SOLAR TURBINES CUSTOMER SERVICES TECHNICAL TRAINING PACKAGE LEVELING AND ALIGNMENT
Course # 4020
Administration
Course Schedule Emergency Exits and Safety Briefing Personal Introductions Complete Pre-Test
2
Course Objectives
1. Describe the use of precision measuring equipment during package leveling and alignment checks 2. Have the necessary knowledge and skills to complete the leveling of a Solar package as part of the package commissioning activities 3. Describe the basic principles of machinery alignment 4. Locate and be able to apply sources of alignment information found on a Solar project 5. Complete practical exercises on test-rigs (shaft alignment simulators) to gain familiarity with alignment procedures and equipment 6. Complete practical exercises on actual turbine packages to align engines and driven equipment to 3 within Solar specifications
List of Lessons and Appendices
LESSON 1 Precision Measuring Equipment LESSON 2 Package Leveling LESSON 3 Principles Of Machinery Alignment LESSON 4 Solar Alignment Information LESSON 5 Solar Alignment Techniques LESSON 6 Simulator Exercises LESSON 7 Package Alignment Exercises APPENDIX A Glossary of Terms APPENDIX B Alignment Specifications and Readings for Lesson 6 Exercises APPENDIX C Alignment Specifications and Readings for Lesson 7 Exercises
Safety
Safety is our first consideration Before commencing any work in the lab, a Work Hazard Assessment and Task Risk Assessment will be completed
LESSON 1
Precision Measuring Equipment
Objectives
1. Describe the basic principles of a Vernier Scale 2. Describe general procedures for taking measurements using:
Vernier Calipers External Micrometers Internal Micrometers Dial Indicators Go / No-Go Gages Machinist's Level Feeler Gages
3. Correctly measure the dimensions of selected test pieces
7
INTRODUCTION TO THE BASIC TOOLS
Vernier Calipers
Can be used to measure:
Shim thicknesses Distance between shafts Depth of blind holes
Accurate to 0.001 Range of sizes available
9
External Micrometer
Can be used to measure:
Shim thicknesses
Accurate to 0.001 0-1 Larger sizes available
10
Internal Micrometer
Can be used to measure:
Internal dimensions from around 2 to a maximum dependent of the extension rods installed
Accurate to 0.001
11
Dial Indicators
Can be used to measure:
Alignment readings (rim Alignment readings (rim and face) and face) Machinery movement using Machinery movement using jacking bolts jacking bolts
Spring loaded plunger Dial increments in 0.001 Different ranges available
12
Go / No-Go Gage No-Go
Can be used to measure:
Small gaps between Small gaps between surfaces when other tools surfaces when other tools will not fit will not fit
Manufactured from steel or other metal Different ends are machined to a specific sizes that correspond to the gap tolerance
One side should fit One side should fit Other side should not fit Other side should not fit
13
Machinists Level
Precision spirit level Mounted on machined surfaces to check package level
14
Feeler Gages
Thin strips of steel of a known thickness Normally 0.001 increments Can be used with a machinists level during package levelling checks
15
HOW TO USE THE TOOLS
16
Vernier Caliper Scales
Vernier scales used in calipers and micrometers Allows reading of fractions of small divisions Principle involves two scales
Main Scale Vernier Scale
17
Vernier Scale Divisions
Vernier Scale (top) has same number of divisions as Main Scale (bottom) However it takes up less length Mathematical principle is not important we will concentrate on how to read the values
18
Vernier Caliper
Vernier calipers can measure internal or external dimensions Note the:
Main Scale Vernier Scale Index Mark
Available in English or Metric
We will use English units
19
Example of Reading a Vernier Caliper
Main Scale divided into 0.1 increments Further 0.025 sub-divisions Index Mark alone will indicate measured dimension to within 0.025
20
Example of Reading a Vernier Caliper
Vernier Scale gives greater accuracy Subdivided into 25 increments Vernier Scale mark than lines up exactly with ANY Main Scale mark should be added to the previous reading
21
Example of Reading a Vernier Caliper
Step 1 Index mark just past 0.125 Step 2 Vernier Scale mark 10 lines up exactly Step 3 Total reading = 0.135 Accuracy to 0.001
22
Other Vernier Caliper Features
Depth Rod can be used for blind holes Clamping Screw can be locked to prevent the reading being affected Fine Adjust (with its own clamp screw) allows greater feel Zero check prior to use
Vernier Scale position may be adjusted
23
External Micrometer
Micrometers operates on same principle as Vernier calipers, except using screw-thread pitch Different types available:
External Internal Depth
24
External Micrometer
Ratchet stop used to provide greater feel Locking lever to lock spindle in position Zero check prior to use
Tools provided to adjust position of outer sleeve
25
External Micrometer
Example is 0 1 External Micrometer Accurate to 0.001 Note:
Inner Sleeve with Main Scale 0.1 divisions 0.025 subdivisions
Outer Sleeve with Vernier Scale
25 x 0.001 divisions
26
Example of Reading a Vernier Micrometer
Step 1 end of outer sleeve aligned with 0.225 mark Step 2 Vernier Scale mark 17 lined up with centerline Step 3 Total reading = 0.242
27
Internal Micrometer Kit
Range dependent on extension rods Minimum length = 2 plus extension rod Accurate to 0.001
28
Internal Micrometer Features
Inner Sleeve
Main Scale 0.1 divisions 0.025 subdivisions
Zero check prior to use
Ensure when end of outer sleeve lines up with zero on Main Scale, the Vernier Scale zero is also lined up with the centerline Tools provided for 29 adjustment
Outer Sleeve
Vernier Scale 25 x 0.001 divisions
Example of Internal Micrometer Reading
Minimum length = 4.000 Position of inner sleeve = 0.325 Vernier Scale mark aligned = 0.007 Total Reading = 4.332
30
Internal Micrometer with Handle Attached
Used when inserting into deep recesses
31
Dial Indicator
Metric or English 0.001 graduations on main scale One revolution = 0.1 Number of revolutions up to 5 Total range of this model = 0.5
32
Dial Indicator Ready for Use
Depress plunger to around 50% when setting up Then zero by rotating dial Note position of small needle (2) Depressing plunger = Positive / Clockwise Extending plunger = Negative / CCW
33
Example of Dial Indicator Reading
Large needle = 22 Small needle = past 3 (must have moved one complete revolution) Direction = CW (positive) Total reading = +0.122
34
Example of Negative Dial Indicator Reading
Large needle = 45 Small needle = less than 2 Direction = CCW (negative) Total reading = -0.055
35
Gap to be Tested
Unable to use internal micrometer with small gaps Can use Go/No Go Gage
36
Go / No-Go Gage No-Go
Minimum gap = 1.490 Maximum gap = 1.510 If 1.490 gage fits, and 1.511 gage does not fit, then gap is within tolerance
37
Machinists Level
Simple method to level a package Precision spirit level placed on package machined surface Graduations represent deviation from level (0.001 increments) Example
If bubble is at 0.002 mark Level = 6 long Deviation = 0.004 per foot
38
Using Feeler Gages
Alternative method is to use feeler gages under one end, until level
39
Machinists Level
Either method - then extrapolate distance to foundation pads to calculate shim requirements Example:
Deviation = 0.004 per foot Distance to low foot = 10 feet Insert 0.040 shim under that foot
40
QUESTIONS ON PRECISION MEASURING EQUIPMENT?
Complete Student Exercise
41
Student Exercise
1. List five items of measuring equipment commonly used during package leveling and machinery alignment i. Vernier Calipers ii. External Micrometers iii. Internal Micrometers iv. Dial Indicators v. Go / No-Go Gages vi. Machinists Level vii. Feeler Gages >
42
Student Exercise
2. Depressing the plunger on a dial indicator will give a positive reading
TRUE / FALSE
43
Student Exercise
Questions 3 5 Instructor will pass round various objects to be measured Student will write the measurement in the table Instructor will confirm the measurement
44
Objectives - Recap
1. Describe the basic principles of a Vernier Scale 2. Describe general procedures for taking measurements using:
Vernier Calipers External Micrometers Internal Micrometers Dial Indicators Go / No-Go Gages Machinist's Level Feeler Gages
3. Correctly measure the dimensions of selected test pieces
45
LESSON 2
Package Leveling
46
Objectives
1. Describe the requirements for package leveling during installation and commissioning of a Solar package 2. List the available sources of information related to package leveling 3. Briefly describe the methods used to level a Solar package 4. Complete a practical exercise to check a Solar skid for level
47
Purpose of Package Leveling
Ensures that: Machinery shafts are parallel
Prevents load of thrust bearings
Machinery shafts are square in the bearings
Prevents sideways loading
Fluid flow is not adversely affected Vertical height of package is also set, to allow external connections to be made
48
Available Information
Mechanical Installation Drawings
Project specific information
Engineering Specification 9-414
Generic information
The following now be given as handouts
Drawing 72341-149606 ES 9-414
49
Mechanical Installation Drawings
Reference 72341-149606
Sheet 1
Look at examples of notes Torque requirements Soft foot check, etc.
50
Skid Foundation Detail
Reference 72341149606
Sheet 6
Base mounting pad dimensions Tie-down bolt details
51
Extract From Package Dimensions
Reference 72341-149606
Sheet 6
Dimensions useful when calculating package shim corrections Dimensions useful when calculating package shim corrections during leveling during leveling
Sheet 11
General notes on leveling General notes on leveling
52
Engineering Specification 9-414 9-414
Covers multiple package configurations
Section 2.0B
Definitions of terminology Identification of datum points
53
Engineering Specification 9-414 9-414 Section 3.2A
Basic leveling procedure for one type of package configuration Read through this section in ES 9-414, and then the summary in the SWB
Section 4.0
Basic procedure for shimming and torquing Read through this section in ES 9-414, and then the summary in the SWB
QUESTIONS?
54
Leveling Methods
Machined surfaces for levels
Preparation
Equipment mounting pads to be level to within 0.005 per foot
If a 6 inch level is used, it should be level to 0.0025 Use level graduations or feeler gages
Extrapolation of feeler gage sizes can help determine shim corrections see example in SWB
55
Objectives - Recap
1. Describe the requirements for package leveling during installation and commissioning of a Solar package 2. List the available sources of information related to package leveling 3. Briefly describe the methods used to level a Solar package 4. Complete a practical exercise to check a Solar skid for level
56
QUESTIONS ON PACKAGE LEVELING?
Complete Student Exercise
57
Student Exercise
Complete the graphic in the SWB with dimensions taken from the C40 skid (or other skid if this course is not in Mabank) Prepare the mounting pad surfaces for the level Calculate the package deviation from level Specify shimming corrections in the table in the SWB
58
(Calculations) AFT/FWD
59
(Shim Correction Diagram) AFT/FWD
60
LESSON 3
Principles of Machinery Alignment
61
Objectives
1. Define the term alignment 2. Identify possible machinery problems that may be caused by poor alignment 3. List and describe the principles of different methods used in machinery alignment 4. Discuss negative influences that may affect final alignment accuracy
62
Basic Alignment Terms
63
Basic Alignment Terms When two machines are coupled together, the shaft center-lines should be concentric when the machinery is operating at normal temperatures Why? Abnormal loading
Reduced performance High vibration Premature failure
64
Parallel Misalignment
Parallel Misalignment
Shafts centerlines are not co-linear However shafts are parallel
65
Angular Misalignment
Angular Misalignment
Shaft center-lines intersect at an angle
66
Misalignment
In practice:
A combination of both normally exists in the COLD condition (cold offset) At operating temperatures the shafts become aligned (thermal growth)
67
Illustration of Thermal Growth
Different parts of the machinery experience different temperatures Hot stations will thermally grow more
Power Turbine (Station 2) Power Turbine (Station 2) Discharge end of compressor (Station 6) Discharge end of compressor (Station 6)
Calculated thermal growth produces Cold Alignment specifications Hot alignment techniques are also available will be discussed68 later
Illustration of DBSE
Measuring points vary but commonly called Distance Between Shaft Ends (DBSE)
Ensures adequate gap to install coupling Prevents axial loading as machinery heats up
69
Problems Caused by Misalignment
What problems can be caused by poor alignment? Limitation on operating range Higher operational costs Higher maintenance costs Seal failure Bearing failure Coupling failure >
70
Typical Vibration Spectra Due to Misalignment
High 1x RPM and 2x RPM components Can also be high axial vibration Can cause high bearing temps due to loading This can result in reduced efficiency or failure
71
Methods of Performing Shaft Alignment Checks
72
Typical Rim-and-Face Rim-and-Face Setup
Rim and Face
Uses two dial indicators Mounted on one machine shaft Target is shaft, coupling, or bearing housing on other machine
73
Typical Rim-and-Face Rim-and-Face Setup
Rim and Face
360 degree sweep made Readings taken at four clock positions Interconnect shaft should be disconnected
74
Typical Rim-and-Face Rim-and-Face Setup
Rim and Face
Face reading = angular misalignment Rim or Bore reading = parallel misalignment
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Dial Indicator Clock Positions
12 oclock =
FT = Face Top BT = Bore Top
6 oclock =
FB = Face Bottom BB = Bore Bottom
etc.
76
TIR
TIR = Total Indicator Reading
The actual reading on the dial gage
TIR = 2 x Actual Offset Solar specifications are normally TIR
77
TIR
Example:
Actual BB = 0.060 (TIR) Desired BB = 0.040 Shim Correction = 0.010 (1/2 the difference)
78
Rim-and-Face Rim-and-Face Advantages / Disadvantages
Advantages
Simple Easy access
Disadvantages
Susceptible to Tool Sag and inconsistent readings Face reading susceptible to axial motion of shafts
Standard method used by Solar
79
Reverse Alignment Tooling Setup
Also uses dial gages One mounted on each shaft Both measure bore Shafts rotated together Readings taken at four clock positions
80
Reverse Dial Alignment Graph
Readings plotted on graph paper Machinery corrections are read from the scale on the graph paper
81
Reverse Alignment Advantages / Disadvantages
Advantages
No Face readings No Face readings necessary necessary
Not subject to axial shaft Not subject to axial shaft motion motion
Coupling can remain Coupling can remain installed installed
Disadvantages
Same problems with dial Same problems with dial gages as rim and face gages as rim and face method method Graph can be difficult to use Graph can be difficult to use
Not normally used by Solar
82
Typical Laser Alignment Setup
Similar to reverse dial alignment, but uses laser Coupling remains installed
83
Sample Laser Alignment Readout
Graph computed by the instrument Shows correction to be made Can be monitored live as the corrections are made
84
Laser Alignment Advantages / Disadvantages
Advantages
Quick Accurate Limited Tool Sag
Disadvantages
Cost Cannot be used on all applications due to space
Laser specifications are now included on Solar drawings
85
Example of Essinger Bar Installation Used for Hot Alignment checks Directly measure various data points on the package Not very common
86
Abnormal Conditions That May Affect Alignment
87
Tool Sag Check Setup
Tool Sag caused by the weight of the tooling Causes erroneous readings Can be measured and corrected by biasing the readings
88
Tool Sag Check Setup
Basic Procedure:
Install extension rod Install alignment tooling with dial gage targeting the shaft of the same machine Zero dial gage at 12 oclock Rotate shaft 180 degrees Record reading should always be a negative value Subtract this value from all future BB readings Subtract this value from all future BR and BL readings If Tool Sag exceeds 0.010 rectify tool setup
89
Tool Sag Example
Assuming tool sag of 0.004 Measured BB = -0.020 Corrected BB = -0.020 (-0.004) = -0.016
90
Other Causes of Poor Alignment
Target Surfaces
Clean and even True indication of the shaft position Use bearing housing, not movable end cap
Bent shaft
Only a problem if this is the target surface Should be evident during a runout check Will not affect readings if it is the sight machine shaft (where the tools are mounted) The tools will be at the same relative position as the bent shaft rotates
If using coupling hub as target
Center the hub Install dial gage on magnetic base, with the hub as the target Runout <0.001
91
Angular and Parallel Soft Foot
Soft foot causes problems in completing alignment checks
As bolts are tightened, the machines can walk
Also causes machinery problems when operating
Stress on foundations and casings
Angular soft foot
May need tapered or stepped shims
Parallel soft foot
Need more shims under one foot
92
Angular and Parallel Soft Foot
Carry out soft foot check prior to starting alignment checks Basic Procedure:
Tighten hold down bolts Install dial gage on a magnetic base on one foot Loosen bolt on that foot Record reading (should be <0.002) Check remaining feet
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Other Causes of Poor Alignment Temperature Variations
Specifications are for Cold Alignment Allow 24 36 hrs to cool Ambient temperature variations can have a significant impact
Generator Magnetic Center
DBSE readings on generators should be taken with the rotor at magnetic center Often marked on the shaft
94
Monitoring Shaft Axial Float
Monitor shaft axial float when taking face readings Normally thrust collars should be against active thrust bearings If shaft is moving about install a dial gage as shown to check and make necessary corrections
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Other Causes of Poor Alignment
Springy Shims
Where shims do not provide a firm support Can cause vibration problems
Piping Strain
Piping or ducting can exert forces on the machinery especially compressor header pipes Piping should be selfsupporting Dial gages should be monitored during piping connection to check for abnormal loading Maximum deviation 0.005
Shim Requirements
Clean, free from rust Stainless steel Recommend 3 shims max under each foot Maximum 6 shims under each foot Minimum thickness 0.010 Minimum total 0.025 Maximum total 1
96
Bound Bolts
Can cause:
Lateral motion of the equipment when bolts are tightened Difficulty in moving the equipment during alignment checks
Solution
Increase foundation bolt-holes
97
QUESTIONS ON ALIGNMENT PRINCIPLES?
Complete Student Exercise
98
Student Exercise
1. The fundamental principle of machinery alignment is:
a. Machinery shafts will be co-linear when the machines are not operating and cold. b. Machinery shafts will be co-linear when the machines are not operating and hot. c. Machinery shafts will be co-linear when the machines are operating and cold. d. Machinery shafts will be co-linear when the machines are operating and hot.
99
Student Exercise 2. The three main considerations in machinery alignment are:
a. Parallel misalignment; angular misalignment; DBSE b. Parallel misalignment; vertical misalignment; DBSE c. Angular misalignment; horizontal misalignment; DBSE d. Horizontal misalignment; vertical misalignment; DBSE
100
Student Exercise
3. The machine that the alignment tooling is located on is known as the ___________ machine; the machine that the dial indicators are touching is known as the _____________ machine.
a. b. c. d. Target; Sight Target; Aiming Sight; Target View; Sight
101
Student Exercise
4. Which of the following would not normally be caused by poor alignment?
a. b. c. d. High vibration High bearing temperatures Increased machinery performance or efficiency Premature machinery failure
102
Student Exercise
5. The primary alignment method used by Solar is known as:
a. Rim and Face b. Tool Sag and Soft Foot c. Reverse Dial Alignment
103
Student Exercise
6. If a dial indicator Bore Top reading is zero, and Bore Bottom reading is 0.050, what is the TIR and actual shaft Vertical Offset?
a. b. c. d. TIR = 0.100; Offset = 0.050 TIR = 0.050; Offset = 0.100 TIR = 0.050; Offset = 0.025 TIR = 0.050; Offset = 0.050
104
Student Exercise
7. A condition where unequal shims may be required under machinery feet is known as:
a. b. c. d. Tool sag Soft foot Thermal growth Bent shaft
105
Student Exercise
8. If tool sag is measured as 0.002, and the BB reading during an alignment check is -0.018, what is the corrected BB reading?
a. -0.016 b. -0.018 c. -0.020
106
Objectives - Recap
1. Define the term alignment 2. Identify possible machinery problems that may be caused by poor alignment 3. List and describe the principles of different methods used in machinery alignment 4. Discuss negative influences that may affect final alignment accuracy
107
LESSON 4
Solar Alignment Information
108
Objectives 1. List available sources of information related to alignment 2. Describe the responsibilities of Solar and other personnel in relation to machinery alignment under different project situations 3. Convert both Solar-supplied and vendorsupplied thermal growth figures to alignment specifications 4. Given example figures, use available formulae or software tools to identify machinery shimming requirements
109
Main Sources of Information
Mechanical Installation Drawings
Using Taurus 70 CS PD72341
Vendor information
When third party equipment is used
Solar Align-It program
On CD Demo, but not used
Solar Alignment spreadsheet
On CD Used for exercises this week
110
Mechanical Installation Drawing
Reference 72341-149605 (Sheet 11)
Grid Reference H-118
Look at general alignment notes
Shipping braces Header pipes, etc.
111
PD72341 Package Stations Grid Reference E-112 E-112
Identifies stations (1 6) Identifies dimensions (D1 D5) Important to follow station identification (some specs will reverse sign if opposite direction is used)
112
PD72341 Thermal Growth Figures and Package Dimensions Table shows:
Thermal growth figures for stations Dimensions (useful for calculating shim corrections using formula or spreadsheet)
113
PD72341 Distance Between Shafts Grid Reference H-115 H-115
This project uses a Kopflex flexible diskpack type coupling DBSE shown (44.100) However in practice the distance between the coupling hubs will be used See next slide
114
PD72341 Coupling Shim Calculation
When hubs are free (locking and collapsing screws removed) the distance should be 26.642 +/- 0.010 This includes the 0.085 prestretch gap (to allow thermal expansion) and assumes that one complete 0.060 shimpack is installed After measuring the actual gap the complete shimpack may be removed OR one additional 0.060 shimpack may be installed Shims should be about equal on both sides of the coupling spacer Shims are normally in increments of 0.010
115
PD72341 Coupling Shim Calculation
Example 1:
Specified = 26.462 +/0.010 Measured = 26.425 Difference = 0.037 less gap than specified Shim correction = remove 0.040 from original shimpack (leave 0.010 on either side)
116
PD72341 Coupling Shim Calculation
Example 2:
Specified = 26.462 +/0.010 Measured = 26.482 Difference = 0.020 more gap than specified Shim correction = insert additional 0.020 shims (leave 0.040 on either side)
117
PD72341 Alignment Tool Installation Grid Reference D-115 D-115
Note direction of tooling
Station 4 to Station 3 Station 4 to Station 3 Reverse sign of bore specs Reverse sign of bore specs if opposite direction used if opposite direction used
Spacer used as tool extension, but disconnected at other end PT housing is target
No need to center either No need to center either hub hub
Note face diameter (17)
Recalculate face specs if Recalculate face specs if this is significantly different this is significantly different
Note bore internal sweep
Reverse sign of bore specs Reverse sign of bore specs if outside sweep used if outside sweep used
118
Other Alignment Information
Reference 72341-149605 Sheet 12 Equipment Alignment Notes
Grid Reference H-128 Read through all alignment notes
Specs in TIR Bearing pre-lube required, etc.
119
Clock Positions and TIR Grid Reference G-125 G-125
Accurately locate clock positions All Solar specs in TIR
120
Dial Indicator Alignment Specifications Grid Reference H-121 H-121
BB = -0.095 (inside sweep) FB = -0.002 Allowable tolerances:
BB = 0.005 BL / BR = 0.002 FB = 0.002 FL / FR = 0.001
Face readings only valid at specified diameter (17) Metric units also given Question is the PT higher or lower than the Compressor? 121
Student Exercise
Sketch the above
Left bore readings Right face readings
Use the table at H-121 to complete the sketch with the correct specifications
122
Laser Alignment Specifications Grid reference E-121 E-121
Laser alignment specs approx dial indicator specs Precise conversion can be made with the alignment spreadsheet
123
Torque Values Grid reference C-123 C-123
Standard torque values for various sizes of fastener Some packages use super-bolts for equipment hold-down bolts
Use multiple small allen-screws to stretch the main bolt
124
Alignment Tool FT Number Grid Reference B-123 B-123
125
Vendor Information
If the driven equipment is supplied by a thirdparty (e.g. Dresser) then alignment information will have to be extracted from their data
May use laser or reverse-alignment
Thermal growth figures and dimensions can be input to the alignment spreadsheet to produce rim-and face specs
This will be an exercise later
126
Solar Align-It Program Align-It
Useful program for alignment Available on the CD, with the instruction manual Will use a simpler method during the exercises
Solar Align XL spreadsheet
127
Alignment Spreadsheet
Various versions available in the field Replicates the complex formula that was contained on older package drawings Also useful for other purposes Available on the CD
128
QUESTIONS ON SOURCES OF INFORMATION?
Complete Student Exercises
129
Student Exercise 1
Use 72341-149605 and Align XL Open up the Master XL and save it under a new name Follow directions in Exercise 1 to compare specifications obtained from Align XL to specifications on the drawings Instructor: Answer XL is on the CD
130
Alignment Specifications From Drawing
131
Student Exercise 2
Use the XL spreadsheet produced in Exercise 1 Follow the instructions in Exercise 2 to obtain shim correction values Compare the values to the answers in the table Instructor: Answer XL is on the CD (same XL as Exercise 1)
132
Personnel Responsibilities Scenario 1 All Solar equipment
Solar provide all data on drawings
Scenario 2 Generator Package
Solar obtain growth figures from generator manufacturer, and provide all data on drawings
Scenario 3 Third Party Driven Equipment
See SWB for options
133
QUESTIONS ON PERSONNEL REPONSIBILITIES?
Complete Student Activity
134
Student Activity
1. Use the following flange-to-flange measurements to specify the coupling shim corrections:
Specified flange-to-flange = 26.462 +/- 0.010 Measured flange-to-flange = 26.418 Required correction = REMOVE 0.040 FROM ORIGINAL SHIMPACK
135
Student Activity
2. List three package conditions required prior to commencing alignment checks
Package to be level and secured Shipping braces to be removed Machinery must be cool (24 36 hrs after running) Oil tank to be filled All manifolds above the level of the oil to be loose Compressor header pipes to be disconnected Air inlet and exhaust ducts to be disconnected
136
Student Activity
3. Use the Alignment XL Master to create a spreadsheet that will be used later for the test-rig exercises
137
Student Activity
4. Use the spreadsheet just created to calculate shimming corrections
Shimming Corrections
Near Foot Correction
0.027
Far Foot Correction
0.024
138
Objectives - Recap 1. List available sources of information related to alignment 2. Describe the responsibilities of Solar and other personnel in relation to machinery alignment under different project situations 3. Convert both Solar-supplied and vendorsupplied thermal growth figures to alignment specifications 4. Given example figures, use available formulae or software tools to identify machinery shimming requirements
139
LESSON 5
Solar Alignment Techniques
140
Objectives
1. Describe the installation requirements for alignment tooling on a range of Solar equipment 2. Describe the different types on interconnect shafts used on Solar packages, and the general alignment procedures associated with each type 3. Define package requirements to be established prior to commencing alignment
141
ALIGNMENT TOOLING
142
Alignment Tooling Example 1
Typical tooling for a generator package
Mounting Tool Dial Gages Internal Micrometer Shaft Rotation Tool
143
Alignment Tooling Example 2
Similar tooling to previous example
Mounting tool screws into generator shaft Target is coupling hub on gearbox (generator usually easier to rotate) Rotating tool (not shown) uses bolt holes in generator coupling half
144
Alignment Tooling Example 3
Typical tooling on two-shaft machine
Uses coupling spacer as tool extension Dial gage clamps bolt to spacer flange
145
Alignment Tooling Example 4
Solar PTs are supported by two bearings
PT disk will overhang, and droop
PT shaft should be leveled
When using the shaft as a mount for the dial indicators, or When using the shaft or hub as a target surface
Tooling is supplied for this purpose
146
Alignment Tooling Example 5
Tool bolted to PT housing Rollers contact PT shaft Hand knob is tightened a prescribed number of turns
147
Other Considerations
Rotation of shafts Adequate lubrication
Try and operate pump before rotation Minimum is to pour oil into the bearing before rotation, and at regular intervals
Rotate in normal direction only
148
TYPES OF COUPLING
149
Gear Type / Wet Coupling
Older design requires grease Generator application illustrated Splined hub on each shaft (3 and 15) Secured by locknut/washer and key Splined coupling (5 and 13) Connected through shear coupling assembly (9 and 10) Slight misalignment absorbed by splines
150
Gear Type / Wet Coupling Assembled
SHEAR BOLT
O RING STANDARD BOLT
151
Dry Type Coupling Hubs
Newer design no lubrication Flanged hub on each shaft Secured by locknut/washer and key Flexible diskpacks absorb misalignment Spacer (may be shear coupling) not shown
152
Dry Type Coupling With Spacer
Shown for two-shaft application
No shear coupling
Axial motion (thermal growth) absorbed by prestretch
Correct shim installation important
153
Kopflex Coupling Shipping Screws
Kopflex coupling use red and yellow locking and collapsing crews for maintenance Should be removed prior to operating the equipment Kopflex data is available in the OMI manual (Supp Data section)
154
Package Requirements for Alignment
Reference 72341-149605 Sheet 6 Review the pre-alignment requirements
Skids joined and level Machinery cold Shipping braces removed, etc
155
QUESTIONS ON ALIGNMENT TECHNIQUES?
Complete Student Activity
156
Student Activity
1. The gear type coupling does not require lubrication with grease TRUE / FALSE Shear couplings are normally installed on generator applications TRUE / FALSE Shear couplings are only available with gear type couplings TRUE / FALSE The red and yellow shipping screws should be removed from a Kopflex coupling prior to operating the equipment TRUE / FALSE During alignment of a compressor to an engine or gearbox, the header pipes should remain connected to the compressor TRUE / FALSE
157
2.
3. 4.
5.
Objectives Recap
1. Describe the installation requirements for alignment tooling on a range of Solar equipment 2. Describe the different types on interconnect shafts used on Solar packages, and the general alignment procedures associated with each type 3. Define package requirements to be established prior to commencing alignment
158
LESSON 6
Simulator Exercises
Complete simulator exercise detailed in Lesson 6 Use the table as a general guide, and to sign off the steps Instructor will also sign off on the main steps Use Appendix B for specifications and worksheets
159
Appendix B1 Exercise Alignment Specifications
160
Appendix B2 Initial Alignment Readings
161
Appendix B3 Final Alignment Readings
162
LESSON 7
Package Exercises
Complete package exercise detailed in Lesson 7 Instructor will provide either a drawing or just alignment specifications Use Appendix C for specifications and worksheets Use the table as a general guide, and to sign off the steps Instructor will also sign off on the main steps
163
Appendix C1 Alignment Specifications
164
Appendix C2 Initial Alignment Readings
165
Appendix C3 Final Alignment Readings
166
END OF COURSE
Complete Post-Test
167
