Professional Documents
Culture Documents
STD 126
STD 126
Amended edition
FOR RESTRICTED
CIRUCULATION
No.
FOR RESTRICTED
CIRCULATION
NO.
Prepared by
COMMITTEE ON
INSPECTION OF ROTATING EQUIPMENT
OISD publications are prepared for use in the Oil and gas
industry under Ministry of Petroleum and Natural Gas. These are the
properties of Ministry of Petroleum and Natural Gas and shall not be
reproduced or copied and loaned or exhibited to others without written
consent from OISD.
Though every effort has been made to assure the accuracy and
reliability of data contained in these documents, OISD hereby expressly
disclaims any liability or responsibility for loss or damage resulting from
their use.
With this in view, the then Ministry of Petroleum & Natural Gas, in
1986, constituted a Safety Council assisted by Oil Industry Safety
Directorate (OISD), staffed from within the industry, in formulating and
implementing a series of self regulatory measures aimed at removing
obsolescence, standardising and upgrading the existing standards to
ensure safe operations. Accordingly, OISD constituted a number of
Functional Committees of experts nominated from the industry to draw up
standards and guidelines on various subjects.
CONTENTS
SECTION PAGE NO.
2.0 Balancing
2.1 Scope
2.2 General
2.3 Selection of Number of Balancing Plane
2.4 Balancing Tolerances
5.0 References
Appendix I
General Safety Precautions
SPECIFIC MAINTENANCE PRACTICES FOR ROTATING EQUIPMENT
1.0 ALIGNMENT SYSTEMS AND Shims are vital link between the machine and
PROCEDURES foundation. All shim packs should be removed at
every machine support just prior to alignment. If
1.1 SCOPE the shims have burrs, rust etc. these should be
removed and shims without rust, wrinkles, burs,
This section covers the standard alignment hammer marks and dirt should be used. Use as
systems and procedures for rotating machinery, few shims as possible and replace many thin
precautions to be taken before carrying out the shims with fewer shims of greater thickness.
alignment and general alignment guidelines. Stainless steel shims minimise alignment
problems associated with shim deterioration.
1.2 SYSTEM SURVEY
1.2.5 Checking for Misalignment
Many steps vital to good machinery alignment
should be taken well ahead of the actual ‘cold Misalignment should be checked in the following
alignment’. Some of the items, which warrant manner. A dial indicator should be mounted on
specific attention, are as follows: the machine support with the indicator stem
resting on the sole plate. Watch the indicator as
1.2.1 PIPING the hold-down bolts are loosened. If movement
of the indicator is more than 0.025 to 0.05 mm, it
A Visual inspection of piping is vital. The is an indication of a problem that must be defined
following checks should be carried out: and eliminated. Remove the shim pack and
check with feeler gauges to be certain the
a) Whether the piping is installed in apparent machine support is parallel with the sole plate. If
agreement with the design criteria and is not, regrout, re-machine the support or prepare
complete in all respects as per the drawing. tapered shims.
b) Whether proper placement and adjustment 1.2.6 Checking the Causing for distortion
of guides, anchors and supports have been
done, whether proper adjustment of tie bolts Test for gross distortion of casing can be made
on expansion joints, correct positioning of when shim packs are checked in the following
hangers have been carried out, whether manner:
make up of flanges with gaskets in place
have been completed and the bolts a) With three supports tightened down, remove
tightened. the shim pack from the fourth support.
c) Whether the system is in order so that post b) Determine the total thickness of the shim
alignment piping modifications will not nullify pack and record the dimension.
the alignment effort.
c) Using feeler gauges, determine the distance
from the sole plate to the machine support.
d) Nomenclature with flow direction on pipes
Measure the dimension.
shall be given. Note 1
d) Subtract the feeler gauge dimension from the
1.2.2 Grouting shim pack thickness. This is the total
deflection of the machine casing with no
Grouting should be checked to be sure it is support at the corner being checked.
complete and satisfactory.
e) Repeat the procedure at each of the four
1.2.3 Foundation bolts supports and compare the deflection of each.
Gross differences in deflections at any of the
Foundation bolts should be checked for four supports is an indication of probable
tightness. casing distortion.
1.2.4 Shim packs 1.2.7 Checking for piping strain
Piping strain is seldom detectable by visual Cold alignment is normally the only check made
observation. However, gross problems can be to directly determine the relative position of the
detected by the following tests. Following the two shafts. Results of the check form the basis
check of casing distortion, place dial indicators for determining shaft alignment during operation.
on the machine to monitor both vertical and
horizontal movement of the casing or shaft. The face and rim method and the reverse
Loosen all the hold down bolts. If the machine indicator method are commonly used for
moves more than the average observed when accurately measuring the shaft alignment
checking individual supports, it is obviously the between machinery. In the face and rim method,
result of an external force, i.e. the piping. a face (axial) measurement and a rim (radial)
measurement determine the angle and position
1.2.8 Bearings respectively of one shaft relative to another. The
reverse indicator method uses two rim
Ensure that the bearings are properly installed in measurements, one from each coupling to locate
the machines and they are lubricated. Also one shaft center line relative to the other. Both
check the bearing covers for proper tightening. the face and rim measurements are to be taken
with dial indicators.
1.3 PLANNING
The face and rim method of alignment can be
Alignment program should be properly planned in carried out by using a single dial indicator for
order to achieve good results within minimum taking the face reading or using two dial
time. Plans should include: indicators for taking the face readings. The use
of two dial indicators for taking face readings
a) Determination of the desired placement of eliminates the effect of axial movement of the
the shafts (cold settings) considering shafts during alignment. Procedure for carrying
anticipated thermal growth of the various out the alignment using three dial indicators is as
components. Definition of movement of follows:
shafts within bearing clearances, hydraulic
loading and any other factors expected to 1.4.1 Alignment measuring procedure
produce relative movement of shaft center -Three dial method
when the machines are operated.
The normal method of alignment measurement
b) Determining the sequence of alignment for for turbomachinery is by using an apparatus with
multi unit trains. For two component trains three dial indicators as shown in fig 1. The dial
determine which of the two machines is to be indicator with its axis in a radial direction
moved. measures the radial misalignment of the shafts.
The two dial indicators with their axis in an axial
c) Selecting a specific method for determining direction measures the axial misalignment of the
relative shaft positions. shafts. Normally the heaviest or the most
centrally placed machine is made the reference
d) Deciding on tolerances for theoretical cold for alignment.
alignment settings.
1.4.2 Reading of the radial misalignment
e) Ensuring the quality of alignment bracket,
dial indicators and shims required for Zero the radial indicator in correspondence to the
alignment. vertical plane as indicated in the figure. Rotate
the shaft in the operational direction of rotation
f) Making provisions for permanent recording and note the gauge readings at 900 intervals.
of alignment data. Interpret the readings as positive if the dial
indicator rod re-enters its appropriate place and
g) Ensuring that jack bolts are provided and negative if it does not. The readings are to be
they are free for moving the machine for taken at least twice and ensure that the indicator
alignment. operates with the rod at half stroke. It is
advisable, especially for couplings with spacers,
1.4 COLD ALIGNMENT to recheck by moving the apparatus with the
indicators from one shaft to the other.
The term ‘cold alignment’ refers to the position of
a machine’s shaft center line relative to the shaft The value of the misalignment in the vertical
center line of a connected machine, with both plane is rv=b/2 where b is the reading effected
machines in a non operating or ‘cold condition. on the dial indicator after a rotation of 1800.
Such are the values read after a rotation of 90 0 --------------
(W) and 2700 (Z) that their algebraic addition o
coincides, with the measurement taken after
180oC , i.e. b =W + Z (approx.), while their To correct the vertical radial misalignment, lift
algebraic semi difference indicates the radial and lower the machine and without changing its
misalignment in the horizontal plane, i.e. values angular position, insert or withdraw a shim from
of W’, Z’ and ‘b’, must be considered with their each support plate of the machine feet.
sign.
To correct the axial and radial misalignment on a
1.4.3 Readings of the axial misalignment horizontal plane, it is sufficient to horizontally
move the machine by turning the set screws of
The axial misalignment of the shafts (angular the machine.
misalignment of the coupling) is read by means
of two offset indicators of 1800 and zeroed to 1.5 HOT ALIGNMENT
their initial position. For taking the reading of
axial misalignment use the two vertically aligned Alignment of machineries changes from ambient
indicators. Zero the indicators. Then rotate both to operating conditions. Correction for this can
shafts and record the measurements read on the be done in two ways:
dial indicators for each misplacement of 900 as
indicated in figure 4. a) By calculating the thermal growth of
individual machineries and giving allowances
Supposing that the two comparators are installed for it in the cold alignment.
on the flange of the P Shaft (with the indicator
button bearing on the flange of the Q shaft) b) By shutting down a machine which had been
and that the readings are made looking at the allowed to stabilise at temperature, installing
unit from left to right, we have the value of the dial indicators and taking measurements.
axial misalignment in the vertical plane “av as av
= d-g/2. If “av” is negative, the flanges appear The second procedure should be adopted for
open downwards and if av is positive flanges pumps where the couplings are readily
appear open upwards. The value of the axial accessible and indicators can be installed in a
misalignment angle in the vertical plane is matter of minutes. But this method is difficult for
obtained through high speed machineries where it takes more time
to install the indicators by which time the
tg < v = av/o machine gets cooled and a change in alignment
takes place. Hence, for these machines first
The value of the axial misalignment in the procedure is to be adopted.
horizontal plane as will be
1.6 Alignment Tolerance
ao = (c-o) --(F-h)
___________ Alignment tolerance means the misalignment
that can be permitted between the driver and the
2 driven shafts. This misalignment is specified at
operating pressure and temperature of the driver
If “ao” is negative flanges appear open leftwards. and driven equipment irrespective of the type of
If “ao” is positive flanges appear open coupling used for power transmission.
rightwards. The value of the axial misalignment
angle in the horizontal plane “L” is obtained Tolerances are as given below:-
through tg < O = ao/o. Values of c,d,e,f,g and h
must be considered with their sign. 1. Maximum radial misalignment shall not
exceed 5/100 mm TIR (Total indicator
1.4.4 Alignment correction procedure reading).
First perform the correction of axial alignment on 2. Maximum axial misalignment shall not
the vertical plane. It can be corrected by exceed 5/100 mm TIR (Total indicator
verifying the height of the shims placed reading).
underneath the support plates of the machine.
As shown in figures the shims to be removed
from underneath of the external support is
obtained as follows:
S= av.L
required, the ratio of the length of the rotor
exclusive of supporting shaft to the diameter of
2.0 BALANCING the rotor can be used as a guideline as given in
table 2.1
2.1 SCOPE
This section covers the balancing procedures to Since the unbalance of a rotor could be in any
be followed in shop after repair jobs and the plane or planes located along the length, it is
maximum specific residual unbalance allowed for very difficult to locate the plane. Moreover, it
various rotors. may not always be possible to make weight
correction in just any plane. In these conditions,
2.2 GENERAL corrections can be made in the convenient
planes available. (Follow procedure specified by
Imbalance is basically a very simple problem manufacturer).
caused by an asymmetry in the rotating element
which results in an offset between the shaft 2.4 BALANCING TOLERANCES
center line and center of mass. This asymmetry
can be of center weight distribution or it can be a When machines are being balanced in place, it is
thermal mechanism which produces uneven customary to use the vibration criteria to
heating and bowing of the rotor. Imbalance is determine when an acceptable balance has been
nearly always characterised by a high radial attained. API Standard 612 and 617 for special
vibration at running frequency which may also be purpose steam turbines and centrifugal
accompanied by a high amplitude in the axial compressors respectively specify that “ the
direction. This is a normal problem encountered maximum allowable unbalanced force at any
in maintenance and it becomes essential to carry journal at maximum continuous speed shall not
out balancing of rotors and couplings. exceed ten per cent of the static loading of the
Guidelines for carrying out balancing are given journal”. Both API standards state that the
below: maximum residual imbalance shall not exceed
When a lubricant is to be chosen for any service, It should be rotated by 1800 position after
the exact conditions to which the lubricant is to three months
be subjected should be known and proper
lubricant should be chosen. Just any oil is not a It should be rotated by 900 position after
lubricant. In the name of inventory control or three months.
variety control do not choose the oil at random.
Ensure that the oil selected is exact equivalent It should be again rotated by 900 position
as per manufacturer’s recommendation. after three months.
4.3.3 Alternative method of preserving In all cases the bearings should be wrapped in
rotor grease proof paper and then placed in a box
which has a lid. The box should be sealed with
Another method of preserving the rotors is to adhesive tape so that the bearings are well
store it vertically by suspending in a container protected against dust. Moisture absorbing
sealed and preserved under nitrogen pressure of sachets should be provided in the box Note 1.
0.5 kg/cm2. The pressure gauge indicating the
pressure of nitrogen in container should be The bearing designation should be written
inspected periodically and positive nitrogen outside of the box so that the contents will be
pressure is required to be ensured at all time. known at a later date without the need to open
Such preservation will not require periodic the box.
rotation of turbine rotor and corrosive effects of
the atmosphere, accumulation of dust, etc. will 5.0 REFERENCED PUBLICATIONS
be avoided.
i) Machinery analysis and Monitoring by John
4.4 PRESERVATION PROCEDURE FOR S. Mitchell.
OTHER SPARE PARTS
ii) Turbomachinery Handbook published by
4.4.1 Pump rotor assembly Hydrocarbon Processing.
Crank shaft of compressor and diesel engines v) Instruction Manual of Hard bearing balancing
are protected by painting with bituminous paint machines.
on all surfaces except the journals which are
protected as indicated in the case of journal of vi) Predictive Maintenance Manual of Indian Oil
the rotors. Corporation.
vii) Mechanical balancing of Rotating Bodies
BS5265 PART 1981
1.4 Whenever a pump handling 1.11 Gaskets and bolts used for making up
hydrocarbons is taken out of service, all the the flanges should be suitable for the service.
hydrocarbon lines connected to the pumps
should be isolated by blinding. In the case of a 1.12 A display board with clear & bold writing
back pull out pump, the casing should be blinded of "EQUIPMENT UNDER MAINTENANCE"
by a special fluid instead of blinding the lines. should be kept at working site Note1.