BET 060 Shaft Alignment Lab Hand Out

8/9/2019 BET 060 Shaft Alignment Lab Hand Out

1/23

gGE Power Systems

Shaft Al ignment

PSU Shaft AlignmentSimulator Lab Introduction

g GE Power SystemsShaft Al ignment

Why is Shaft AlignmentImportant?

A gas turbine shaft bearing is damaged causedfrom shaft mis-alignment. The customers turbineis down for repair for 30 hours. When the turbine

is running the customer makes $41,000.00 an hour.

How much money did the customer loose?

$1,230,000.00

Scenario

Course Introduction


2/23

gGE Power Systems

Shaft Al ignment

Proper shaft alignment is necessaryto ensure:

Low vibration levels

Optimum efficiency

Reduced maintenance

Increased service life

MENU

Course Introduction


MENU

Alignment is typically performed when anyof the following occur:

Foundation settling or distortionor deterioration

Repair or installation of a majorcomponent

Bearing wear

Course Introduction


3/23

gGE Power Systems

Shaft Al ignment

Course Objectives

At the completion of this lesson youshould be able to:

Understand the reason for performingshaft alignment

Understand how to calculate the data that is

collected when performing shaft alignment

Understand how to perform rough alignment

Understand how to perform Fine alignment


L R

T

B

FACE DATA

0.146

0.156 0.200

0.210

Lesson OneCalculating the Data

T+B=

L+R

0+4=

10+6

4=16

T+B=L+R

+10 +6

0

+4

T

L

B

R

RIM DATA

Thesums

areboth

356.The

refore

thedatac

hecksout


4/23

gGE Power Systems

Shaft Al ignment

Lesson OneIntroduction

Once the data has been obtained, you mustknow how to calculate the data. If the data isnot calculated correctly a move in the wrongdirection is very likely.


Lesson OneObjectives

At the completion of this lesson youshould be able to:

1. List the reasons for calculating the shaftalignment data.

2. Select the proper calculating method

3. Calculate for a parallel (rim) corrections

4. Calculate for an angular alignment (face)correction

5. Calculate for a combined parallel (rim and anangular face)alignment correction


5/23

gGE Power Systems

Shaft Al ignment

Calculating an alignment move requires several steps:

Select a calculation method

Visualize relative coupling positions

Calculate for parallel alignment (rim) corrections

Calculate for angular alignment (face) corrections

Calculate for a combined parallel (rim and an

angular face) alignment correction.

MENU


Selecting a Calculation Method

How the calculation for an alignment correctionis made will vary, depending on how the datawas obtained. The type of coupling used on theshaft will determine how the alignment reading

is taken. The two basic methods of data collectionused are for:

Close couple shafts

Distant coupled shafts with the couplingshaft removed

MENU


6/23

gGE Power Systems

Shaft Al ignment

Rim

Face

This drawing will helpyou understand some ofthe terminology that willbe used in this lesson.

Indicator

MENU


Selecting a Calculation Method

Selection of the calculating method is straight-forward. A universal calculating method is usedwith any data collection method which producesseparate rim and face readings. An alternative

calculation method is used when the data collectedconsists of two sets of face readings.

RIM DATA

0

+9 +6

+4

T

L

B

R L R

T

B

0.140

0.154 0.165

0.210

FACE DATA

T = Top

B = Bottom

L = Left

R = Right

MENU


7/23

gGE Power Systems

Shaft Al ignment

Data Check

A Quick check of rim and face readings shouldbe done before you draw your diagrams. Thischeck can reveal incorrectly recorded data. Tocheck your data, compare the sum of the topand bottom readings with the sum of the leftside and right side readings. These sums should

be equal. Do this for both the rim and facereadings. See the example on the next page

MENU


Example A.

L R

T

B

0.727

0.737 0.732

0.742

FACE DATA

Top Reading + Bottom Reading

0.727 + 0.742 = 1.469

Left Reading + Right Reading

0.737 + 0.732 = 1.469

The sums are both 1.469. Therefore,the data checks out.

MENU


8/23

gGE Power Systems

Shaft Al ignment

Rough Alignment

Sliding ParallelAdjustment Shims

Allen Wrench

The following tools will be used toperform rough alignment

MENU


These are the onlybolts that may beloosened for shaftalignment while inthe shaft alignmentlab at PSU.

MENU


9/23

gGE Power Systems

Shaft Al ignment

Your relative position in performing shaft alignment

is critical in collecting and recording your data.

LeftRight

Top

Bottom

Getting Started

MENU


Rough Alignment

Set the parallels across bothsurfaces to get top distancedifference for shim dimension. Choose a shim that will slide

under parallels. Dont tryto get to exact at this point.

Step 1.

Step 2.

MENU 34


10/23

gGE Power Systems

Shaft Al ignment

Fine AlignmentThe following tools will be used toperform fine alignment

Indicator clamps Magnetic IndicatorBase

Indicator RodsSliding Parallels

1 MicrometerDial Indicators

MirrorMENU


MENU

Before starting to performthe fine alignment, the endplate must first be markedwith four reference points.One at 0 ,90 , 180 , and270 , degrees.

oo o

o

Fine Alignment


11/23

gGE Power Systems

Shaft Al ignment

The most important stepin diagramming the relativeposition of coupling rims isrecognizing which couplinghalf is referenced.

Turbine

Top position

Generator

MENU

(short shaft) (long shaft)


Now it is time to take therim readings. Start at thetop and take readings every90 degrees.

Note: when you get back

to the top position recheckthe indicator and it shouldread zero on the dial.If it does not read zero thenthe indicator has been bumpedand you will need to re-zeroand take the readings again.

0

Click on The picture

MENU


12/23

gGE Power Systems

Shaft Al ignment

When taking the rim readings you shouldcontinually watch the dial indicator. Bywatching the dial indicator you will knowif the dial is going in the + or direction.

Record the rim readings as you go to eachof the four positions.

MENU


As a Field Engineer you will be required to documentall shaft alignment information. These calculation formsare part of that documentation.


13/23

gGE Power Systems

Shaft Al ignment

This form is used tocollect informationthat is important toour customers as wellas the techniciansthat will perform shaft

alignment

02/15/02 287125 John Smith

Lube oil Temp

Initial shims

Weather Conditions

Time

Ambient Temperature

Name of crew Page 1 of ?

Turbine to Generator


Left

Top

Right

BottomRim readings for top, left,bottom, and right will beentered in the appropriatebox on your Data Sheet.

0 +1 +30 +29

MENU


14/23

gGE Power Systems

Shaft Al ignment

0 +1 +30 +29

The face readings will consist of 16 readings.Starting with the indicator in the top positiontake face readings in the following order.

TopReading 1

LeftReading 2

BottomReading 3

RightReading 4

710 724 720 707


0 +1 +30 +29710 724 720 707

You must rotate the shaft 90 degrees to theleft to take the second set of readings. Noticethat the top always remains the top.

TopReading 5

LeftReading 6

BottomReading 7

RightReading 8

705 721 725 710

90 to left0


15/23

gGE Power Systems

Shaft Al ignment

Once you have allthe face readings,you must find theaverage of each ofthe columns andrecord them in the

average row.

705 721 725 710

0 +1 +30 +29710 724 720 707

710 717 722 716714 720 718 711710 720.5 721 711


705 721 725 710

0 +1 +30 +29710 724 720 707

710 717 722 716

714 720 718 711710 720.5 721 711

Find the lowest number inthe Average row.

Enter a zero in the columunder the lowest average

number.

0 Subtract 710 from eachof the column averagesand record the numberin the relative row.

+10.5 +11 +1


16/23

gGE Power Systems

Shaft Al ignment

705 721 725 710

0 +1 +30 +29710 724 720 707

710 717 722 716714 720 718 711710 720.5 721 711

+.5

+30+11

0 +10.5 +11 +1

+30+11.50

Based on the informationthat has been collectedthe data checks out.

If there were a differenceof more than 2 then thedata would need to betaken again.

Reasons for difference

of more than 2 could beloose foot, indicator hasbeen bumped, or micro-meter not correctly read.


Top

LeftRight

BottomRim readings for top, left,bottom, and right will beentered in the appropriatebox on your Data Sheet.

0

+29+1

+30

MENU


17/23

gGE Power Systems

Shaft Al ignment

Measurements are taken from this face

Centerline of boltCenterline of bolt

7.539.5

Support #1Support #2


Shaft #1

T

B

Shaft #1

T

B

Shaft #1

L

R

Shaft #1

L

R

RIM

FACE

Initial Data Sketches

15 14

11

9.5

MENU


18/23

gGE Power Systems

Shaft Al ignment

Shaft #1

T

B

Shaft #1

T

B

Shaft #1

L

R

Shaft #1

L

R

RIM

FACE

Required Alignment Sketches

20

18

MENU


Face Correctionat Support

=(Face Move) (Support Distance)

(Sweep Diameter)

HorizontalCorrection

#1(9.5) (7.5)

(12)#2

(9.5) (39.5)

(12)

5.9 31.3

95.518.1

VerticalCorrection #1

(29) (7.5)

(12)#2

(12)

(29) (39.5)

Sweep Dia. = 12

A = 7.5B = 39.5

MENU


19/23

g Al ignmentMS 3002, 5001, 5002, 6001B, 7001E, 9001E Accesso r y Coup l i ng

Date Turbine S/N Prepared by

FSR # Sketches Enclosed? Photos Enclosed?

Data Type

Alignment Readings (Insert readings in (mils)

Position Top Left Bottom Right

Rim

Face 0

Face 90

Face 180

Face 270

Average

Relative

Check Face Rim

Top + Bottom=

Right + Left = Sweep Diameter (Inches) Indicator Mounted on

Difference=

Alignment Based on 12" sweep diameter.

Comments

INSPECTION REPORT

Gas Turbine Maintenance

NOTE:1. Checks to be made in direction of turbine flow.

2. "Rim" readings should reflect indicator riding at

coupling OD or on male rabbet; if indicator rides

on female rabbet, the sign conventions must be

changed.

Alignment Form Blank.XLS GE Energy Serv ices Company Propr ietary In fo rmation


20/23

FACE

T

B

L R

RIM

Initial Data

Final Data

B

A

S1 S2

SHAFT #1 SHAFT #2

SHAFT #1

B

T

R

SHAFT #1

LRIM


SHAFT #1

T

B

SHAFT #1

FACEL

R

LT

SHAFT #1

B

SHAFT #1

R


SHAFT #1

T

B

SHAFT #1

FACE

RIML

R

SUPPORT #1 SUPPORT #2

HORZ VERT VERTHORZ

RIM CORRECTION

FACE CORRECTION

TOTAL MOVE

(FACE MOVE) (SUPPORT DISTANCE)

(SWEEP DIAMETER)

FACE CORRECTIONAT SUPPORT

HORIZONTALCORRECTION

#1( ) ( )

( )

(

( )

( )#2

CORRECTIONVERTICAL #1

( )

( )

( )

#2

(

( )

( )

SWEEP DIA.(COUPLING DIA.)

CA03 9/2000

SHAFT ALIGNMENTDATA SHEET

A

B

NOTE:

1. SKETCH POSITION OF

DIAL INDICATOR

2. RECORD MEASURING

TOOLS USED

IN THE

ILLUSTRATION

CHECK: T + B = L + R

FACE:

RIM:


21/23




Data Type



Rim

Face 0

Face 90

Face 180

Face 270

Average

Relative

Check Face Rim

Top + Bottom=


Difference=


Comments

INSPECTION REPORT






changed.

Alignment Form Blank.XLS GE Energy Serv ices Company Propr ietary In fo rmation


22/23

FACE

T

B

L R

RIM

Initial Data

Final Data

B

A

S1 S2

SHAFT #1 SHAFT #2

SHAFT #1

B

T

R

SHAFT #1

LRIM


SHAFT #1

T

B

SHAFT #1

FACEL

R

LT

SHAFT #1

B

SHAFT #1

R


SHAFT #1

T

B

SHAFT #1

FACE

RIML

R

SUPPORT #1 SUPPORT #2

HORZ VERT VERTHORZ

RIM CORRECTION

FACE CORRECTION

TOTAL MOVE

(FACE MOVE) (SUPPORT DISTANCE)

(SWEEP DIAMETER)

FACE CORRECTIONAT SUPPORT

HORIZONTALCORRECTION

#1( ) ( )

( )

(

( )

( )#2

CORRECTIONVERTICAL #1

( )

( )

( )

#2

(

( )

( )

SWEEP DIA.(COUPLING DIA.)

CA03 9/2000

SHAFT ALIGNMENTDATA SHEET

A

B

NOTE:

1. SKETCH POSITION OF

DIAL INDICATOR

2. RECORD MEASURING

TOOLS USED

IN THE

ILLUSTRATION

CHECK: T + B = L + R

FACE:

RIM:


23/23




Data Type



Rim

Face 0

Face 90

Face 180

Face 270

Average

Relative

Check Face Rim

Top + Bottom=


Difference=


Comments

INSPECTION REPORT






changed.

Documents

BET 060 Shaft Alignment Lab Hand Out