55597347 Turbine Erection

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Chapter Chapter 22 Installation Installation INTRODUCTION INTRODUCTION

Proper installation of the machinery will contribute to long trouble-free operating life

Proper installation of the machinery will contribute to long trouble-free operating life withwith minimum

minimum maintenance. maintenance. To aid To aid in making in making a proper a proper installation, this chapter installation, this chapter describes adescribes a detailed

detailed procedure that has proven procedure that has proven successful for installing numerous turbines and successful for installing numerous turbines and thethe as

assocsociaiated eted eququipipmenment.t. ThThe e folfollolowinwing chapg chapter coter contantains thins the e ininstastallallatiotion methn methododss recommended by KEPL-Elliott Company.

recommended by KEPL-Elliott Company. Other procedures Other procedures do exist which do exist which can provide can provide aa satisfactory installation; however, prior to using any of these alternate procedures, it is 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 recommended that the purchaser carefully investigate both the procedure and the ability of workers to produce a permanent and satisfactory installation.

workers to produce a permanent and satisfactory installation.

KEPL-Elliott Service Representatives are experienced in installation procedures and can KEPL-Elliott Service Representatives are experienced in installation procedures and can assist

assist inin provprovidiniding g a gooa good id instanstallatllation.ion. The insThe installtallatioation procn proceduedures conres containtained in ed in thisthis chapter are as specific as possible but cannot possibly cover all variations in field chapter are as specific as possible but cannot possibly cover all variations in field conditions.

conditions. Therefore, the Therefore, the KEPL- EKEPL- Elliott Service Representative lliott Service Representative may sometimes may sometimes deviatedeviate slightly from the published procedures.

slightly from the published procedures. This is done This is done to give a to give a better installation by usingbetter installation by using procedures to fit specific field and

procedures to fit specific field and service conditions. service conditions. Regardless of the Regardless of the procedure used,procedure used, first class materials and quality workmanship should be employed.

first class materials and quality workmanship should be employed.

The procedure recommended by KEPL- Elliott involves the following items: The procedure recommended by KEPL- Elliott involves the following items: 1 1.. FFoouunnddaattiioonn 2 2.. CChhoocck k BBlloocckkss 3 3.. GGrroouuttiinngg 4.

4. SeSettitting ng the the eqequiuipmepment nt on on foufoundndatiationon 5

5.. SShhaaft ft aaliliggnnmmeenntt 6.

6. CoCoupupliling Ing Insnstatallllatatioionn 7.

7. PiPipiping ng ReRecocommmmenendadatitiononss

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

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Chapter 2 Chapter 2 Installation Installation

While many aspects of an installation are the responsibility of the purchaser or While many aspects of an installation are the responsibility of the purchaser or hishis engineer,

engineer, some suggestions are some suggestions are offered which may offered which may contribute to suitable installation. contribute to suitable installation. OneOne such example is whether to install the machine outdoors under only a roof, or in a such example is whether to install the machine outdoors under only a roof, or in a completely

completely enclosed enclosed building. building. While While this class this class of of equipment equipment can can generally generally be be installedinstalled outdoors, local conditions may

outdoors, local conditions may suggest alternate suggest alternate arrangements. arrangements. Freezing or Freezing or low ambientlow ambient temperatures around machinery can create difficulties during start-ups and shutdowns; for temperatures around machinery can create difficulties during start-ups and shutdowns; for exa

examplemple, lubr, lubricaticating ing oil oil must bmust be wae warm brm beforefore se startitarting ng equequipmeipment.nt. WateWater r and and steasteamm equipment must be drained completely or heated during shutdown.

equipment must be drained completely or heated during shutdown. Alternate

Alternately, ly, in in tropical tropical areas, areas, direct direct sun sun on on one one side side of of the the foundatiofoundation n might might causecause expansions which, when coupled with other factors in the system, could create expansions which, when coupled with other factors in the system, could create unacceptable alignment.

unacceptable alignment.

In addition to operating considerations, maintenance and equipment inspections will be In addition to operating considerations, maintenance and equipment inspections will be required

required -- somesometimetimes scs schedheduled uled and oand occasccasionaionally lly unscunschedheduleduled.. RegaRegardlerdless ss of of whicwhich,h, weather

weather conditionsconditions mamay noy not alt alwayways cos coopoperaerate.te. RaRain, snin, snowow, win, wind and ld and low or hiow or highgh temperatures generally extend maintenance and inspection when workers are exposed temperatures generally extend maintenance and inspection when workers are exposed directly

directly toto these elements. these elements. In addition, quality of In addition, quality of workmanship may be workmanship may be lowered to a pointlowered to a point where work accomplished is futile.

where work accomplished is futile.

For inspection and maintenance, a permanent overhead crane or hoist is recommended. For inspection and maintenance, a permanent overhead crane or hoist is recommended. Casing top halves and rotors have close clearances which must be protected, therefore, Casing top halves and rotors have close clearances which must be protected, therefore, move

moves muss must bt be slow ae slow and nd posipositivetive.. This is seldThis is seldom achiom achievaevable wible with crawlth crawler or wheeer or wheel- l-mounted cranes.

mounted cranes.

Installation of the machinery may be on either steel soleplates or a self-supporting Installation of the machinery may be on either steel soleplates or a self-supporting fabricated steel baseplate.

fabricated steel baseplate. The functional The functional purpose of purpose of these intermediate these intermediate supports is supports is toto provide a permanent mounting plate for the machine feet

provide a permanent mounting plate for the machine feet that can be that can be shimmed. shimmed. When theWhen the foundation support is not continuous or is mounted directly on columns, a self-supporting foundation support is not continuous or is mounted directly on columns, a self-supporting fabricated steel baseplate must be designed that will minimize deflections between contact fabricated steel baseplate must be designed that will minimize deflections between contact supports.

supports.

Soleplates usually provide

Soleplates usually provide support for only support for only one machine one machine or smaller equipment or smaller equipment strings. strings. InIn most cases, a baseplate

most cases, a baseplate is made to is made to support larger equipment support larger equipment strings. strings. Some baseplatesSome baseplates are also

are also designedesigned to contain or d to contain or support lubricasupport lubrication and seal system piping andtion and seal system piping and instrumentat

instrumentation in addition ion in addition to the to the machinery. machinery. Baseplates with Baseplates with the lubrication system the lubrication system builtbuilt in may require less space and have lower installation cost, but are generally more difficult in may require less space and have lower installation cost, but are generally more difficult to maintain.

to maintain.

Installations of a self-supporting baseplate on a reinforced concrete foundation should 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 follow the guidelines presented with only the sections indicated on the outline drawing left unsupported.

unsupported. When the When the installation of a self-supporting baseplate installation of a self-supporting baseplate is on structural steel is on structural steel or or columns, care must be exercised to insure that the mounting surfaces are machined level columns, care must be exercised to insure that the mounting surfaces are machined level (from end to end and side to side there should be less that

(from end to end and side to side there should be less that 00°°, 6’ slope) and flat (each pad, 6’ slope) and flat (each pad

must be flat within .003”

must be flat within .003” (.076mm)).(.076mm)). Full contact between the mounting surfaces isFull contact between the mounting surfaces is required without

required without the use of the use of step shimming. step shimming. With this installation arrangement, With this installation arrangement, grouting isgrouting is not

not usedused to fill in gaps, but other procedures presented in this chapter should be followed.to fill in gaps, but other procedures presented in this chapter should be followed. See Figure 2-1.

See Figure 2-1.

2-2

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While many aspects of an installation are the responsibility of the purchaser or While many aspects of an installation are the responsibility of the purchaser or hishis engineer,

engineer, some suggestions are some suggestions are offered which may offered which may contribute to suitable installation. contribute to suitable installation. OneOne such example is whether to install the machine outdoors under only a roof, or in a such example is whether to install the machine outdoors under only a roof, or in a completely

completely enclosed enclosed building. building. While While this class this class of of equipment equipment can can generally generally be be installedinstalled outdoors, local conditions may

outdoors, local conditions may suggest alternate suggest alternate arrangements. arrangements. Freezing or Freezing or low ambientlow ambient temperatures around machinery can create difficulties during start-ups and shutdowns; for temperatures around machinery can create difficulties during start-ups and shutdowns; for exa

examplemple, lubr, lubricaticating ing oil oil must bmust be wae warm brm beforefore se startitarting ng equequipmeipment.nt. WateWater r and and steasteamm equipment must be drained completely or heated during shutdown.

equipment must be drained completely or heated during shutdown. Alternate

Alternately, ly, in in tropical tropical areas, areas, direct direct sun sun on on one one side side of of the the foundatiofoundation n might might causecause expansions which, when coupled with other factors in the system, could create expansions which, when coupled with other factors in the system, could create unacceptable alignment.

unacceptable alignment.

In addition to operating considerations, maintenance and equipment inspections will be In addition to operating considerations, maintenance and equipment inspections will be required

required -- somesometimetimes scs schedheduled uled and oand occasccasionaionally lly unscunschedheduleduled.. RegaRegardlerdless ss of of whicwhich,h, weather

weather conditionsconditions mamay noy not alt alwayways cos coopoperaerate.te. RaRain, snin, snowow, win, wind and ld and low or hiow or highgh temperatures generally extend maintenance and inspection when workers are exposed temperatures generally extend maintenance and inspection when workers are exposed directly

directly toto these elements. these elements. In addition, quality of In addition, quality of workmanship may be workmanship may be lowered to a pointlowered to a point where work accomplished is futile.

where work accomplished is futile.

For inspection and maintenance, a permanent overhead crane or hoist is recommended. For inspection and maintenance, a permanent overhead crane or hoist is recommended. Casing top halves and rotors have close clearances which must be protected, therefore, Casing top halves and rotors have close clearances which must be protected, therefore, move

moves muss must bt be slow ae slow and nd posipositivetive.. This is seldThis is seldom achiom achievaevable wible with crawlth crawler or wheeer or wheel- l-mounted cranes.

mounted cranes.

Installation of the machinery may be on either steel soleplates or a self-supporting Installation of the machinery may be on either steel soleplates or a self-supporting fabricated steel baseplate.

fabricated steel baseplate. The functional The functional purpose of purpose of these intermediate these intermediate supports is supports is toto provide a permanent mounting plate for the machine feet

provide a permanent mounting plate for the machine feet that can be that can be shimmed. shimmed. When theWhen the foundation support is not continuous or is mounted directly on columns, a self-supporting foundation support is not continuous or is mounted directly on columns, a self-supporting fabricated steel baseplate must be designed that will minimize deflections between contact fabricated steel baseplate must be designed that will minimize deflections between contact supports.

supports.

Soleplates usually provide

Soleplates usually provide support for only support for only one machine one machine or smaller equipment or smaller equipment strings. strings. InIn most cases, a baseplate

most cases, a baseplate is made to is made to support larger equipment support larger equipment strings. strings. Some baseplatesSome baseplates are also

are also designedesigned to contain or d to contain or support lubricasupport lubrication and seal system piping andtion and seal system piping and instrumentat

instrumentation in addition ion in addition to the to the machinery. machinery. Baseplates with Baseplates with the lubrication system the lubrication system builtbuilt in may require less space and have lower installation cost, but are generally more difficult in may require less space and have lower installation cost, but are generally more difficult to maintain.

to maintain.

Installations of a self-supporting baseplate on a reinforced concrete foundation should 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 follow the guidelines presented with only the sections indicated on the outline drawing left unsupported.

unsupported. When the When the installation of a self-supporting baseplate installation of a self-supporting baseplate is on structural steel is on structural steel or or columns, care must be exercised to insure that the mounting surfaces are machined level columns, care must be exercised to insure that the mounting surfaces are machined level (from end to end and side to side there should be less that

(from end to end and side to side there should be less that 00°°, 6’ slope) and flat (each pad, 6’ slope) and flat (each pad

must be flat within .003”

must be flat within .003” (.076mm)).(.076mm)). Full contact between the mounting surfaces isFull contact between the mounting surfaces is required without

required without the use of the use of step shimming. step shimming. With this installation arrangement, With this installation arrangement, grouting isgrouting is not

not usedused to fill in gaps, but other procedures presented in this chapter should be followed.to fill in gaps, but other procedures presented in this chapter should be followed. See Figure 2-1.

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EQUIPMENT

EQUIPMENT BASEPLATEBASEPLATE

Chapter 2 Chapter 2 Installation Installation FOUNDATION BOLT FOUNDATION BOLT BASEPLATE BASEPLATE PADPAD SHIMS

SHIMS

STRUCTURE STRUCTURE PADPAD

PLANT SUPPORTING STRUCTURE PLANT SUPPORTING STRUCTURE

FIGURE FIGURE 2-12-1

TYPICAL BASEPLATE MOUNTING ARRANGEMENT ON STRUCTURAL STEEL TYPICAL BASEPLATE MOUNTING ARRANGEMENT ON STRUCTURAL STEEL

FOUNDATION FOUNDATION

The principle function of the foundation is to provide a permanently rigid, non-warping The principle function of the foundation is to provide a permanently rigid, non-warping support for the

support for the machinery. machinery. In meeting these In meeting these requirementsrequirements, the , the foundation should:foundation should:

•

•hold machines in proper alignment under all operating conditionshold machines in proper alignment under all operating conditions •

•support the machine's weight and load, and distribute it uniformly and evenly to thesupport the machine's weight and load, and distribute it uniformly and evenly to the

soil or main

soil or main support structuresupport structure

•

•maintain established equipment locationsmaintain established equipment locations •

•minimize transmission of vibration to or from the machines.minimize transmission of vibration to or from the machines.

While the responsibility for a successful foundation rests with the purchaser, the following While the responsibility for a successful foundation rests with the purchaser, the following suggestions are offered for assistance and consideration:

suggestions are offered for assistance and consideration: 1.

1. The outThe outline drline drawinawing provig provides eqdes equipmuipment moent mountiunting surng surface aface areasreas, ancho, anchor r boltbolt locations,

locations, main piping connections, and other information necessary in designing amain piping connections, and other information necessary in designing a foundation.

foundation. 2.

2. A A founfoundatdation oion of f reinreinforcforced ced conconcrete rete shoshould buld be of ample sie of ample size anze and prod proportportionion for for adequate

adequate support of the machinery, as well as piping forces such as inlet andsupport of the machinery, as well as piping forces such as inlet and discharge piping.

discharge piping. 3.

3. ProvProvisioision shoun should be made in the fold be made in the foundundatioation desn design for acign for accesscessibilibility to all parity to all parts of thets of the machine or its auxiliaries during operation, inspection and maintenance.

machine or its auxiliaries during operation, inspection and maintenance.

BYR PE

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4.

4. ThThe fe fououndndatiation on shoshould uld resrest et entintirelrely oy on nn natuatural ral rocrock ok or er entintirelrely oy on sn sololid id eaearthrth.. AA foundation resting partly on one or partly on another may warp due to settling of part foundation resting partly on one or partly on another may warp due to settling of part of t

of the fouhe foundandation tion suppsupport.ort. DistDistortioortion may alsn may also occur duo occur due to uneque to unequal preal pressurssureses created by differences in ground water level.

created by differences in ground water level. 5.

5. FouFoundandationtions supps supporteorted on pilid on pilings shongs should hauld have a rigid contve a rigid continuinuous caous cap over the pilp over the pilingsings on which the foundation rests.

on which the foundation rests. 6.

6. TemperatuTemperature re surroundsurrounding ing the the foundatfoundation ion should should be be uniform. uniform. TemperatuTemperature re differencedifferencess between the top slab and mat, for instance, can create substantial bending stresses between the top slab and mat, for instance, can create substantial bending stresses in columns.

in columns. Care must be taken Care must be taken to reduce thermal distortion from radiation or unevento reduce thermal distortion from radiation or uneven heating and

heating and cooling.cooling. DirectDirect sunlight on outdoor tropical installations is to be avoided.sunlight on outdoor tropical installations is to be avoided. Steam lines passing

Steam lines passing closeclose toto the foundation should also be avoided; but whenthe foundation should also be avoided; but when unavoidable, the lines should be insulated and the foundation shielded.

unavoidable, the lines should be insulated and the foundation shielded. 7.

7. FouFoundandation tion shoushould be isld be isolatolated froed from all othm all other struer structuctures ares and arnd arrangranged so ted so that ohat outsiutsidede vibrations are not

vibrations are not transmitted to transmitted to it. it. Where foundations Where foundations must be must be supported by supported by floor floor beams,

beams, aa vibration dampening material should be interposed between the beams andvibration dampening material should be interposed between the beams and the foundation.

the foundation. 8.

8. DesiDesign of foungn of foundatidation struon structucture shoure should avold avoid resoid resonannant freqt frequenuencies of opcies of operaterating sping speedeed,, 40% to 50% of operating speed, rotor critical speeds, and two times operating 40% to 50% of operating speed, rotor critical speeds, and two times operating speeds.

speeds. 9.

9. It is recoIt is recommenmmended ded thathat conct concrete rete founfoundatidations bons be alloe allowed twed to cure o cure for apfor approxproximatimately 2ely 288 days before

days before loadingloading.. This will allThis will allow for deow for developmenvelopment of t of strength strength and reduand reduction ction inin shrinkage rate.

shrinkage rate. Curing procedure Curing procedure should be should be in accordance in accordance with American Concretewith American Concrete Institute recommendations.

Institute recommendations. 10.

10. Recommended size of Recommended size of foundation anchor bolts foundation anchor bolts and projection above and projection above foundation isfoundation is shown

shown onon the outline drawing. the outline drawing. Suggested installation of Suggested installation of the anchor the anchor bolt is as bolt is as shownshown in Figure 2-2.

in Figure 2-2. Use of a Use of a pipe sleeve around anpipe sleeve around anchor bolt allows for some chor bolt allows for some shifting of theshifting of the anc

anchor bhor bolt olt if foif found und necnecessaessary ry duriduring ng instinstallaallation tion of eof equiquipmenpment.t. It It alloallows for ws for increased stretch length of anchor bolts.

increased stretch length of anchor bolts. 11.

11. When establishing the When establishing the top elevation for the top elevation for the foundation, allow approximately 0.5 foundation, allow approximately 0.5 inchinch (12 mm) for removal of

(12 mm) for removal of top crust of concrete top crust of concrete by chipping. by chipping. Reinforcing rods, ties, or Reinforcing rods, ties, or steel members

steel members should be sufficiently below the surface to permit should be sufficiently below the surface to permit chipping away of chipping away of approximately 1.00 inch

approximately 1.00 inch (25 mm) (25 mm) of concrete of concrete without making without making contact. contact. A A minimumminimum space of 1.00 inch (25

space of 1.00 inch (25 mm)mm) shouldshould be provided between foundation and chock blockbe provided between foundation and chock block to provide adequate

to provide adequate room for insertion of grout. room for insertion of grout. The maximum distance The maximum distance between thebetween the foundation and soleplate or baseplate should not exceed 4.00 inches (100 mm).

foundation and soleplate or baseplate should not exceed 4.00 inches (100 mm).

Figure 2-3 is a cross-sectional view showing the location of a soleplate with chock blocks, Figure 2-3 is a cross-sectional view showing the location of a soleplate with chock blocks, cho

chock blocck block grk grout out and and finafinal grl grout.out. FiguFigure 2-4 is similre 2-4 is similar but shar but shows thows the locate location of aion of a baseplate with chock blocks, chock block grout and final grout.

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Chapter 2 Installation BASEPLATE BOXBEAM CHIPPED HALF OF ROUGH FOUNDATION 0.50 IN. (12 mm) + 1.5 D 4.00 IN. (100 mm) MAX. BETWEEN BOTTOM OF BASEPLATE AND FOUNDATION FINAL GROUT

(DO NOT POUR UNTIL FINAL ALIGNMENT ADJUSTMENTS

HAVE BEEN MADE) 1.00 IN. (25 mm) MIN.

BETWEEN CHOCK BLOCK AND TOP OF ROUGH

FOUNDATION _{2 x D}

MIN. D

9 x D MIN.

CHOCK BLOCK 2 x D RADIUS

PIPE SLEEVE 5 x D MIN. CONCRETE FOUNDATION 7 x D MIN. ANCHOR BOLT REINFORCING ROD (PLACE SUFFICIENTLY

BELOW FOUNDATION SURFACE TO PERMIT NECESSARY CHIPPING)

FIGURE 2-2

SUGGESTED ANCHOR BOLT ARRANGEMENT

EQUIPMENT SOLEPLATE SHIMS CHOCK BLOCK ROUGH FOUNDATION SURFACE FOUNDATION BOLT PIPE SLEEVE HOLD DOWN SCREW LEVELING SCREWS

CHOCK BLOCK GROUT

FIGURE 2-3

TYPICAL SOLEPLATE MOUNTING ARRANGEMENT

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Chapter 2 Installation

Foundation Preparation

When 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. After 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.

FOUNDATION BOLT BASEPLATE PAD SHIMS CHOCK BLOCK ROUGH FOUNDATION SURFACE LEVELING SCREWS PIPE SLEEVE CHOCK BLOCK GROUT HOLD DOWN SCREW FIGURE 2-4

TYPICAL BASEPLATE MOUNTING ARRANGEMENT

In order to obtain good bonding surfaces for the grout, all defective concrete, laitance, dirt, oil, wax, 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. Removal of approximately 0.5 inch (12 mm) of the top concrete surface should provide a strong, laitance-free surface for bonding and anchoring of the grout.

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CHOCK BLOCKS

In this manual, the term "chock block" is used to describe steel or grout blocks that serve to level and support the soleplate or baseplate prior to full grouting. The size of a steel chock block may vary, but the two sizes shown in Figure 2-5 will generally satisfy most all conditions. When steel chock blocks are furnished by Elliott Company, the blocks will conform to the information provided in Figure 2-5 or when desired this figure can be used to make chock blocks. To provide for ease of installation and leveling, four jackscrews are furnished in the chock block. A screw anchor in the center of the block is used to anchor the chock block securely until grouting in of the blocks.

Chock Block

1. Material carbon steel plate

2. Machine both top and bottom flat

3. Break all corners and chamfer all holes

1.0 in. 25 mm 0.5 in. 13 mm 8.00 in. OR 12.00 in. 203 mm OR 305 mm 4.00 in. 101 mm 0.75 in. 19 mm 4 - SET SCREWS 1/2" - 13 x 1-1/2" LONG OVAL POINT OR EQUIVALENT

SCREW ANCHOR SHIELD TO MATCH MACHINE SCREW

MACHINE SCREW 1/4" - 20 x 3" LONG

FLAT HEAD OR EQUIVALENT

FIGURE 2-5

TYPICAL CHOCK BLOCK

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Epoxy grout chock blocks can also be used in place of steel chock blocks. When using epoxy grout chock blocks, small forms should be positioned at each anchor bolt just 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. Forms should be anchored, coated with wax and sealed around the bottom. When pouring grout, forms should be completely filled. This will minimize need for shimming between chock and baseplate or soleplate.

Use 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 minimized. With chock blocks, the soleplate or baseplate can be easily shifted horizontally without disturbing established elevations.

For maximum effectiveness, two chock blocks should be positioned at each foundation anchor bolt as shown in Figure 2-6. Machines 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 Figure 2-6.

For 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.

CHOCK BLOCK APPROXIMATELY 4.00" (100 mm) ANCHOR BOLT BASEPLATE OR SOLEPLATE FIGURE 2-6

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Chapter 2 Installation Figure 2-7 shows a preferred arrangement when space is available, while Figure 2-8 illustrates an alternate arrangement that may be used. The arrangement used should provide maximum support and minimize deflection or warping to the soleplate or baseplate during installation work.

36.00 in. (900 mm)

12.00 in (300 mm)

CHOCK BLOCKS

FIGURE 2-7

PREFERRED LOCATION OF CHOCK BLOCKS

20.00 in (500 mm)

9.00 in (320 mm)

TWO CHOCK BLOCKS

FIGURE 2-8

ALTERNATE LOCATION OF CHOCK BLOCKS

Figure 2-9 illustrates a typical arrangement with chock blocks positioned on either side of the foundation anchor bolt. As 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. Surfaces must be free of oil, dirt and oxidation.

If the chock blocks have been coated with a catalyzed epoxy 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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Chapter 2 Installation Temporary plug Chock block Leveling screws

Foundation anchor bolt

Seal

Obtain this dimension from the certified outline drawing Chock block grout Chipped foundation surface Form _Sea l 1.00 in (25mm) min. Screw anchor

Hold down screw Reinforcement rods

FIGURE 2-9

TYPICAL CHOCK BLOCK ARRANGEMENT

The chock block surfaces should be sandblasted if coated with rust or some other surface coating. Sandblasting 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 required. A 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 epoxy 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 0.5-inch (12 mm) diameter by 1.00-inch (25 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 Figure 2-9. Level the individual blocks using the four setscrews provided. All blocks must be level and approximately 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 equipment much easier. On installations where overall length of the equipment is short, elevation of the chock blocks can best be set by use of a straight edge and precision level. On installations where the overall length of the equipment is large, use of a precision tilting level may be advantageous.

Regardless of the method used, shimming should be used between the chock blocks and soleplate or baseplate to correct any elevation variations required.

NOTE

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GROUTING

The procedure to be followed for grouting in of chock blocks, soleplates or baseplates is the same except for quantity of grout placed. Elliott recommends that the grout used be a good quality epoxy grout system from a reliable manufacturer of heavy machinery grouts. Epoxy grouts consist of an epoxy 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 expansion compatibility and absorb heat released by curing. With proper application, an epoxy grout should provide a permanent, reliable installation. Use of sand-cement grout or sand-sand-cement grout with various additives may also provide an adequate 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:

•Fill 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.

•Make the soleplate or baseplate more or less an integral part of the concrete

foundation.

As 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.

Use of epoxy grouts requires some installation procedures that differ from those used for sand-cement grouts. The procedure that follows provides a general guide for use with epoxy grout; but for more specific details, consult the grout supplier's bulletins or labels. This is particularly important in regard to safety precautions.

-WARNING-MOST EPOXY GROUT IS FLAMMABLE, TOXIC,

POISONOUS, AND CORROSIVE. THEREFORE,

MATERIAL SHOULD BE KEPT AWAY FROM OPEN FLAME, HIGH HEAT SOURCES OR SPARKS. IT SHOULD BE MIXED IN A WELL-VENTILATED AREA. WORKMAN SHOULD WEAR EYE PROTECTION AT ALL TIMES DURING MIXING OF GROUT AND HARDENER AND ALSO WHEN APPLYING MIXED GROUT. GLOVES AND PROTECTIVE CLOTHING SHOULD BE WORN AT ALL TIMES.

When grouting in baseplates, thermal expansion rates between sand-cement grout and steel or an aggregate filled epoxy grout and steel generally can become significant. Therefore expansion joints should be installed when stretches greater than approximately three feet are encountered. After the foundation has been dressed, the surface of the expansion joint should be sealed with silicone rubber.

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Timing and proper mixing are the secrets to successful grouting. Before mixing the components together, everything else should be ready - surfaces cleaned and dry, forms completed and sealed, pushing tools, rags, cleaning solvents available and adequate manpower.

Because of epoxy grout's 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.

Grout forms should be built of materials of adequate strength and should be securely anchored and shored to withstand the pressure of the grout under working conditions.

For epoxy grout, the forms must be waxed to keep them from becoming bonded to the grout. For chock block grouting, the anchor bolt sleeve should be sealed and the form height sufficient to provide a grout height approximately half way up the chock block. Because the epoxy 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, wax or cover all surfaces where grout may splash.

For 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. Normal grouting temperature should be between 40° and 90°F (4° and 32°C). Due to the accelerated rate of curing at high temperatures, shade the foundation from summer sunlight for at least 24 hours before and 48 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. Low temperatures make the grout stiff and hard to handle. For best results, ingredients should have an actual temperature of 70°F (21°C) or higher. Refer to instructions for the particular grout mix being used for allowable working time at various ambient temperatures.

Flow grade epoxy grouts can generally be handled with the same methods and tools that are used with flow grade sand-cement grouts. Mixing can be done in small mortar mixers. Use 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. Some contractors prefer to force the materials into place while others through years of experience, 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. Generally, 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 frequently for leaks. Leaks do not self-seal. If not stopped, leaks will cause voids.

Forms 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.

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SETTING THE EQUIPMENT ON FOUNDATION

Once the chock block grout has cured sufficiently to withstand static load, installation of the equipment on the foundation may proceed.

If the soleplates or baseplates have been coated with a catalyzed 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. While sandblasting is best, a disk grinder or some other mechanical method may be used. The cleaned surface should be coated with epoxy 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 approximately 0.125 inch (3.0 mm) thick shim pack having an assortment of shim thicknesses on each chock block. Shim pack should be full size, clean, smooth and rust free. This will provide a means of lowering any portion of the machine or baseplate that requires adjustment during leveling.

Set the baseplate or soleplates on the shimmed chock blocks and tighten down all the foundation bolts. Check for level and make necessary adjustments by adding or removing shims. Normally, it is best to start at the middle and work towards the ends. All soleplate or baseplate leveling should be done using the machined support foot surfaces.

Before mounting the equipment on the soleplates or baseplate, place a 0.125 inch (3.0 mm) thick stainless steel shim pack having an assortment of shim thicknesses on each machine support. A stainless steel shim pack is generally preferred. Full size shims are preferred when setting machinery or when making elevation changes during alignment.

NOTE

Shims 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 manufacturer's literature.

After machinery has been placed on soleplates or baseplate, install and tighten hold down bolts. Check for a "soft foot" 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 exceeds approximately 0.002 inch (0.05 mm) at any foot, shim changes to eliminate the "soft foot" should be made before proceeding.

With soleplates or baseplate set and leveled, machinery mounted and rough aligned, remove all temporary shipping braces.

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NOTE

The journal 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 jobsite.

Then clean the bearings and bearing housings. All clearances should then be checked. Refer to clearance table and drawings. Thoroughly oil all bearings and reassemble bearing housings. Refer to appropriate sections in Chapter 4. The machinery is now ready to be "cold aligned". The "cold alignment" method to use is dependent on the distance between the coupling hubs. For 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 maximum flexibility and minimum confusion, the cold alignment should be completed with all piping disconnected from the machinery. Axial coupling separation indicated on outline drawing must be maintained during cold

alignment.

COUPLING INSTALLATION

A flexible coupling is used between the turbine and the driven equipment. 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 manufacturer's instructions for specific details pertaining to the coupling.

Installing A Straight Bore Coupling

1. Clean and de-burr the coupling hub and shaft end.

2. Place the coupling sleeve (if applicable) on the equipment shaft with the bolting flange positioned toward the shaft end.

3. Check the key fit in the coupling hub and the shaft keyways. The key must have a side clearance of .001 inch to .003 inch (0.03 mm to 0.07 mm) between the key and coupling keyway. The fit between the key and shaft keyway must be .000 inch to .002-inch (0.0 mm to 0.05 mm) interference. The key must be fitted to provide .005 inch to .013-inch (0.13 mm to 0.33 mm) top clearance in the coupling keyway.

4. After the key has been fitted to provide the proper clearances, insert it in the shaft keyway.

5. Apply a light coat of suitable anti-galling lubricant on the mounting surface of the shaft.

6. Heat the coupling hub in oil or in an oven to approximately 300°F (150°C). The coupling should not be heated with an open flame or be allowed to exceed 600°F (315°C).

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-WARNING-HEAT-RESISTANT GLOVES SHOULD BE WORN WHEN HANDLING THE HEATED COUPLING.

Chapter 2 Installation BOLTING FLANGE SLEEVE KEYWAY LOCKNUT THREADED SHAFTEND HUB BOLTING FLANGE TAPERED BORE HUB KEYWAY SLEEVE STRAIGHT BORE FIGURE 2-10

FLEXIBLE COUPLINGS/TAPERED AND STRAIGHT BORE

7. Place the coupling hub on the shaft and position it so that the hub face is flush with the shaft end.

CAUTION

Do not drive the coupling on or off the shaft with a hammer. The force of the hammer will result in internal equipment damage.

Installing a Tapered Bore Coupling

1. Clean and de-burr the coupling hub and shaft end. 2. Apply a light coating of Prussian blue to the rotor shaft. 3. Place the coupling hub on the shaft.

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CAUTION

Hand lapping the coupling hub on the rotor shaft may form a ridge that will affect the coupling contact when pulled up. Correct the contact by lightly stoning any ridges, burrs or high spots.

5. Check the key fit in the coupling hub and the shaft keyways. The key must have a side clearance of .001 inch to .003 inch (0.03 mm to 0.07 mm) between the key and coupling keyway. The fit between the key and shaft keyway must be .000 inch to .002 inch (0.0 mm to 0.05 mm) interference. The key must be fitted to provide .005 inch to .013 inch (0.13 mm to 0.33 mm) top clearance in the coupling keyway.

6. After 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.

7. Place the coupling sleeve (if applicable) on the shaft. Position the bolting flange toward the shaft end.

8. Fit the coupling hub on the shaft (at room temperature).

9. Take a reference dimension from the hub to a fixed part on the machine case or a shaft shoulder. Make certain the shaft is seated against either of the thrust bearings. 10. Put a small amount of thread lubricant on the drive nut.

11. Tighten the shaft locknut to obtain an interference fit between the coupling and shaft. See the Turbine Outline drawing in Chapter 10 for specifications on coupling pull up. 12. Recheck referenced dimension (step 9) and record for future use.

13. Lock drive nut.

CAUTION

Do not drive the coupling on or off the shaft with a hammer. The force of the hammer will result in internal equipment damage.

SHAFT ALIGNMENT

The turbine and the driven equipment are normally connected by flexible couplings. Flexible 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. For high-speed, high-performance applications such as between compressors and turbines, the coupling is usually the gear, disk or diafram type.

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Chapter 2 Installation All flexible couplings have limits within operation without failure or undue wear. Even

when operating within the design limits, these couplings generate some resistance to flexing. The force usually increases as the misalignment increases, thereby increasing or decreasing bearing load fluctuations as the shaft rotates. Furthermore, operating with collinear shafts at normal operating conditions minimizes tooth-sliding velocity or diafram flexure while providing the maximum reserve for movement in any direction should it be required.

Experience indicates that excessive vibration of compressors and their drivers is often caused by improper shaft alignment. Frequently, high or unusual bearing and seal wear can be traced to improper shaft alignment. In extreme cases, poor alignment can precipitate a coupling, bearing or shaft failure. For smooth operation and long trouble-free runs, good shaft alignment procedures are essential and cannot be over-emphasized.

An understanding of good shaft alignment techniques must begin with a few basic definitions.

"Cold or ambient alignment" is the procedure that involves positioning the frames or casings of compressors and other rotating machines while at standstill and ambient conditions. The "cold shaft alignment" 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 stabilized 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 expansion or contraction, multiply original length (generally distance from machine shaft centerline to top of baseplate or soleplate) times expansion coefficient (0.0000067 for steel) times temperature change in degrees Fahrenheit. (Expansion coefficient is 0.000012 for steel and temperature change in degrees Celsius.)

∆ _{L (change in length) = L (length) x 0.0000067 x} ∆ _{T (change in temp.}

°F)

∆ _{L (change in length) = L (length) x 0.000012 x} ∆ _{T (change in temp. °C)}

NOTE: ∆ _{L and L in same units.}

Normally, the vertical movement is minimized by use of a bolted joint where the support foot attaches to the casing. Therefore, the average temperature of the support foot may be considerably lower than the average of adjacent casing temperature to foot temperature. A good "hot shaft alignment" will either verify or suggest alternate growth figures to use.

"Hot shaft alignment" 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. Knowing the "cold shaft alignment" 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.

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A. COLINEAR ALIGNMENT

B. ANGULAR MISALIGNMENT

C. PARALLEL MISALIGNMENT

FIGURE 2-11

TYPES OF SHAFT MISALIGNMENT

A. Collinear alignment - In Figure 2-11 part A; the two machine shaft ends are considered to be "collinear aligned" when the two shaft ends rotate about the same straight line (no misalignment). All 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. Each coupling must be analyzed individually.

B. Angular or Face displacement - In Figure 2-11 part B; indicates the amount of angular misalignment at a shaft end. Normally, angular displacement is measured in mils of offset per inch (in mm of offset per meter) of coupling diameter or axial separation.

C. Parallel offset - In Figure 2-11 part C; indicates the amount of parallel misalignment between the centerlines of two adjacent shaft ends. Figure 2-11 part C, shows two shafts with only parallel offset.

"Axial separation". When the coupling connecting two shaft ends is a gear type, an axial separation of plus or minus .0625 inch (1.60 mm) tolerance is usually acceptable. When the coupling connecting the two shaft ends is a disk or diafram type, an axial separation as shown in Figure 2-11 of less than plus or minus .015 inch (0.40 mm) tolerance is usually required. Check coupling drawing and coupling instructions for precise limits.

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Chapter 2 Installation When aligning disk or diafram type couplings, the dimension information shown on the coupling drawings must be adhered too. Measurements should be taken with the equipment in normal thrust position (turbine rotor toward exhaust). Usually, the critical dimension is a coupling flange face dimension as shown in Figure 2-13. For further information on axial separation, refer to coupling vendor drawing and installation procedure. AXIAL SEPARATION c_L c_L FIGURE 2-12 AXIAL SEPARATION GUARDS DIAFRAMS CENTER TUBE

COUPLING FLANGE FACE TO FLANGE FACE

FIGURE 2-13

AXIAL 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 "Rim and Face Method" is the preferred procedure when the distance between the two adjacent 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 "Hub and Face Method" or "Two Indicator Method."

The "Reverse Indicator Method" is the preferred procedure when the distance between the adjacent shaft ends is greater than one-half the coupling diameter.

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Shaft Alignment Map Instructions

Preparation and use of a "Shaft alignment map" for each installation is recommended. A typical shaft alignment map is shown in Figure 2-14. Use of a shaft alignment map provides a convenient form on which to record indicator readings and calculate equipment moves. Maintaining this information for comparison during maintenance inspections or for reference, should problems develop, can provide valuable diagnostic information. A blank form for your use is provided in Figure 2-17.

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 horizontal or abscissa coordinate should be scaled using some convenient scale such as 1.00 or 2.00 inches per division (25 or 50 millimeters per division). All support feet and coupling faces should be located. When more than two machines are involved, a larger map or graph may be advantageous. The vertical or ordinate coordinate should be an expanded scale such as 1 mil (0.02 millimeters) per division in order to clearly identify misalignment. Mark North compass direction in plan view and corresponding compass directions in indicator reading circles so no confusion develops during measurements. When making shaft alignment corrections, it is usually advantageous to hold one machine in a fixed position and align other machine or machines to the fixed machine. Some guidelines to determine the best machine to hold stationary are as follows.

1. If the equipment consists of turbine driven compressor, it is generally preferred to level turbine and move compressor into desired cold alignment.

2. If a gear is present, level and square the gear to the foundation or baseplate and move the other machinery into alignment with the gear.

3. If the equipment string consists of three or more pieces of equipment, level the machine nearest the center, square 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 expansion or contraction change for each support location on shaft alignment map. Connect points plotted for each machine with a dashed line.

Use dashed line for desired "cold alignment setting". Read off differences between the two dashed lines in vertical plane and record desired readings in circles so marked. Plan or horizontal 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 expand toward bull gear shaft thus requiring alignment allowances in plan view at bull gear or low speed shaft end.

NOTE

(For All Rim Measurements)

Actual measurement is 1/2 TIR (Total Indicator Reading); therefore, value of measurement shown on indicator reading circle should be twice the distance indicated on plot.

Offset value is plus (+) if projected centerline of machine that indicator is attached to is above coupling mark of the machine that indicator is riding on.

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SHAFT ALIGNMENT MAP

USER ABC Company SERVICE Propane Refrigeration EQUIP. NO. C508xxx /

C5037xx DATE

10 / 95

COUPLING TYPE MP 153 LUBE Grease AMBIENT TEMP. 60

F NAME

NOTES: ALIGNMENT METHOD

1) Show North in Plan view of sketch.

Reverse Indicator ALIGNMENT BAR SAG Negligible MILS/MM

2) Mark compass direction in

circles. LEFT RIGHT LEFT RIGHT

3) If offset value is plus, projected center line of machine that the indicator was attached to will be above the coupling

mark of the opposite machine.

-12.5 0 COMP W TO E -12.5 +10 0 TURB W TO E +10

DESIRED COLD READING

. -14 0 C/T ACT

4) If offset value is minus, projected center line of machine that the indicator was attached to will be below the coupling mark of the opposite machine.

-10 TURB -25 0 COMP W TO E -4 TURB COMP +20 0 TURB +7 W TO E +9 COMP Vo = Bot - Top = -7 2 -4 -10 Ho = Right - Left = +3 2

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SHAFT ALIGNMENT MAP

USER ABC Company SERVICE Propane Refrigeration EQUIP. NO. C508xxx /

C5037xx DATE

10 / 95

COUPLING TYPE MP 153 LUBE Grease AMBIENT TEMP. 60

F NAME

NOTES: ALIGNMENT METHOD

Reverse Indicator ALIGNMENT BAR SAG Negligible MILS/MM

2) Mark compass direction in

circles. LEFT RIGHT LEFT RIGHT

3) If offset value is plus, projected center line of machine that the indicator was attached to will be above the coupling

mark of the opposite machine.

-12.5 0 COMP W TO E -12.5 +10 0 TURB W TO E +10

DESIRED COLD READING

. -14 0 C/T ACT

-10 TURB -25 0 COMP W TO E -4 TURB -14 COMP +20 0 TURB +7 W TO E +9 COMP +16 Vo = Bot - Top = -7 2 -4 -10 Ho = Right - Left = +3 2

ACTUAL COLD READING

STEAM END FOOT _{EXHAUST FOOT} _{DISCHARGE FOOT} _{SUCTION FOOT}

PLAN

SEPG5

STEAM TURBINE COUPLING

MOVE 6 MIL WEST

38M4

DESIRED OPERATING LINE

MOVE 22 MIL WEST W N

E c_L c_L c_L COMPRESSOR _c L VERTICAL MOVE 3 MIL UP

DESIRED OPERATING LINE

MOVE 17 MIL UP 48 " 14" 14" PICK A CONVE NIENT SCALE SCALE 18" 2 inches 5 7 "

PER DIVISION SUGGEST 1" OR 2" PER DIVISION FIGURE 2-14

SHAFT ALIGNMENT MAP EX

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18"

2 inches

5 7

"

PER DIVISION SUGGEST 1" OR 2" PER DIVISION FIGURE 2-14

SHAFT ALIGNMENT MAP EX

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Sometimes the work descriptions such as used on an alignment map can be confusing. Figure 2-15 is a pictorial view of Note 3 on alignment map. It reads:

"If offset value is plus, projected centerline of machine that the indicator was attached to will be above the coupling mark of the opposite machine."

FIGURE 2-15

PICTORIAL OF NOTE 3 ON ALIGNMENT MAP Figure 2-16 is a pictorial view of Note 4 on alignment map. It reads:

"If offset value is minus, projected centerline of machine that the indicator was attached to will be below the coupling mark of the opposite machine."

FIGURE 2-16

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2-23

FIGURE 2-17

SHAFT ALIGNMENT MAP

USER SERVICE EQUIP.NO. DATE

COUPLING TYPE LUBE AMBIENT TEMP. NAME

NOTES: ALIGNMENTMETHOD ALIGNMENTBAR SAG MILS/MM

2) Mark compass direction in circles. 3) If offset value is plus, projected

center line of machine that the indicator was

LEFT RIGHT LEFT RIGHT

V o

=

Bot -Top =

attached to will be above the coupling _TO _TO mark of the opposite machine.

TO TO H o = 2 Right - Left = 2

PLAN _{DESIRED OPERATING LINE}

LEFT

VERTICAL

RIGHT

PICK ACONVENIENTSCALE SCALE PERDIVISION SUGGEST 1" OR 2" PER DIVISION

Rim and Face Method of Alignment

1. Use Rim and Face Method when distance between the two adjacent shaft ends is less than one-half the coupling diameter.

2. Lubricate bearings before rotating shafts.

3. Mark both coupling hubs at four locations 90° apart so that their position is evident at

all times during alignment work.

4. All piping strain must be removed from machine. For initial alignment work during installation, all piping should be left unconnected from machinery. After 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. Should movement exceed 2 mils (0.05 mm), piping strain is considered excessive. Reason for strain should be investigated and condition corrected before proceeding with alignment.

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Rim and Face Method of Alignment

1. Use Rim and Face Method when distance between the two adjacent shaft ends is less than one-half the coupling diameter.

2. Lubricate bearings before rotating shafts.

3. Mark both coupling hubs at four locations 90° apart so that their position is evident at

all times during alignment work.

4. All piping strain must be removed from machine. For initial alignment work during installation, all piping should be left unconnected from machinery. After 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. Should movement exceed 2 mils (0.05 mm), piping strain is considered excessive. Reason for strain should be investigated and condition corrected before proceeding with alignment.

5. Shift rotors to running position and determine that coupling spacer distance is as specified on coupling drawing.

6. Mount dial indicator so indicator button rides near center of rotation. Rotate shaft against which button rests to measure axial wobble. If unable to maintain axial wobble to less than 0.001 inch (.025 mm) on either shaft, use of two face indicators 180° apart or multiple measurements is recommended.

NOTE

Axial shaft movement during face reading measurements can cause false readings. Two dial indicators mounted 180° apart should be used when axial float cannot be easily controlled. When using this setup, set dial indicators at 0° and 180° position and zero indicators. Dial indicator at 0° should be tagged prime dial indicator. At each interval, subtract second dial indicator's reading from prime dial indicator reading. Divide this result by two and record result in prime's location. Be sure to retain proper plus or minus signs.

7. Measure angular misalignment with inside micrometer, feeler gauges or dial indicator such as shown in Figure 2-18. This is best accomplished by marking measurement point at 0° and recording readings or change in readings between 0° point and points at 90°, 180°, 270° and 360°.

On return to 0° position, indicator should return to zero or repeat measurement. Take several sets of readings, to be sure no mistake has been made or something has moved that shouldn't have. When taking measurements, rotate both shafts equal amounts to cancel out eccentricity and surface imperfections.

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DIAL INDICATOR WITH HOLE ATTACHMENT

0

INSIDE MICROMETER MEASUREMENT POINT

270 90

FEELERS

GUAGE BLOCK OR BAR STOCK 180

FIGURE 2-18

MEASURING ANGULAR MISALIGNMENT

8. Readings observed in step 7, above should be recorded on alignment map. As face readings provide the slope of shaft on which dial indicator is mounted relative to coupling face of the opposite machine (See Figure 2-19), use an indicator recording circle for an axial location equal to the "face reading measurement diameter" away from the hub on which the indicator button is riding.

A

B

ANGULAR DISPLACEMENT

ANGULAR DISPLACEMENT DISTANCE EQUAL TO

MEASUREMENT DIAMETER

FIGURE 2-19

ANGULAR DISPLACEMENT

9. To measure Parallel Offset, attach the dial indicator to bracket mounted on machine that will be moved. Set the indicator button to contact periphery of opposite coupling hub at top approximately 0.25 inch (6 mm) from edge (as shown in Figure 2-20). Set the indicator to zero at top, rotate both shafts together and record dial readings on alignment map for 90°, 180°, 270°. On return to top position, the indicator should return to zero. Repeat this procedure several times to be sure no mistake has been made or something moved. These four readings will be TIR (Total Indicator Readings), and actual parallel offset is one-half of indicator (TIR) readings.

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Chapter 2 Installation o o o o DIAL INDICATOR FEELER GAGE

FIGURE 2-20

MEASURING PARALLEL OFFSET

10. Readings observed in Step 9 should be recorded on alignment map in indicator recording circle corresponding to same axial location as dial indicator measuring location (fixed machines coupling).

11. Vertical offset (Vo) and horizontal offset (Ho) for projected centerline of machine to be moved at fixed machine's coupling face can be determined by using alignment map Note 3 or 4.

12. Slope of machine's shaft to be moved relative to fixed machine is determined by (a) drawing a line thorough point determined in Step 11 and parallel to fixed machine's centerline, (b) applying alignment map Note 3 of 4 to face readings at the axial location previously determined in Step 8 above.

13. In each view, draw a straight line through points located in Step 11 and 12 with line extended to intersect both supports of machine to be moved. Read off distance between line just 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.

14. Make adjustments indicated in Step 13.

15. Repeat Steps 7 through 14 to verify adjustments made in Step 14 correct.

16. Unless otherwise noted, a final hot alignment should provide for an angular displacement between machine coupling hub centerline and coupling spacer centerline of approximately 0.25 mil per inch (0.25 mm per m) at the coupling gear teeth or flex elements. This angular displacement is not a limit, but a suggested alignment goal. Refer to coupling literature for more information on maximum

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Reverse Indicator Method of Shaft Alignment

1. Use the reverse indicator method of shaft alignment when distance between two adjacent shaft ends is greater than one half the coupling diameter.

Note

For 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. Key factor is to spread two indicators as far apart as practical with negligible bracket sag. (As 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 adjoining shaft and vice versa as shown in Figure 2-21.

READ HERE SHAFT "A"

SHAFT "B" FIRST SET OF READINGS

READ HERE

SHAFT "A"

SHAFT "B" SECOND SET OF READINGS

FIGURE 2-21

REVERSE INDICATOR READINGS

3. Lubricate bearings before rotating shaft.

4. Mark both the coupling hubs at four locations 90° apart so that their position can easily be seen at all times during the alignment work.