ease of preventive maintenance online Flash Point: Lowest temperature at

LUBRICATION greasing system is available but initial

cost is expensive
which oil gives off vapors that will ignite
when flame is passed over
Worked Penetration: Consistency or
hardness of grease after it has been
API 614
Oil Mist: Application where only limited worked or churned
oil feed supply is required. Additives: Anti-wear, anti-foam, extreme
Lubrication: Supply of liquid lubricant or
pressure, oxidation and rust / corrosion Shear Stability: Ability of grease to
grease to facilitate movement of two
Lubricating Oil: (1) A blend of base oil preventives, etc. withstand repeated working with
mating surfaces
and specific additives which enhance the minimum change in its structure and
performance characteristics of the Oxidation: Chemical action between consistency
Functions of Lubrication: (1) Create lift
lubricants e.g. hydraulic oil, way oil, oxygen producing by product of acid and
by forming a thin film of oil between shaft
compressor oil, machine oil, motor oil, sludge Dropping Point: Temperature at which
and bearings (2) Cooling effect keeping
bearing oil, wire rope oil, gear oil, etc. (2) oil separate from thickener
bearings at it at optimum temperature (3)
Can be pumped, circulated, heated, Foaming: Because of increased in
Protection from corrosion (4) Flush away
cooled and filtered making it more operating speed, lubricating oil is subject Synthetic Oil: (1) Lubricant produced by
wear by product or debris
versatile than grease (3) Suitable for to severe agitation and churning which combining lower molecular weight
severe application involving extreme entraps air in oil, which in turn causes a component via chemical reaction to form
Type of Lubrication: (1) Oil bath (2)
speed and temperature (4) Difficult to foaming condition – foaming oils can not higher molecular weight compound (2)
Circulating System (3) Grease (4) Oil
contain in bearing and housing unlike provide an adequate lubricating film and Developed to increase performance that
mist lubrication – spray
grease – require complicated system (5) entrapped air accelerates oxidation exceed petroleum lubricants to satisfy the
most common oil system is a need for wider temperature range
Oil Bath:
hydrocarbon oil that corresponds to ISO Demulsibility: Ability of oil to separate
Grade 32 from water Oil Selection: (1) Temperature (2) Load
Wear: Result of rubbing action between (3) Speed
Types of Oil: (1) Mineral oil (2) Synthetic two moving parts surface
oil Varnish: (1) A thin layer of orange,
Extreme Pressure: Ability of lubricating brown or black insoluble film deposit
Base Oil: Basic building block of any oil to carry heavier loads and withstand occurring on the interior of lubrication
lubricant, usually 80% – 85% e.g. high operating pressures systems due to oxidation or heat (2)
paraffinic, napthenic, white oil and Cannot be filtered by normal filter (3) Can
synthetic Total Acid Number (TAN): (1) A cause blockage of servo valve internal
neutralization number intended for filter
(1) For low moderate speed (2) Oil level
Viscosity: (1) Measurement of measuring all acidic and acid-acting
in housing should not be less than the lip
‘flowability’ of a lubricant at a certain materials in the lubricant, including strong Varnish Filtration: (1) Balanced Charge
of outer ring (3) Not higher than the
temperature (2) Based on expected and weak acids (2) Weak acids can Agglomeration Technology (2)
center of lowest rolling element – verify
bearing operating temperature (3) Light attack coatings (3) Strong acids tend to Electrostatic Technology
during bearing not rotating (4) Oil ring
oil has lower viscosity while heavier oil be corrosive and are much more
can be used to splash oil to bearings (5)
has higher viscosity (4) Viscosity Index necessary to control (4) Drain or sweeten Balanced Charge Agglomeration:
(VI) is the rate of change in viscosity of (drain partially and top with fresh oil) if Particles are passed across high-voltage
Circulating System: (1) Excellent way to
an oil within a given temperature range TAN increased of 2.0 to 50% (whichever electrodes, charging the particles ‘+’ and
lubricate bearing in large equipment (2)
(4) Lower VI – large change in viscosity is greater) against baseline (new ‘–‘ in separate path. Oppositely charged
Reduce maintenance and prolong life of
within a temperature range while Higher lubricant reference) particles are mixed and are attracted to
oil (3) Oil introduce on one side and drain
VI – small change in viscosity within a each other, forming larger particle
from the other side (4) Require sufficient
temperature range (100 is consider Grease: (1) Lubricant composed of oil clusters that can be removed using
speed to allow absolute formation of oil
excellent) (5) Excessive viscosity may thickened with soap or thickener into a conventional filtration – it is a side stream
film (5) System shutoff with loss of oil
cause skidding of rolling element and semi-solid or solid consistency (2) system
pressure
high friction (6) insufficient viscosity may Mixture of base oil, additives and
result in metal to metal contact of rolling thickener or soap – keep oil in place / Electrostatic Technology: Plate is use
Greasing: (1) Can be added by hand or
surface form or from running out (3) Suitable for to attract varnish particle. This plate need
grease gun – depend on the availability
low load application to be replaced as varnishes accumulate.
of fitting (2) Not to overfill grease – can
Pour Point: Lowest temperature at
induce heat in bearing (3) Add grease
which an oil will pour or flow Penetration: Consistency or hardness of
slowly while bearing is running until some
grease
grease are visible coming out (4) For

LUBRICATION
API 614
Oil Reservoir:
1. Manway shall be located on top of
reservoir
2. Oil return line shall be located away
from pump suction line to avoid
disturbance of flow
3. Baffle or internal piping can be put
in-place to avoid turbulence that can
cause foaming
4. Drain connection shall be located at
the lower point of the slope
5. The rundown level (Level A) is the
highest level that oil in the reservoir
may reach when the entire system
is shut down.
6. The maximum operating level (Level
B) is the highest level that oil will
reach during normal operation of the
equipment.
7. The minimum operating level (Level
C) is the lowest level that oil will
reach during normal operation of the
equipment.
8. The suction-loss level (Level D) is
the level above the pump section
level (Level E) at which the pump
begins to lose prime. The pump
suction level is defined by the pump
suction vortex and net positive
suction head requirements.
9. The charge capacity is the total
volume below the rundown level.
10. The normal operating range is any
level between the maximum and
minimum operating levels.
11. The retention capacity is the total
volume below
operating level.
the minimum
12. Retention time is the time allowed
for disengagement of entrained air
or gas.
13. The rundown capacity is the volume
between the rundown level and the
maximum operating level
14. The working capacity is the volume
between the minimum operating
level and the suction-loss level.
15. A low-level alarm shall actuate at
the minimum operating level.
16. The working capacity between Level
C and Level D shall be sufficient for
at least 5 minutes of normal flow.
17. The minimum retention capacity
shall be calculated based on 8
minutes of normal oil flow.
18. The rundown capacity shall allow for
all of the oil contained in all of the
components, such as bearings and
seal housings, overhead seal tanks,
rundown tanks, accumulators,
control elements, and vendor-
furnished piping that drain back to
the reservoir.
19. The rundown capacity shall also
allow for at least an additional 10
percent of these volumes for the
purchaser’s inter-connecting piping
20. A temperature indicator is installed
at reservoir to ensure right
temperature (540C – 710C) for
correct lube oil viscosity during
startup
21. Heater is provided in the reservoir to
provide oil at the correct
temperature for start-up
22. N2 is supplied to oil reservoir as
blanket to avoid gas contact with oil
vapor.
Heaters: Induce heat in order to achieve
/ maintain minimum oil start-up
temperature
Pump and Drivers: (1) Equipped with a
main oil pump and a standby oil pump
installed with flooded suction – shall be
identical and suitable for continuous
operation (2) An emergency oil pump 4. Oil Sight Flow Indicators: Installed in
shall be in place to allow safe shutdown
without damage to the main equipment
the atmospheric oil drain return line
from each bearing, gear and seal
(3) Able to supply additional 20% of 5. Solenoid Valves: Act as a pilot valve
normal oil flow for transient requirement to pneumatic valves, hydraulic
(4) Check valves shall be provide on valves, or equivalent alternate valve
each pump discharge to prevent arrangement
backflow of oil through standby pump 6. Pressure Limiting Valves
7. Control Valves: Maintain system
Pressure Regulating Valves: Regulate pressure, reduce pressure, regulate
pressure to prevent fluctuation of the oil flow, or maintain a differential
pressure to the equipment when both the pressure
main and the standby pump are in
operation or either the main or the Oil Demister: (1) For oil recovery from
standby pump is in operation and the mist (2) Create a certain level of vacuum
other pump is started or stopped at the top of lube oil tank
Coolers: (1) Shall be of shell and tube
type unless specified – Fin fan coolers
can be used (2) Oil side (shell) operating
pressure must be higher than the water
side (tube) operating pressure to prevent
oil contamination
Filters: (1) Replaceable elements /
cartridge (2) Located downstream of
coolers (3) Water and corrosion resistant
(4)
Transfer Valves: (1) Switch coolers or
filters if fouling or clogged occurs (2) Are
not intended to be used as tight shut-off
devices for the maintenance of coolers
and filters
Accumulators: Needed to maintain
control oil pressure during servo-control
transient or to maintain lube or seal oil
pressure while standby pump accelerates
from idle condition to operating speed –
the control pressure shall be maintained
above the equipment manufacturer’s
minimum specified supply pressure at all
operating conditions (including transient)
Instrumentation, Control and
Electrical Systems:
1. Temperature Indicators
2. Thermocouples and Temperature
Resistance Detectors
3. Pressure Indicators: Shall not be
over ranging
Simplify Lube Oil Schematic:

Example Frame-7 DLN Gas Turbine:

Lube oil header around 6-7 bar

Aux cut in at 5 bar

Lube oil press at bearing 2 bar (pressure drop due to orifice)

BEARING
Bearings: Any kind of support for a
rotating shaft or spindle or guide of a
piece of equipment which slides across
another – use in equipment and
components that moves
Functions of Bearings: (1) To carry /
support weight / loads (radial, thrust and
combination) subjected on rotor (2)
Maintain correct radial clearance
between rotor and casing (3) Permit
smooth movement between surfaces –
reduce friction that can induce heat and
wear rate
Type of Bearings: (1) Hydrodynamic
bearings – plain bearings, journal
bearings (2) Anti-friction bearing
Plain Bearings
1. Solid bearings use the principle of
sliding action
2. Shaft turns on the bearing surface
made of soft metal (to minimize
danger of scoring / damage of rotor
shaft)
3. A thin layer of oil separates the
bearing surface and the shaft
4. Categorized into ‘Split Half’ type and
‘Sleeve’ (one piece) type
5. Oil hole and oil groove are made for
rapid supply of oil around bearing
surface
Advantage: (1) Support large radial load
(2) Less radial space required (3) Quieter
in operation (4) Less likely to be
damaged by contaminating particles (5)
Better resistance to unexpected overload
and shock conditions
Disadvantage: (1) Good lubrication is
necessary
Characteristics of Plain Bearing
Material: (1) Score resistance (2) Load
capacity (3) Fatigue strength (4)
Conformability (5) Embedability (6)
Corrosion resistance

Babbitt (tin-base, lead-base) – melt
about 1100C

Copper Lead




Bronzes
Aluminum

Silver (over-plated)
Tilting Pad Bearings: (1) Consist of
three or more pads located around
circumference (2) Each pad able to tilt in
order to assume most effective working
position
Installation
1. Split Half bearings are installed with
the ends of the bearings are pushed
together, and the bearings are
forced (‘Bearing Crush’ – complete
contact of the bearing back with the
bearing bore and prevent rotation of
the bearing in the bore) into the
bearing bore
2. Sleeve bearings are normally
installed with a press fit using a
bearing driver – if a sleeve bearing
has an oil hole, the hole must be in
alignment with the oil hole in the
part into which the bearing is
installed
Bearing Repair: Can be repaired by
reconditioning its inside surface –
machine smooth or relining
Anti-Friction Bearings
1. Parts: Inner race, outer race, ball /
roller, cage and seal
2. The term ‘rolling bearing’ refers to
both ball (point of contact) and roller
bearings (line of contact)
3. Ball bearings are used for radial
loads but will take a considerable
axial load – may also be used for
thrust bearings
4. Roller bearings of the same size of
ball bearings can be subjected to
higher radial load but will not take
axial load
5. Taper roller bearings and spherical
roller bearings will take radial load
as well as axial load
Advantage: Coefficient of friction is low
compared with plain bearings especially
at low speeds - lower power loss (2)
Wear is negligible if lubrication is correct
(3) Much shorter than plain bearings and
take up less axial space (4) Because of
extremely small clearance they permit
more accurate location (5) Self-aligning
types permit angular deflection of the
shaft and misalignment.
Disadvantage: (1) Outside diameter is
large (2) Noise is greater than for plain
bearings, especially at high speeds.
(3) Greater need of cleanliness when
fitted to achieve correct life (4) More
expensive for small quantities but
relatively cheap when produced in large
quantities (5) Failure may be catastrophic
Angular Contact Ball Bearing
1. Back-to-back is a very stiff
arrangement
2. Face-to-face the shaft can tilt
3. Tandem - higher axial load only one
direction
Thrust Ball Bearing
1. Carry axial load in one direction only
2. Can’t carry radial load
Thrust Washers / Plates
1. Thin solid bearing used for thrust
loads only.
2. Used on shafts next to gears and
other bearings.
3. Most common materials are bronze
and steel, aluminum and steel or
lead and tin.
Installation of Anti-Friction Bearing
1. Hot oil bath heaters are used to
2.
heat bearings and housings.
Dry bearing heaters are electric or
gas air ovens – used only for small
bearings.
3. Induction heaters operate the
fastest of all bearing heaters
4. Dry ice or freezer can be used for
tight fit installation in housings – are
often too large to be heated when
an outer race is installed
Removal of Anti-Friction Bearing
1. To remove bearings with press fits,
a bearing puller is used
2. When a bearing driver or a press is
used, put the force on the inner race
or outer race.
3. Force must not be put on balls,
rollers, or the bearing cage. This will
cause damage to the bearings.
Bearing Maintenance
1. Must be kept clean and correct
lubrication.
2. When bearings are serviced, your
hands must be clean and dry.
3. Do not spin the bearings or dry
them with air pressure.
4. If the bearing is to be used at a later
time, put oil on all of the bearing
surfaces, and wrap it in clean paper.
5. Do not remove the paper from any
bearing until the time of installation.
6. Dirt in an anti-fraction bearing can
cause the bearing to lock – rolling
components will not move, this can
cause the shaft to turn in the inner
race or the outer race to turn in the
bore.
Causes Bearing Failures: (1) Mounting
errors (2) Faulty lubrication (3)
Contamination (4) Shaft or housing
seating errors / misalignment (5)
Vibration
Symptoms: (1) High Vibration (2)
Excessive heat (3) Abnormal noise
L10 Life of Anti-Friction Bearings: ISO
equation for basic rating life in millions of
revolution
p
C 
L10 =  
P
Where
C is the external load
P is the bearing load
p is 3 for ball bearing and 10/3 for roller
bearing

Thrust Bearings: (1) Manage the net

resultant thrust (2) Net resultant thrust
will determine which side is active and
inactive (3) Balancing drum is used to
balance suction pressure and discharge
pressure(4) Manufactured by Kingsburry
(5) Wear marks will always be on the
active side.

SEALING
API 682
Purpose of Sealing: Prevent leak of
pumped product from leakage and
escaping to atmosphere
Type of Sealing: (1) Face / mechanical
seal (2) Non-contact seal
Basic Mechanical Seal Component: (1)
Primary seal – rotating and stationary
face (2) Secondary seal - ‘O’-ring,
gaskets or packing (3) Hardware –
spring, retainer and etc.
Design and Selection: Chemical
properties of liquid being seal put high
constraint upon the type of seal
arrangement, material of construction
and seal design (1) Product – pressure
temperature, lubricity, abrasion, corrosion
and toxicity (2) Environment (3) Seal
arrangement (4) Equipment
Principle of Face Seal / Mechanical
Seal: (1) Mechanical force from spring
(single or multiple) or metal strip bellow
that keep two flat polished mating face
together to perform sealing effect (2) A
very thin oil film (3 – 5 micron) formed in
between the faces as lubrication to
reduce friction and overheating (3) A
secondary seal such as ‘O’-ring, gaskets
or packing is put in place to prevent
leakage around faces back – for high
temperature application above 4000C
‘Graphoil’ or Kalrez material is used (4)
Seal Leak depends on the pressure drop
across the faces
Single Spring:
Advantages: (1) Variations in face
loading can be attained with a single coil
spring, but the rate of deflection is such
that it requires a large axial displacement
to effect a relatively small force change.
(2) A corrosion allowance can be built
into larger cross section wire.
Disadvantages: Shaft rotation is a big
factor in single-spring seal applications.
The spring should be placed in a retainer
to resist unwinding. The retainer is large
and heavy, introducing a balance and
vibration problem.
Multiple Springs
Advantages: (1) The multiple-spring
design has a shorter axial stuffing box
space requirement than a single coil
spring (2) Face loading (about 30 lb/f)
can be more readily varied simply adding
or subtracting springs (4) Multiple-springs
also resist unwinding from centrifugal
forces to a much higher degree than
single coil springs, since the forces act
differently and the springs are caged in
retainers.
Disadvantages: (1) The small cross
section of the wire can corrode easily -
stainless steels and Hastelloy can
compensate for much of this
disadvantage (2) The small springs are
more likely to clog from debris.
Lubrication and Cooling: Pumped
product is injected into the seal chamber
and a small amount passes through the
interface of the mating surfaces
Seal Configuration: (1) Single
Mechanical Seal (2) Tandem Mechanical
Seal (3) Double Mechanical Seal
Single Mechanical Seal:
(1) Use for non-toxic and non-flammable
application (2) Can be installed inside or
outside
Advantages of Inside Installation:
Better cooling, less space requirement
and low leakage
Advantages of Outside Installation:
Ease in maintenance
Tandem Mechanical Seal:
(1) Use for toxic and flammable
application (2) Consist of two mechanical
seals – primary and back-up (3) Primary
seal is flushed by any selected seal flush
plan (4) Back-up seal is provided with
flush system incorporating a safe, low
flash point liquid (5) A pressure alarm is
provided to actuate on increase stuffing
box pressure between the primary and
back-up seal indicating primary seal
failure
Double Mechanical Seal:
(1) Use for toxic and flammable
application – cannot be tolerated under
any circumstances such as H2S,
Hydrofluoric Acid Alkylation or Sulfuric
Acid (2) Leakage of the pumped fluid to
the atmosphere is positively prevented by
providing a sealing system, whose liquid
is compatible with pumped liquid, that
continuously provides a safe barrier liquid
at a pressure higher that the pumped
fluid (3) Seals are usually identical in
design with exception that one seal
incorporates pumping ring to provide
continuous flow of liquid to cool the seals
(4) Can be installed Face-to-Face or
Back-to-Back
Advantages of Face-to-Face
Installation: Can accommodate reversal
pressure
Advantages of Back-to-Back
Installation: Ideal for highly corrosive
service
Quench System: Quenching involves
the introduction of a medium, usually
water, nitrogen or steam, on the
atmospheric side of a mechanical seal
assembly. Quenching is normally applied
if the material being sealed is noxious,
flammable, oxidizes, polymerizes, or will
crystallize when dried. Quenching can
also be used for heating or cooling. The
gland plate is equipped with a throttle
bushing to prevent moisture or steam
leakage from a quenched seal from
entering the bearing housing and
contaminating the lubricating oil, and to
maximize containment of the quench
fluid.
Vacuum Condition: Mechanical seal
should not be subjected to vacuum
condition
Mechanical Seal Failure: (1) Heat check
– a pattern of parallel cracks at seal
contact surface (2) Blistering – crescent
shaped cracks or craters on carbon
graphite seal face (3) Spalling – voids on
the outside diameter or back surface of
carbon-graphite seal face (4) Face
distortion – intermittent and uneven wear
track pattern (5) Thermal distress –
elastomer charred and flaky, ‘O’-ring has
taken the shape of the groove (6) Cuts,
tears and Splits – ‘O’-ring flattened out,
torn and split (7) Fretting corrosion –
pitted or shiny area on the shaft or sleeve
at the location of the dynamic gasket (8)
Drive pin wear – excessive wear on
torsional drive pins, slots and lugs.
Pre-Installation Check: (1) Check shaft
run-out (2) Check shaft endplay (3)
Check radial deflection (4) Stuffing box to
shaft perpendicularity (5) Stuffing box
concentricity

SEALING
API 682
Flush Plan: A means to provide sealing
with continuous clean and abrasive free
lubricant to prevent seal failure such as
wear of seal faces and cooking of
elastomer due to heat
Plan 11 (Clean Product Systems):
Recirculation from pump discharge
through a flow control orifice to the seal.
The flow enters the seal chamber
adjacent to the mechanical seal faces,
flushes the faces, and flows across the
seal back into the pump.
Plan 13 (Product Flush System):
Recirculation from pump seal chamber
through a flow control orifice and back to
the pump suction. Use primarily in
vertical pumps applications because it
provides positive venting of the stuffing
box.
Plan 23 (High Temperature Product
Flush):
Recirculation from a pumping ring in the
seal chamber through a cooler and back
into the seal chamber. This plan can be
used on hot applications to minimize the
heat load on the cooler by cooling only
the small amount of liquid that is
recirculated.
Plan 52 (Low Temperature Product
Flush / Buffer System):
Consist of a tandem seal with buffer
liquid between them. External reservoir
providing buffer liquid for the outer seal.
During normal operation, circulation is
maintained by an internal pumping ring.
The reservoir is usually continuously
vented to a vapor recovery system and is
maintained at a pressure less than the
pressure in the seal chamber.
Plan 53 (Toxic and Flammable Product
Flush / Barrier System):
Consist of a dual seal arrangement with
barrier liquid between them. Pressurized
external barrier fluid reservoir supplying
clean fluid to the seal chamber.
Circulation is by an internal pumping ring.
Reservoir pressure is greater than the
process pressure being sealed. Inner
seal leakage will always be barrier
leakage into product.
Barrier Fluid: (1) Fluid between two seal
use for complete isolation of product to
environment (2) Higher pressure
compared to product
Buffer Fluid: (1) Fluid between two seal
face use as lubricant (2) Lower pressure
compared to product
Non-Contact Seal: (1) Labyrinth Seal (2)
Ring Seal – fixed and floating type
Labyrinth Seal:
(1) Simple configuration as compared to
mechanical seal – more reliable (2) Can
be categorized to dynamic (as part of
rotating part) and static (as part of
casing) (3) A series of circumferential
metal strip (4) Utilize when small loss in
efficiency can be tolerate (5) Leakage
can be kept at minimum by providing
minimum clearance between seal land
and seal sleeve and sharp edges on the
seal land (6) High tolerance to dirt
Ring Seal:
(1) A series of sleeves in which the bores
forms a small clearance around the shaft
(2) Arrange in a stuffing box – a type of
gland seal used to prevent leakage of
fluid, such as water or steam, between
sliding or turning parts of machine
elements.
 SEALING
API 682

Simplify Seal Oil Schematic:


ALIGNMENT
Alignment: Procedure by which the shaft
centerlines of one machine is adjusted to
be co-linear with the center line of
another equipment shaft at operating
temperature and speed – shaft position
changes due to operating condition i.e.
thermal growth, pipe strain
Purpose of Alignment: (1) Maintain
performance level of equipment by
minimizing forces transmitted to the
equipment internals (bearing, seals etc.)
when equipment is connected (2)
Increase bearing life and rotor stability (3)
Reduce power consumption – 5%
savings (4) Minimize amount of wear in
coupling (5) Maintain proper internal
clearance (6) Lower vibration level
Misalignment: (1) Misalignment -
deviation of shaft position from a co-
linear axis of rotation when equipment is
in operation – Parallel or Angular
(2) 'Cold Offset' - Misalignment set on
purpose by the equipment manufacturer
to account for the different values of
equipment support growth from 'Cold'
position to 'Hot' (running) position
Cause of Misalignment: (1) Improper
foundation and base plate (2) Pipe stress
(3) Thermal Growth (4) Soft foot (5)
Improper pipe support (6) Loose or
broken foundation bolt (7) Shim problem
(8) Inadequate knowledge in performing
alignment
Symptoms of Misalignment: (1) Pre-
mature bearing, seal, shaft, coupling etc.
failure (2) Excessive radial and axial
vibration (3) High Bearing temperature
(4) Loose coupling bolt or flexible
element (5) Loose foundation bolt (6) Hot
coupling after stop (7) Abnormal sound
(8) Induced heat
1. Lay a straight across coupling rims axis of the driven and driver
Soft Foot: Condition in which one of the
feet does not sit flat on the base.
or faces (top-bottom-sides)
2. Add shims (minimize) or move 2.
equipment – Rim
Take reading at 0,3,9,12 positions
equipment side to side - until by rotating both shafts
Soft Foot Check straight edge touches all the way 3. Formula:
Alternately loosening hold down bolts across both couplings or gap FRONT =
L1× ( Rim ⋅ TIR1 + Rim ⋅ TIR2) Rim ⋅ TIR2
+
and checking that a maximum differential between coupling faces is 2d 2
rise of .002 of an inch is not exceeded. approximately equal all around
L2 × ( Rim ⋅ TIR1 + Rim ⋅ TIR2) Rim ⋅ TIR2
Advantage: Fast – rough alignment, BACK = +
2d 2
Guidelines of Alignment: (1) Pre- suitable close coupling and low rpm
Alignment (2) Rough Alignment (3) Final equipment
alignment Disadvantage: Trial and error, many Note: No reading taken on the face of the
coupling because both the angular and
factors that may affect accuracy,
parallel misalignment is corrected by
Pre-Alignment
computing the readings taken on the rim
1. Lock-Out-Tag-Out (LOTO) in place Rim and Face Dial Indicators
of two couplings
2. Select method of alignment Preferred for DBSE < 1/2 coupling length
Advantage: Precision alignment, axial
3. Prepare necessary tool and shims
float will not affect readings
(stainless steel)
Disadvantage: Difficult to read direction
4. Check foundation from void
of moves from dial gauge, coupling
5. Check existing shims – change if
backlash
necessary
6. Loosen vertical and horizontal jack
bolts Laser (same as Reverse Dial
1. Set-up one dial gauge with the Indicators)
7. Decide which machine to move
plunger perpendicular to the shaft 1. Set-up the laser transmitter and
8. Ensure bearing are well lubricated
axis – Rim detector on each shaft / coupling
before turning shaft
2. Set-up another dial gauge with the 2. ‘Zero’ the reading for base
Rough Alignment plunger parallel to the shaft axis – reference
1. Check ‘Soft Foot’ acceptability Face 3. Take reading at 0,3,9,12 positions
2. Check all hold down bolts - properly 3. Take reading at 0,3,9,12 positions by rotating both shafts
torque by rotating one shaft Advantage: High precision alignment,
3. Equipment properly leveled 4. Formula: capable of handling long spans between
4. Equipment aligned as per vendor L1 × Face ⋅ TIR Rim ⋅ TIR couplings, automated computing for
FRONT = +
‘Cold Offset’ value D 2 correction
Disadvantage: Expensive
Final Alignment BACK =
L 2 × Face ⋅ TIR Rim ⋅ TIR
+
D 2 Sweep Reading Validity Rule:
1. Re-check Rough Alignment
Advantage: Precision alignment,
2. Re-check ‘Soft Foot’
Disadvantage: Disassembly of coupling, TOP
3. Install coupling according to vendor
time consuming, trial and error in putting (0.00)
procedure and set proper axial face
shimming
gap based on Distance Between R+L=B ( ± 0.05mm)
Shafts End (DBSE) tolerance
Reverse dial indicators
4. Confirm piping to machinery bolting
Preferred for DBSE > 1/2 coupling length
is properly torque LEFT RIGHT
(0.60) (0.30)
Methods of Alignment: (1) Straight
edge / Thickness gauge / Taper gauge
(2) Rim and Face dial indicators (3)
Reverse dial indicators (4) Laser (5)
Thread / String – for pulley and sprockets BOTTOM
Straight edge / Thickness gauge / (0.90)
Taper gauge 1. Set-up two dial gauges with the
plunger perpendicular to the shaft

BALANCING
Balancing: Procedure by which the
mass distribution of a rotor is checked
and if necessary adjusted in order to
ensure that the vibration of the journals
and / or forces on the bearings at a
frequency corresponding to the service
speed are within specified limit
Purpose of Balancing: (1) Increase
bearing life (2) Minimize vibration (3)
Minimize audible and signal noises (4)
Minimize operational stress (5) Minimize
power losses
Unbalance: (1) Excess mass on one
side of a rotor – due to centrifugal force
exerted by m during rotation the entire
rotor is pulled in the direction of F
(2) Condition which exists in a rotor when
vibratory force or motion is imparted to its
bearing as result of centrifugal forces (3)
Unbalance in just one rotating
component of an assembly may cause
the entire assembly to vibrate – include
structure
Units of Unbalance: Mass multiplied by
the distance from shaft axis
Cause of Unbalance: (1) Tolerance in
fabrication (2) Variations within materials
such as voids porosity, inclusions, grain,
density and finishes (3) Non-symmetry of
design (4) Non-symmetry in use including
distortion, dimensional changes – due to
rotational stresses
Balancing Machine: (1) Necessary to
detect, locate and measure unbalance –
data furnished by balancer permits
changing the mass distribution of a rotor
(2) Balancer only measure unbalance,
never balance
Types of Unbalance (ISO 1925): (1)
Static Unbalance (2) Couple Unbalance
(3) Dynamic Unbalance (4) Quasi Static
Unbalance
Static Unbalance:
(1) Force unbalance (2) Exist when the
principal axis of inertia is displace parallel
to the shaft axis (3) Found in narrow, disc
shaped parts such flywheels and turbine
wheels (4) If large enough can be
detected with conventional gravity type
balancing method – on a knife edge level
rotor will turn until the heavy or
unbalance spot reaches the lowest
position
Couple Unbalance:
(1) Moment unbalance (2) Exist when the
principal axis of inertia intersect the shaft
axis at the center of gravity (3) Arises
when two equal unbalance masses are
position and spaced 180 degrees apart
(4) Each end will vibrate in opposite
directions
Dynamic Unbalance:
Principal Inertia Axis
Center of Gravity
Unbalance
(1) Exist when the central principal axis
of inertia is not parallel to or intersecting
the shaft axis (2) Most frequently
occurring type (3) Can only be corrected
by mass correction in two planes
perpendicular to the shaft axis
Balancing Methods: (1) Gravity
balancing machines (2) Centrifugal
balancing machines (3) Field balancing
equipment
Gravity Balancing Machines:
Advantage taken of the fact that a body
free to rotate always seeks position in
which its center of gravity is lowest
Centrifugal Balancing Machines (Soft
Bearing and Hard Bearing)
1. The amplitude and phase of
motions or reaction forces caused
by centrifugal forces resulting from
unbalance are sensed, measured
and indicated by appropriate means
2. Direction of rotation is unimportant
except for bladed rotors in which the
direction with least turbulence
3. High Speed Balancing is balancing
at speed passing critical speed or at
running speed (especially for
flexible rotor) while Low Speed
Balancing is balancing at below
operating speed or less than 3000
RPM
4. Balancing speed should be as low
as possible to decrease cycle time,
horsepower requirement, wind,
noise and danger to balancing
machine operator
Field Balancing Equipment
Provide sensing and measurement
instrumentation only while rotor runs in its
own bearing and under own power –
convert vibration readings to magnitude
and phase angle of required correction
masses
Unbalance Correction Methods: (1)
Addition of prefabricated correction
masses of different sizes at a number of
locations identified (2) Removal of mass
– drilling (most effective method in
production balancing), milling and
grinding (trial and error)
Note: The select correction method
should ensure that there is sufficient
capacity to allow correction of the
maximum unbalance which may occur
Balance Quality Grade for Rigid Rotor:
(1) The product of specific unbalance and
the maximum angular speed of the rotor
– ISO 1940 (2) The higher the service
speed the smaller should be the residual
unbalance
Allowable Residual Unbalance:
Acceptable ⋅ Re sidual ⋅ Unbalance × 10
Radius × Number ⋅ of ⋅ Plane
Rigid Rotor: A rotor is considered rigid
when it can be corrected in any two
planes and after that correction, its
unbalance does not significantly exceed
the balancing tolerances at any speed up
to maximum service speed
Pre-Balancing Check:
1. Assemble all rotating parts –
inclusive coupling hubs
2. Check rotor weight
3. Check rotor rotation
High Speed Balancing of Rotor:
1. Cleaning
2. Perform Dimensional check
3. Conduct non-destructive testing
4. Check run-out at probe area (limit
10 micron)
5. Check residual magnetism (limit 2
gauss)
6. Test for overspeed – to ensure all
components are intact
7. Performed low speed balancing at
ISO 1940 Grade 1.0 – stricter
8. Performed high speed balancing at
ISO 1940 Grade 1.0
9. Performed low speed balancing at
ISO 1940 Grade 2.5

REPAIR
REFURBISHMENT
API 687
Guideline for Rotor Repair and
Refurbishment:
1. Develop Initial Scope of Inspection /
Repair / Upgrades
2. Select Vendor Shop
3. Transport to Vendor Shop
4. Receiving Inspection
5. Phase 1 Inspection of Assembled
Rotor
6. Hold Point and Scope Evaluation
7. Phase 2 Inspection of
Disassembled Rotor
8. Hold Point and Scope Evaluation
9. Repairs / modifications
10. Reassembly and Balancing
11. Hold Point and Final Inspection
12. Preparation for Shipment Shipping /
Storage Container Documentation
13. Post Shipment Review
Develop Initial Scope of Inspection /
Repair / Upgrades: Scope shall at least
include the Phase 1 Inspection
Vendor Shop: The repair shop should
be selected on the basis of the shop’s
ability to perform the scope of repair. This
depends upon the repair shop’s:

Facilities.

Engineering capability and support.

Experience repairing similar
equipment.

Having a quality system in place
similar to that recommended by API
Transportation: Rotors being returned
for repair shall be adequately preserved
to prevent from any damage or
environmental deterioration.
Receiving Inspection: Vendor to record
the condition of the shipping container,
skid, box, etc., photographed to clearly
show details of any damaged areas and
immediately reported to carrier, vendor
representative and owner representative
Inspection:

Conduct dimensional check – shaft
run-out, clearance

Conduct visual inspection for
physical damage; clearly
photograph in detail; and note on a
sketch the size, location, and
orientation (including any required
physical reference point) of any
erosion, corrosion and any unusual
appearances or other damage
resulting in loss or displacement of
material, deposits, and buildup.
Standardized sketches, forms, and
tabulations are desirable.

Vendor shall clean the rotor to
remove dirt, rust and other foreign
material using a procedure
appropriate for the Non-Destructive
Examination (NDE) methods to be
used.

Performed NDE on component

Radiographic

Ultrasonic,

Magnetic Particle and Liquid
Penetrant Inspection
Hold Point and Scope Evaluation:

Owner and Vendor to define hold
point in which both parties have to
agree to proceed with repair or not

Scope of repair and components
replacement must be reviewed and
accepted by Owner prior to
commencement of repair activity
Repairs / Modifications:

New material used for the repair of
existing parts or the manufacture of
replacement parts shall be equal to
or better than the original for the
intended service. Compatibility of
the materials and the process in
which they serve must be verified.

All drawings procedures and
processes used in the repair or
manufacture of any component shall
be available and agreed owner
review.

The vendor shall consult with the Hold Point and Final Inspection:
owner on material selection and the
Owner and Vendor to define
owner shall approve the material. whether an Factory Acceptance

Shaft areas can be restored by the Test (FAT) is required
following processes as per the
Vendor to issue preliminary repair
procedures report and final inspection report for

Tungsten Inert Gas (TIG) owner acceptance prior to shipment
Process.

Submerged Arc Welding Preparation for Shipment Shipping /
(SAW) Process. Storage Container Documentation:

High Velocity Oxygen Fuel
Rotors and components for all
(HVOF) Process. classes shall be placed in

High Velocity Liquid Fuel containers with covered tops. The
(HVLF) Process. basic differences in these

Intermittent Combustion containers are the material and the
Process design for long term storage.

Damaged shaft area can be turned
Rotor retainers shall be used at the
down resulting in an undersize cradles to prevent any movement
shaft. during transit – do not support rotors
on bearing, probe or seal areas and
Reassembly and Balancing: at any exposed rotor blades or gear

Rotors to be balanced shall be teeth.
rotated in a direction that is “normal”
Rotor shall be protected with a
to reduce “windage” effects on the corrosion barrier. Critical shaft areas
components mounted on the rotor- such as journals, end seal areas,
blading, vanes, etc. probe target areas, and coupling fit

Rotating components shall be multi- areas shall also be protected by a
plane dynamically balanced during separate barrier material to protect
assembly with the shaft against incidental mechanical

High-speed balancing should be damage.
Considered which may include, but
not be limited to, the following: Example: Frame-7 DLN Gas Turbine

Rotors which have exhibited Parts Send for Repair
high vibration as they pass Frame-7 DLN
Expected Numbers of
Life Repair
through their critical speeds. Combustion Liner 36k 2

Rotors which accelerate slowly End Cover 36k 2
through their critical speeds. Fuel Nozzle 36k 2

Rotors which are running on or Crossfire-Tubes 36k 2
Transition Piece 36k 2
near a critical speed. 1st Stage Bucket 72k 1

Rotors which are sensitive to 1st Nozzle 72k 1
unbalance. 1st Shroud 72k 1

Rotors for equipment in
extremely critical services.

Rotors going to inaccessible
locations, such as offshore.

Very long, flexible rotors.

Places where a critical rotor
cannot be run in its intended
casing prior to installation.

Rotors that have previously
been high speed balanced and
have not been disassembled.

REPAIR
REFURBISHMENT
API 687
Consideration for Repair:

Determination of the base material
and the restoration material

Limitations of the processes
(thickness; environment of the part
chemical, thermal compatibility;
machinability; mechanical bonding
capabilities; velocities of steam /
gas)

Concerns of using the technique for
the application

Durability / economics / risk

Time constraints

Experience using the technique in
that shop and user’s reference list

Qualification of repair procedure
and people

Quality control procedures
Repair Methods: Weld repair, thermal
spray, reducing ‘Turning Down’ the shaft,
plating, shaft straightening, metallizing,
and plasma spray
High Velocity Fuel Processes:
Generates a velocity of molten metallic
stream.

Metal powder impacts the item
being sprayed with high energy

The metal powder bonds with the
base metal. The powder particles
flatten as they impact the surface
and the coating is built-up, layer by
layer, to achieve a fully dense
structure.

HVOF process uses gas as the fuel
and HVLF process uses liquid as
the fuel.

HVOF / HVLF processes differ in
their application methods in the
following ways:

The applying device may be
cooled by a different medium
(air, water, etc.) This will affect
the flame temperature which
will, in turn, affect the
temperature of the powder.

The base metal may be cooled
by air, carbon dioxide,
nitrogen, etc. This will keep the
part from distorting due to heat,
but may also have an affect on
the quality of the coating,
depending on which coating
medium is used.

The powder may be injected in
different locations in the flame
stream to vary the amount of
heat to which the powder is
subjected.

The type of fuel may vary.

Mass flow meters may be used
rather than pressure drop type
flow meters to control powder,
fuel and oxygen flow rates.
Intermittent Combustion Processes:
Oxyacetylene powder method firing a
very high velocity stream of particles

Oxygen, acetylene, and powdered
coating material suspended in
nitrogen are metered into the
combustion chamber

A spark detonates the mixture to
create a hot, high-speed gas stream
which makes the particles plastic
while hurling them from the
applicator

Successive detonations build up the
desired thickness
Reducing (Turning Down) the Shaft:
Reduction of a diameter on a shaft and
leaving the shaft at the reduced diameter
– no build-up to the original diameter is to
occur.

It is important to understand that the
reduction of the shaft diameter may
affect items such as:

Bearing journals - The journal,
thrust bearing, and / or seal
rings for the bearing housing
may have to be redesigned
due to the smaller shaft.

Coupling shaft end – coupling
hub may have to be replaced
and possible modifications to Plasma Spray: The plasma spray
the remaining components of process feeds a powder and gas mixture
the coupling assembly due to into a high energy electric arc producing
the shaft to shaft dimension a molten metallic stream. The resulting
being modified. impact of the metal powder has low bond

Process seals – seals may strength. Plasma spray is not
have to be redesigned due to recommended for shaft repair
the smaller shaft.

Other areas – turned down
dimension may affect the
mating component

Torque capabilities

The modification may affect the
spare rotor, spare parts and
component delivery due to the
non-standard dimensions.

The preferred method is
grinding
Shaft Restoration by Plating: When
specified, components may be restored
to original design size by chrome or
nickel type plating. The application
method, procedure, thickness, quality
control checks, and acceptance criteria
should be mutually agreed upon
Shaft Straightening: When specified,
the restoring of the shaft straightness
may be attempted by stress relieving,
peening, or cold or hot straightening.
Shaft straightening is not preferred due to
the following situations:

Low success rate for all diameters

Shaft does not always maintain this
restored straightness while in
operation under load and
temperature

Smaller diameter shafts are more
difficult to straighten than larger
diameters
Metallizing: The metallizing process
generates a low velocity molten metallic
stream. Since the kinetic energy varies
by the square of the velocity, the
resulting impact of the metal powder has
comparatively lower energy resulting in
low bond strength and high porosity.
Metallizing is not recommended for shaft
repair
 OPERATIONAL PERFORMANCE
PUMP PERFORMANCE CURVE
TOTAL HEAD (H)

IF OPERATING POINT MOVED

CHECKED SYSTEM FOR ANY
ABNORMALITY IN THIS CASE
CHECK THE DISCHARGE VALVE
OPENING

TOTAL SYSTEM CURVE

NORMAL
OPERATING POINT

PUMP CURVE

NPSHA
STATIC HEAD

NPSHR

FLOWRATE (Q)

10
Head = ∆P ×
ρg
Q × H × ρg
Hydraulic ⋅ Horse ⋅ Power ⋅ ( kw) =
367 .1
Hydraulic ⋅ Horse ⋅ Power
Brake ⋅ Horse ⋅ Power =
η
Where
∆P is the differential pressure between suction and discharge
ρ is the density of the fluid
g is gravity (9.81m/s2)
η is efficiency
 MATERIAL
Corrosion: Caused by corrosive
impurities in a particular service

Coating: (1) Is a thermal spray process

transfer of material onto another by
raising the temperature of hard-facing
material (2) Usually in powder form (3)
Used to component that requires
additional corrosion and erosion
resistance (3) The bond strength is
directly influenced by maximum velocity
that the particle of molten material
achieved in thermal spray process –
flame spray, plasma spray, arson, High
Velocity Oxygen Fuel (HVOF)