SPECIAL ISSUE: OUTAGE

HANDBOOK

ROTATING EQUIPMENT

Align pumps and drivers to maximize availability, minimize energy consumption

he focal point of activity during inspection/maintenance outages at combined-cycle plants is the gas turbine. Heatrecovery steam generators, steam turbines, and generators also get their share of attention. However, you dont hear much at usergroup meetings about plant-level experience with all the other equipmentpumps, for example. Thats not to say O&M staffs arent paying the necessary attention to pumps and other critical componentsmost probably are. But the gas-turbine-based sector of the electric generation industry continues to expand despite the economic downturn and many new employees lack in-depth experience with equipment they at least share responsibility for. What percentage of plant personnel would you think have fewer than five years of hands-on experience? And what fraction of that group understands how critical proper alignment of pump and motor are to availability, power consumption, and other key factors? The editors guess: A larger percentage than you might think. Dieter Seidenthal, VP, Ludeca Inc, Doral, Fla, who has exhibited vibration-monitoring and laser-alignment instrumentation at many user-group meetings over the years, says that the biggest contribution one can make to lower the operating cost of rotating equipment is to align it correctly in the first place. Ludecas Pedro Casanova adds that when misaligned, the loading of shafts increases dramatically because of the reaction forces created within the coupling (Fig 1). The result: n Bearings, seals, shafts, and couplings fail prematurely. n Bearing and coupling temperatures run hothigh enough to identify misalignment using infrared thermography. n Vibration becomes excessive.

1. Misalignment can cause premature bearing, seal, shaft, and/or coupling failures
Mechanical-seal life Increase in electric consumption, % 10 8 6 4 2 0 10 20 30 40 Offset, mils 50 60 100 10 1 0.1 0 2 mils

50 Offset, mils

100

2. Significant power savings can be achieved by correcting misalignment

n Power consumption increases sig-

3. Life of mechanical seals decreases quickly as misalignment increases illustrated in Fig 2. If you add up the power consumption of large pumps (circulating water, condensate, feedwater, etc) in an F-class 2 1 combined cycle, the dollars-and-cents argument for holding alignment to manufacturer specs is compelling. Fig 3 presents the relationship between mechanical-seal life and offset misalignment. Note that the scale for seal life is logarithmic. It doesnt take much misalignment to reduce seal life by 90%. Figs 4 and 5 show that the rate of seal and pump repairs declined dramatically with the full-scale use of precision alignment in Year Six. Seidenthal, who has been helping engineers at power and process plants for decades, discussed the evolution of alignment tools during his professional career. He recalled the straight-edge/feeler-gauge methods
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nificantly. A survey conducted by one of the worlds leading service organizations specializing in rotating equipment, continued Casanova, found that fewer than 10% of the 160 machines randomly chosen for measurement were aligned within acceptable limits. Nearly one-third of the sample had offsets from 8.1 to 20 mils, close to one-third exhibited even greater misalignment. To quantify the benefits of proper alignment, Seidenthal took out some charts developed by Prueftechnik Alignment Systems GmbH, Ismaning, Germany, from data provided primarily by users. Ludeca is Prueftechniks exclusive representative in the US for the German firms alignment and vibration monitoring tools. Effects on power consumption are

COMBINED CYCLE JOURNAL, Third Quarter 2008

ROTATING EQUIPMENT
Number of mechanical-seal repairs 50 40 30 20 1 2 3 4 5 Year 6 7 8

SPECIAL ISSUE: OUTAGE

Number of pump repairs 100 80 60 40 20 1 2 3 4 5 Year 6

HANDBOOK
30%

65%

4. Mechanical-seal repairs declined by 65% after precision alignment was introduced. Longer maintenance intervals increase availability

5. Rate of pump repairs decreased as laser shaft alignment became an integral part of the pump repair process. Reduced parts consumption stretches your maintenance budget

Training is required, of course, but most technicians can become expert enough in a day or two of classroom/ field instruction to handle most tasks on their own. If they get stuck, theres a help line to call. With the value plant owners place on availability, its difficult to believe any combined-cycle facility would be without such critical diagnostic tools as a borescope, vibration monitor, laser alignment, ultrasonic NDE, multimeters, etcand technicians onsite capable of using them to their full capability.

User viewpoint
Chuck Hildebrand, who has been trouble-shooting rotating equipment for more than 30 years, agrees. With the convenience and accuracy offered by some of todays laser-based alignment tools, he believes their use provides a healthy return on investment. However, he points out that some plants, having made substantial investment in laser tools, have not committed the time or money essential for developing the necessary onsite knowledge to use them effectively. Hildebrand should know, having spent most of his career at a major East Coast electric utility as the multi-plant companys vibration and alignment problem-solver. He recently started his own firm, Dynamic Balancing Co, Lighthouse Point, Fla (childebrand@bellsouth.net), to help

6. Straight-edge/feeler gauge alignment method is reminiscent of a museum and far too inaccurate for most machines today that were state-of-the-art for years (Fig 6). They rely on the limited resolution of the human eye and are accurate to only 4 mils, which is not good enough for most rotating machines. Dial indicators represented a major advancement in alignment measurement (Fig 7). They offer a resolution of 4 tenths (0.4 mils), but it takes considerable experience to master their use and to obtain good results. Rounding error, sticking/jumping dial needles, play in mechanical linkages, reading errors, tilted dials, sagging indicator brackets, etc, all can have a harmful impact on measurement results. Todays laser-alignment tools are claimed to provide resolution to 4 hundredths of a thousanth (0.04 mils) quickly, accurately, and reliably (Fig 8). There is no human factor to deal with, no sag influence, no reading errors. You can change technicians, but the results remain the same. The handheld alignment instrument/computer in the photo (the top-of-the line Rotalign Ultra) shows a one-cable connection to the laserbeam emitter and receiver, but wireless is an option. Horizontal and vertical coupling and foot values are computed automatically and displayed on the screen. A diagram of the shaft system also can be displayed while you make adjustments
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7. Dial-indicator method works well, but you essentially need machinistlevel skills to obtain the quality of results required for precise alignment so you can track your progress live. The device alerts when shimming is correct. If you have never seen one of these instruments in use, watch the video at www.ludeca.com/prod_ rotalignultra.php.

8. Laser alignment tools are fast, accurate, and reliable. Plus, they document results which then can be exported to produce all manner of customized reports on a personal computer
COMBINED CYCLE JOURNAL, Third Quarter 2008

SPECIAL ISSUE: OUTAGE

HANDBOOK

ROTATING EQUIPMENT

users solve alignment problems on State-of-the-art laser alignment critical rotating machinery. tools can be used to accommodate Focusing on pumps for a moment, a wide variety of alignment tasks. Hildebrand says the need to accu- To illustrate: Relative alignment of rately measure the degree of shaft bearings, bores, and rotational cenmisalignment between a pump and terlines of shafts can all be measured its driver often is a result of exces- and compared in any combination. sive vibration at some time Theres no machinery during normal operation. alignment task I can think Electronic laser-alignment of where laser measuretools are a most convenient ments would not provide way to obtain the exact inforthe desired position information needed to provide mation in a most conveefficient repositioning of nient and accurate way, rotating machinery. It takes Hildebrand says. only a few minutes to obtain But he cautions that the accurate shaft-alignment mere purchase of these measurements for a typitools does not make one Hildebrand cal horizontally mounted an instant expert. A good pump and driver in relatively good understanding of alignment-meamechanical condition. surement concepts and deep knowlSome sophisticated instruments, edge of specific rotating equipment such as Ludecas Rotalign-Ultra, he are necessary for determining the continues, can be considered expert most effective solutions for machine advisors, because they also provide trains troubled by misalignment. a simplified evaluation of the many possible ways to correct misalignment. What is soft foot, Although the latest generation of anyway? these diagnostic tools provides excellent information regarding the posiA gap between one foot of a tion of the shafts centers of rotation, machine and the foundation generachieving and/or maintaining good ally is referred to as soft foot. A alignment conditions during operapump or motor typically has four tion still poses many challenges. To feet and generally rests on three, illustrate: High-energy boiler feed leaving a gap under the fourth. pumps are connected to heavy-walled Recall from high-school geometry piping systems. Normal thermal that three points determine a plane, expansion of this piping during plant which is why dairy-farm milking operation can produce forces large stools only have three legs. enough to move the pump in abnorA soft foot left unshimmed mal directions. means that a machine frame will Various methods have been used distort from its resting position as to measure this dynamic alignment the hold-down bolts are tightened behavior. Once known, the meato secure it in place. This distortion sured dynamic alignment change can binds the shaft and preloads the be compensated for by intentional bearings. The latter is one of the misalignment during the alignment leading causes of premature bearprocess. In some cases, however, the ing failure. only effective solution for achievThus a soft-foot check is vital to ing the desired operating reliabilthe pre-alignment process. Keep in ity requires modifications to piping, mind that there are different kinds foundations, couplings, etc. of soft foot. In its simplest form, a Alignment measurements on foot can either be parallel or bent. vertical pumps are treated a little Its relatively easy to locate a paraldifferently. Although the measurelel foot (think of it as a short leg) and ment concept is essentially the same, correct for it. A bent foot is more vertical pumps do not normally have difficult to fix. flexible shaft couplings. MisalignOne of the benefits of a sophisment is measured with the rotor ticated laser alignment system is and pump shaft hubs disconnected that it will have a soft-foot wizard, and with the pump shaft centered or diagnostic routine, built into in its upper bushing; the pump shaft the firmwear to determine if this remains stationary during alignproblem exists and if it must be ment measurements. Although the addressed immediately to assure setup of the laser alignment tool satisfactory alignment. The wizard is a little more complicated when recommends to the technician the measuring vertical pumps, the same quickest path back to production straightforward alignment correc(maximum availability). tions are provided.
COMBINED CYCLE JOURNAL, Third Quarter 2008

Theres no substitute for experience, Hildebrand adds. The conversation moved to aeroderivative GTs with Hildebrand describing equipment idiosyncrasies he has observed while working on a particular model. Although identical by design, no two units on which he has worked have behaved in the same manner. Troubled by leaking hot exhaust gases (not a problem in itself), dynamic alignment change during operation varied by as much as 25 mils from unit to unit. Furthermore, the ever-changing direction of exhaust leaks on these units caused misalignment that could not be compensated for reliably using the cold offset misalignment procedure described earlier for boiler-feed pumps. In at least one case, reliable operation was achieved only after redesign of the flexible shaft coupling. Hildebrand also shared his experience in aligning shafts of largeframe GT and steam-turbine generator sets. Unlike typical auxiliary machinery, synchronously rotating the shafts of these prime movers to acquire misalignment measurements can be difficult. The same laser-alignment tools can be used, but it is extremely important to assure measurements of the highest accuracy and repeatability. Statistical evaluation of measurement points allows exclusion of abnormal data, thereby resulting in highly reliable shaft-position information. Because adjustments of these behemoths can be labor intensive, this measurement technique is appreciated for minimizing the number of position corrections.

Alignment preparations
Dont let Fig 8 fool you. Set-up and use of electronic laser-alignment tools may be a clean coveralls assignment, but the actual deckplates-level task of machine realignment is of the old-fashioned dirtyfingernails variety that youre more used to. Figuring out what must be done to realign a pump, compressor, or fan and its driver may be far simpler today because of laser alignment, but the devil remains in the details. Making permanent adjustments that will hold the equipment train in alignment requires know-how and good mechanic skills. The editors asked Casanova, who often can be found on the deck plates with users, to suggest an alignment procedure and provide some details on how to prepare equipment for the
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work required. The macro procedure he suggested has six steps: n Pre-alignment checks. n Rough alignment to eyeball clean (with bolts loose). n Rough soft-foot: Loosen all bolts and fill any obvious gaps. n Initial alignment: Get to within 5 to 15 mils at the coupling or less than 20 mils at feet. n Final soft foot: All feet to less than 2 mils. n Final alignment within tolerances. Safety first. Before beginning prealignment checks, make sure the machine youre working on is isolated from the fluid circuits served and from the plant electric systemand tagged out. That done, you can safely check for deficiencies which could prevent the attainment and retention of good alignment. Begin with the foundation. It should be of adequate size and in good condition. Good engineering practice suggests that a concrete foundation be three times the weight of rotating driver and driven equipment, five times for reciprocating machines. Check grout condition; no voids should be in evidence below the baseplate. If grout recently has been poured to fix a battered foundation or to accommodate a new machine, be sure it properly cured prior to starting alignment work. The baseplate must be rigid, so no part of any foot moves more than 1 mil out of plane with the other feet on the same machine. Use a straight edge and feeler gauge to verify that mounting pads are level, flat, parallel, coplanar, and clean. Be sure to select hold-down bolts of proper size, ones with enough clearance to permit any corrective movement required. Foot pads should be sufficiently high so theres enough room under the machine to use lifting jacks. Mount jackscrews on rigid pads ones that wont deflectmade from stainless steel to resist corrosion. Coat jackscrews with an anti-seize compound such as Never-Seez. Piping should be well fitted and supported, and sufficiently flexible, so that shaft movement is no more than 2 mils when the last pipe flanges are tightened (Sidebar). If pipe-flange angular misalignment exists, a dutchman or tapered filler piece may be necessary. Spiralwound gaskets can be helpfulin addition to, or instead of, a tapered filler piece. Excessive parallel offset at the pump flange connection cannot be cured with a filler piece. However, it may be possible to absorb it by offset-

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COMBINED CYCLE JOURNAL, Third Quarter 2008

ting several successive joints slightly, taking advantage of the clearance between flange bolts and their holes. If excessive offset remains, bend the piping to achieve a better fit. In some cases, pipe expansion or movement may cause pump movement, leading to misalignment and increased vibration. Better pipe supports, stabilizers, or flexible spool pieces may be needed in such situations. Shims must be clean for best results and made from a corrosion- and crush-resistant material. Caution: If commercial pre-cut shims are used, verify actual thickness with a micrometer before use. Most manufacturers supply shims in thicknesses of 50 mils and above only in nominal sizes subject to standard material variations. Make sure that shims are free of burrs, bumps, nicks, and dents. Also that size numbers or trademarks are etched into the shimnot printed or stamped. Generally speaking, try to use the smallest commercial shim that will fit around the hold-down bolt without binding. The smaller the shim, the more accurate the alignment corrections will be. Cleanup is important. Use a power wire brush to remove all rust, scale, paint, dirt, etc, from the bottoms of the machines feet, and from the baseplate flats or pads. Take special care to remove all dirt in the area of holddown bolt heads; otherwise, it is sure to get knocked onto the shimming area by wrenches, jacks, etc. Likewise, clean any jacking or lifting surfaces to keep any loose dirt from finding its way under the machines feet. Rough alignment. Use a straight edge and feeler gages (there are other methods) to position the pump and its driver within some reasonable distance from their desired final aligned location. A rule of thumb for close-coupled machines: Coupling offset should be less than a tenth of an inch. The angles or coupling faces should be nearly eye clean, or within 10 mils per inch of coupling diameter. Straight-edge and feeler-gauge alignment can be much more precise than this, but the extra time it would take to be more exacting is wasted. The idea is to just get the shafts within the measuring range of the laser alignment system and use its guidance to finish the job within desired specifications. Interestingly, many experienced mechanics consider themselves good enough to rough align by eyeball alone, without even a straight edge. More often than not they are correct. CCJ
COMBINED CYCLE JOURNAL, Third Quarter 2008

Visit booth 402 WTUI 2008

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