be positioned to measure both the hori8ontal and vertical movement at the coupling of each machine. .enerally, vertical movement is the most important& therefore, placement of brackets or bars should favor making the most accurate readings in this direction :mount along hori8ontal centerline<. The brackets or bars can either be located inside or outside the coupling guard. ,rackets or bars should be constructed and protected to minimi8e deflections due to thermal gradients and local forces such as windage or high velocity lube oil :for brackets mounted in side coupling guard<. (egardless of where brackets or bars are mounted, it must be on a thermally stable part of the machine. (egardless of where brackets or bars are mounted, it is recommended that a guard be provided to protect them.

2. -.

/. 0.

Aormally, some variations can be e%pected in the hot alignment data observed for various operating conditions. The central point about which most of the observations gather will normally indicate the desired operating alignment. (ecording of the change in alignment data between ambient conditions and the central operating condition :desired operating alignment< on the alignment map will provide confirmation of the original data or suggest modifications to original data. The conclusion drawn from this analysis should be recorded for future use during maintenance turnarounds. $nce the alignment bars have been properly installed and referenced to the cold alignment readings, the bars can also be used for aligning the machines. In addition to these methods, there are also other methods available for making a hot alignment check, such as optical alignment, non-contact pro%imity probes mounted on water-cooled pedestals, etc. 9 hot alignment check with optical e uipment measures the movement of reference points :generally tooling balls mounted on the bearing housing< by use of optics. 7hen using this method for making a hot alignment check, great care should be e%ercised as the line of sight between the measuring instrument and the reference point can be bent by temperature gradients or air currents. Instrument stands and their supports are also subHect to vibration and distortions that can influence accuracy of data obtained. In general, it is recommended that measurements be double-checked by making measurements from both sides of machines and comparing results. 9ny lack of correlation should be resolved. ?se of non-contact pro%imity probes mounted on water-cooled pedestals with the probes looking at the shaft, couplings, bearing housing or casing can also be used. 7hen using one of these methods, great care should be e%ercised to design pedestals and mounting such that temperature distortions are minimi8ed.

2--2

*55 .ch52.5165162552

Chapter 2 Installation R!a(i5n a4 N!&!44a > (egardless of the method used for making hot alignment check, it must be evaluated for accuracy of information measured. Temperature variations and air currents can cause significant changes in support temperatures between cold alignment conditions and operating conditions. "%pansions, contractions and heat flow are therefore seldom linear. This can and does contribute to introducing errors if care is not e%ercised in analy8ing results. NOTE ,efore making alignment changes based on hot alignment data, evaluate the setup to be sure data is valid and logical. 7hen the hot alignment check confirms that the machines have been properly aligned, the machines should be doweled as indicated on the outline drawing. TURBINE PIPING RECOMMENDATIONS Ao part of the turbine installation is more important for successful operation than welldesigned and properly installed piping. There are two definite obHectives for good piping) *. 2. To prevent the heated piping from imposing strains on the turbine casing and, thus, affecting the alignment. To connect and drain the turbine inlet and e%haust piping so that dry steam is furnished to the turbine and that water accumulation in these lines is prevented.

9 main steam isolation valve is recommended in the steam piping, preferably at a convenient accessible location in the turbine room, between the steam header and the turbine inlet, to allow working on the turbine without shutting down the boiler. The turbine casing must be protected from piping weight and piping e%pansion strains. The weight of piping should be carried by suitable supports. "%pansion Hoints with limit rods or piping bends should be used adHacent to the turbine flanges. Connections between the piping flanges and turbine flanges are made without forcing the pipeline in any direction in order to make a satisfactory Hoint. Connections may be considered satisfactory if the connecting pipe lines, when heated to operating temperature, do not shift out of line with the turbine flanges when the bolting is withdrawn. (efer to A"@9 standards for ma%imum forces and moments allowable. ,efore piping is connected to turbine, mount at least two indicators from one coupling hub to the other coupling hub-one to measure any vertical movement, the other to measure any hori8ontal movement. Then connect piping to turbine. If movement shown on any indicator e%ceeds 5.5523 :5.50 mm< loosen piping and refabricate, realign or adHust anchors as re uired. 9ll steam piping between the turbine and boiler or steam header must be ade uately 3blown down3 to remove welding beads, scale, dirt, etc. Buring blow down, the piping should be disconnected and directed away from the turbine. ,low down should be at ma%imum design turbine throttle flow to obtain design steam temperature and velocity. The piping should be blown down several times, until a polished metal plate held in the stream indicates the absence of foreign material. 2---

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Chapter 2 Installation If supplied, the trip and throttle valve always contain a permanent screen to guard against the ingestion of large loose particles. In addition, many valves will also have a temporary screen installed around the permanent one. The temporary screen should be removed after appro%imately one month of operation and should never be left in longer than si% months. Not! 'trainers do not take the place of a properly setup and conducted blow down. STEAM LINE BLO2 DO2N CR!9! !n&! SM 23D (at!4t !ditionE 9ll new steam piping between turbine and boiler or e%isting header must be ade uately blown to remove welding beads, scale, dirt, broken backing rings, weld rod, etc. This includes all steam lines that can import steam into the turbine including but not limited to) - @ain 'team - .land 'ealing 'team Proper setup and implementation of a sound blow down procedure are normally the responsibility of the installation contractor. !"P#-"lliott responsibility is normally only as a witness and to verify that placement targets are acceptable before connecting to the turbine. 'ince the steam lines to the turbine can not be connected for blow down, temporary blow down piping will be re uired. Piping must be ade uately secured prior to blow down. Piping also must be rated for steam conditions at the time of the test and discharged into an area that is properly secured and marked off. In broad terms, blowing down the steam lines is a process that uses a cycle of heating and cooling to break free any loose particles. Pressure is built up in the boiler and a valve is opened to release this pressure though the steam lines. ,y the time the pressure is built up again in the boiler, the piping has usually cooled. This forms the heating and cooling cycle. The number of cycles will depend on the attention that was given to cleanliness during erection, the design of the plant piping system, and the design of the blow down system used. Lerification of the blow down is made by installing polished targets in the temporary blow down piping. The targets are usually mild steel bar with a ground finish, however key stock material can be used. "ach target can be used four times by turning the target in ninety-degree increments. The temporary blow down piping setup and si8e are very important. The force on a particle is proportional to the mass velocity head of the fluid& therefore the mass velocity head developed during the blowing cycle must be at least e ual to that developed during full load operation. The temporary piping should not have a greater flow area than the permanent piping, so that satisfactory velocities can be maintained. It is not possible to ascertain how many steam blows will be re uired to properly clean the system since too many variables are involved. "%perience has shown that up to fifty total blows may be re uired for the main steam line and ten to twenty for the secondary lines. Aormally the blow down cycle will re uire one to three hours. The actual steam flow through the pipe should be about fifteen to twenty minutes in duration and the piping should allowed to cool for at least two hours if insulated and one hour if not insulated. 2--/
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Chapter 2 Installation Polished targets are to be installed after appro%imately ten blows on the main steam line. 9t this point the targets should indicate the appro%imate relative condition of the system. 9fter two successive blows with no pitting observed on the targets, the blown down can be considered completed. (etain these targets for reference. Biscoloration of the targets is normal. 9fter successful completion of the blow down procedure, the temporary piping is to be removed. (einstall any piping removed for the blow down. Test the system for leaks and piping strain. Taking proper care to insure an effective blow down procedure has been carried out will assure a successful start-up of the turbine. TURBINE STEAM SUPPLY 'team should at all times be free from moisture. 9 receiver type separator with ample drains should be provided ahead of the stop valve to prevent slugs of water from entering the turbine. 7hen a separator is not provided, a blowoff valve or continuous drain should be connected to the lowest point of the steam inlet piping. 9 strainer should be installed in the steam supply piping for protection against large particles of scale, welding beads, etc. 9 strainer does not guard against abrasive matter, boiler compound or acid or alkaline substances, which may be carried over in the steam. These substances will corrode, erode, or form deposits on the steam parts, reducing efficiency and power. It is imperative that feed water treatment and boiler operation be carefully controlled to insure a supply of clean steam at all times. TURBINE ATMOSPHERIC RELIEF 0AL0ES 9n atmospheric relief valve must be installed between the turbine e%haust flange and the first e%haust line steam isolation valve :'ee +igure 2-2/< or check valve. The purpose of this relief valve is to protect the turbine casing from e%cessive e%haust pressure or failure of e%haust valve. The relief valve must be of ample si8e to pass the ma%imum uantity of steam flowing through the turbine without allowing the turbine casing pressure to e%ceed the ma%imum designed pressure shown on the turbine nameplate. It is the userDs responsibility to install the relief valve in the piping. +ailure to install relief valve may violate local or national codes and must be approved by an officer of the company.

79(AIA.
THE TURBINE SHOULD NOT BE OPERATED UNLESS THE ATMOSPHERIC RELIEF 0AL0E OR OTHER PROTECTI0E DE0ICE HAS BEEN INSTALLED AHEAD OF ANY ISOLATION 0AL0E/ AND IS IN OPERATING CONDITION1 Cond!n4in5 Tu =in!4 The atmospheric relief valve should be si8ed so that it is capable of passing all of the steam which may reach the e%haust with the pressure rising to a value not greater than *5 pounds per s uare inch gage. The relief valve should be installed between the turbine e%haust flange and any shutoff valve. :?sually on the condenser shell for direct connected condenser.<

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2--0

Chapter 2 Installation Non-&ond!n4in5 Tu =in!4 9 relief valve should be installed between the turbine e%haust connection and the first steam isolation valve. The valve should be designed for full relief of the ma%imum steam flow through the turbine with a pressure and flow rating as shown on the turbine outline drawing located in Chapter *5 of this manual. The sentinel valve located on the turbine casing cover, does not serve as a relief valve. The sentinel valve will not pass sufficient steam to relieve the turbine casing of e%cessive e%haust pressure. The relief valve should be set to open at the sentinel valve setting to give a visual or audible indication when the relief valve is starting to lift and be fully open with an additional *5 psig or *5F whichever is greater. If a high back pressure trip is furnished, the relief valve pressure should be raised 0 psig :.-/0 bar< and the high steam pressure trip should be set at the 3start to open3 pressure.
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Fi5u ! 2-2# Su55!4t!d St!a; Pi"in5 A an5!;!nt MISCELLANEOUS PIPING CONNECTIONS Considerable attention should be given to the installation of miscellaneous piping. Poorly planned and installed piping may obscure drain line functions and lead to error when opening or closing drain lines during operation. In addition, poorly installed piping will detract from the appearance of the installation. 9ll drain and leakoff lines should be installed in a neat and orderly manner. They should be grouped and brought to an open collector bo% and, from there, piped to a common sump or sewer.

2--1

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Chapter 2 Installation 9ll valves should be conveniently grouped as close as possible to the collector bo% and all lines should be tagged for identification. Brain lines connected through valves must have the valves tightly closed during operation. $n condensing units, these valves must not be opened unless the turbine casing is no longer under vacuum. #eakoffs, connected without valves must be clean and piped to an open drain. (efer to certified outline and connection drawings for the specific si8es of all connections and for their e%act locations. The pipe si8e must be the same as or larger than connecting si8es. 9ll connections are brought outside the Hacket when the turbine is insulated and Hacketed. NOTE 9ll drains and leakoffs should be run as separate lines to an open collector bo%. NOTE 9ll drains and leakoffs must have sufficient fle%ibility to allow for thermal growth of the turbine without e%cess strains. The following identifies the most common miscellaneous piping connections that may be furnished and e%plains their individual functions :(efer to figure 2-20<. (efer to the certified outline and purchaser;s connection drawing to verify the connection re uired. *. Casing Brain :@<) Connect through a suitable valve to an open drain. $pen before starting the turbine& close when water no longer emerges from the drain. $pen when the turbine is shut down and the e%haust valve is closed. $n condensing turbines, do not open this valve while the turbine is under vacuum. 'team Chest Brains O@/, @0, and @* :,4(C, CC only<P) Connect through high pressure piping and suitable valves to an open drain. $pen before starting the turbine to drain water from the steam chest. Close when water ceases to flow from the drain lines. $pen when the turbine is shut down. $n condensing turbines, do not open this valve while the turbine is under vacuum. 'haft Packing Case #eakoff :#-<) Connect to an open drain without a valve. Connect to a vacuum source when applicable. Trip Lalve 'tem #eakoff :#/<) Connect to an open drain without a valve. .overnor Lalve 'tem #eakoff :#0<) Connect to an open drain without a valve. Cooling 7ater Connections to ,earing Cousings :A0, A1, AG and A*5<) These connections are located on the side of the turbine bearing housings. 'ee +igure 220. Connect to a cooling water supply, which does not e%ceed G5o+ :-2oC<. Pipe the cooling water through a stop cock and hand valve into A0, out of A1, into AG, out of A*5 through a one-foot head loop to an open drain. 9dHust the stop cock to supply water at a rate of 2 gpm :2.0 l6min.< when the hand valve is fully open. 'ee +igure 2-21 for piping arrangement of water cooled bearing housings and caps. These connections are not used on pressure lubricated turbines. NOTE Cooling water pressure must not e%ceed *55 psig :1.EG bar<.
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2.

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2--2

Chapter 2 Installation 2. 'haft Packing Case 'team Piping :T*<) +urnished only when the turbine is operated condensing. Connect through a valve to a pressuri8ed saturated steam supply. 9dmit steam to packing cases until a slight amount of steam leaks out of #-. 9 typical arrangement is shown in +igure 2-22. E. Ao88le ring gage connection :'*<) 9 shut-off valve and gage arrangement may be installed in this connection. The gage can be used for indicating the inlet steam pressure drop across the steam chest. Intermediate leakoff :#--*< for ,4(CC only) Connect to a 20 to *20 psig :0.* to E.1 bar< header. The leakoff line should have a gage located near each packing case. 9 valve should be used to isolate the packing cases from the header.

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*55 .ch52.5165162552

Chapter 2 Installation
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2--G

Chapter 2 Installation
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Fi5u ! 2-2, Su55!4t!d S!a(in5 St!a; Pi"in5 A an5!;!nt Fo Cond!n4in5 Tu =in!4 0ACUUM BREA$ER FOR CONDENSING TURBINES It is recommended that provisions be made in the e%haust piping, or on the condenser for breaking the vacuum. The vacuum breaker may consist of a hand-operated valve to be opened when shutting down the turbine. ,reaking the vacuum serves two purposes) *. 2. It increases the deceleration rate of the rotor. It prevents the in leakage of cold air into the turbine casing along the shaft when gland sealing steam is turned off.

CONNECTING TURBINE TO CONDENSER 9 condenser connected directly to the turbine e%haust flange, when not suspended from the flange or spring-supported, must have an e%pansion Hoint to provide the necessary fle%ibility for e%pansion, unless otherwise approved by !"P# Company. 7hen the condenser is spring-supported or hung from the turbine e%haust flange, no e%pansion Hoint need be used, provided the ma%imum condenser weight under any condition is within the allowable weight that the e%haust end is designed to support. In the latter case, the condenser load on the e%haust flange must be central. Provisions must be made in the supports for lateral e%pansion. 9ll other piping connections to the condenser must be provided with suitable e%pansion Hoints. 2-/5
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Chapter 2 Installation To avoid air leaks and maintain the highest attainable vacuum, see that all Hoints are tight and that the shaft packing is receiving sufficient sealing steam. 'uitable paint applied along the Hoints and around the bolts of the e%haust connection will assist in keeping them airtight. TURBINE INSULATION Insulating a turbine greatly reduces heat loss and sound pressure levels, isolates hot turbine parts from personnel and protects the turbine from the environment. Insulate the high-temperature areas of the turbine surface indicated on the outline drawing. +or condensing turbines, these parts are the steam end casing, intermediate casing :when used<, trip and throttle valve and steam chest. +or non-condensing turbines, insulate the e%haust end casing also. Tu =in! Fa&'!tin5 !"P# supplies a sheet metal, Hacket-type insulation that sheathes the turbine casing. This removable Hacketing, which provides access to turbine parts for servicing, separately houses the high-temperature turbine sections. 9vailable in carbon steel or optional stainless steel, the sheet metal Hacketing s uares the turbineDs shape for a neater appearance. Kacketing for the upper turbine casing consists of a metal shell and a layer of high-temperature fibrous insulation that is fi%ed to its underside. The lower turbine casing is fitted with a metal shell that is stuffed with loose insulation. Kacketing is made to each turbineDs specifications and can be obtained through !"P# field service offices. NOTE !"P#- recommends Hacketing for all outdoor installations to protect high-temperature turbine parts from precipitation.

FIGURE 2-2TURBINE RECOMMENDED INSULATION METAL FAC$ETING

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2-/*

Chapter 2 Installation

2-/2

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Chapter 2 Installation NOTES

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2-/-

Chapter 2 Installation

2-//

*55 .ch52.5165162552