‘SHAFT ALIGNMENT The object of shaft alignment is to put the axis of rotation, which is coincident with the geometrical center; of one shaft exactly in Line and concentric with the axis of rotation of ‘a second shaft: In the following discussion, the terms shaft alignment and coupling alignment will be used synonymously. This is possible because in both solid and flexible couplings, a part if not all of the coupling is rigidly mounted on the shaft and can be treated as. an integral part of the shaft. The purpose of shaft or coupling alignment is to provide for smooth running of the equipment. In the following article, all figures and illustrations are greatly exaggerated for clarity. In actual. practice, one will be dealing in measurements of thousands of an inch to detect misalignment in shafts, which to the naked eye, appear to be in alignment. Also, perfect con- ditions will be assumed regarding the shafts being measured and the. measuring instruments. being used. The alignment of shafts and/or couplings. is determined by taking two sets of readings. One set is taken on the periphery of the shaft and is called "rim" readings; the second set of readings is taken on the end of the shaft and are called “face” readings (see Fig. #1). A rim or periphery check is taken to determine if the projection. of the end or rim of one shaft or coupling is exactly concentric with the rim or end of a second shaft (see Fig. #2). These readings can be taken with either a straight edge and feeler gauge or a dial indicator In-using the straight edge and feeler gauge, the straight edge is laye across the top or against the side of the shafts being aligned and, a feeler gauge used to measure gap "A" (see Fig. #3), which is the-exact amount of vertical or horizontal ‘displacement-or misalignment between the two shafts at their rims, It should’be “noted that the. shaft idfam- eters must be equal for this method to-be used easily:.-The most’ commo method of taking a rim check is by use of the dial indicator. In this method, the dial indicator is mounted on one shaft and reads or indi~- cates on the second (see Fig. #4). The indicator is set at "0" at the youpling Face FIGURE 1 EIGURE 2 Shaft #1 \j--— Shaft #2 ‘) FIGURE 3 Shaft #1 Shaft #2 — fs Top or Side View Top or side ViewFIGURE 4 Dial Indicator Shaft 1 a I Shaft 2 Lo FIGURE 5 Top o Indicator Left +.004 RIM #.004 Right Mounted on Shaft #1 +.008 Bottomtop, and the shaft on which the dial indicator is mounted is turned ) in increments of 90°, the indicator readings being recorded as either a (+) or (-) number at each location until the indicator is back a the top to the initial. "0" position. The data is recorded on a circle (see Fig. #5) on which is noted the left, right, top, bottom of the shaft system, the (+) or (-) dial indicator reading, and on which shaft the indicator was mounted. The second alignment check, the face check, tells if the shafts are:in angular alignment; whether the axes of rotation are in parallel planes,. planes at an angle to each other, or in the case of a perfect’ face and rim check, exactly concentric, It can be seen in Fig. #6 that the projection of the rim of Shaft 1 is concentric with the rim of Shaft 2 or vice versa, but the shafts are not in angular alignment, the axes : of rotation are not concentric. Face readings or measurements can be taken using several different instruments, depending on the size of the gap between shaft ends, these include feeler gauges, sliding: par- | allels and micrometer, dial indicator or inside micrometer. The object of these readings being to measure the gap between the two shafts in four (4) equally spaced places (usually at the same locations ‘the rim ~ readings were taken) on the top and bottom vertical centerline and on the left and right horizontal centerline (see Fig. #7). The face reading data'is recorded in the same manner as the “rim* readings; the left, right, top, bottom are labeled.and the shaft or coupling diameter at which the readings were taken is noted. The readings should be taken on the largest shaft or coupling diameter. possible, usually the outside diameter. When recording the face read- ings, to aid in analysis, they should be reduced’ to relative readings. This is usually done by subtracting the smallest ‘reading from all of the readings to give a "0" reading at one of the four (4) ‘positions (see Fig. #8). Figure #8 is typical of a face reading with the coup!~ ing "open" on the left. Once it has been determined by face and riz checks that two shafts are out of line, it becomes necessary to determine how much and in. what direction one of the two shafts must be moved to produce. the desired In the following examples a "fair" coupling or shaft align- alignment. aoeShaft 1 FIGURE 6 FIGURE 7 Shaft 2 Top View Side View wep View Sitio’ ViewFIGURE 8 Left Shaft Dia. = 1a" PIGURE 9 Shaft 1 Shaft. 2 Top fa Side View Bottom | Left } eS = Top View | Right T 0 so 9 o Indicator Mounted On L +.01q 2010 L 225 pace Oo; R Shaft 1. R 0 ° +.020 . B Bce ment will be sought. A fair alignment being one in which all of the rim and face readings equal zero, In actual practice an alignment other than “fair" may be required. However, the procedure and prin- ciples are the same. CASE 1 The rim and face checks are taken; the face check is good, all rela- tive readings equal to 0, the rim check is bad. ‘(see Fig. #9). From the face and rim readings and sketch of Fig. #9, it can be seen that the axis of rotation are parallel but not in the same horizontal piane, the projection of the rim of Shaft #1 is not concentric with the rim of Shaft #2. In thts case, Shaft #2 is .010" lower than Shaft 1 which is exactly one-half of the algrbraic difference of the top and bottom readings (1/2 [20-0] = 10). Fig. #9 shows that an indicator would travel 2A in going from the top to the bottom of Shaft #2,. but the actual displacement of Shaft #2 1s A, which is the amount of displace- ment that would be measured by a straight edge and feeler gauge. There- fore, to correct this misalignment Shaft #2 would have to be moved up .010" or Shaft #1 would have to move down .010". The shafts are in’ line left to right as one-half the algebraic difference of their read- ings (1/2 [10-10] ) equals 0, so no move is indicated. It should be noticed that when measuring on a circle, the algebraic sum of the top and bottom readings will always equal the algebraic sum of the left and right readings. This fact can be used to check the readings to make sure they are reliable. CASE 2 The face check is found to be acceptable (all relative readings equal to zero) the rim check is bad (see Fig. #10). From Fig. #10 it can be | seen-that the-axes-of rotation are-not: in the same vertical plane. To simplify the analysis of Fig. #10, add +.010 to all readings (See | Rim A). It can now be seen that Shaft #2 is displaced horizontally 010" to the right, which is one-half of the algebraic difference of the left and right readings (1/2 [.020-0]= .010). No vertical move | is indicated as the top and bottom readings are equal. To correct | this misalignment, Shaft #2 would move .010" to the left or Shaft #1 would move .010 to the right.FIGURE 10 | Indicator Left [— OF x" Dia. Mounted Top View Shaft 1 Right ‘a _—— Shaft 1 a — Shaft 2 top Pele Side View SS Bottom ‘ 0 T j -.010{L RIM R}+.010 Lo +.020R, BU CASE 3 (Fig, #11 Once again the face check is good (all relative readings equal zero), but mow the axes of rotation are neither in the same vertical or horizontal plane . From the rim check it can be determined that Shaft #2 is low .010" (1/2 [.020-0] = .010) and .018" to the right of Shaft #1 (1/2 [.028 - (~.008)] = .018). To check the accuracy of the readings, the algebraic sum of the left and right readings equal the algebraic sum of the top and bottom readings. Therefore, to correct the alignment of these shafts, Shaft #2 must move up .010" and to the left .018". When correcting for rim readings, straight up and down or left and right moves were made. This: is not the case when correcting for face readings, Face reading corrections require the shaft to be pivoted about some point so as to correct for the angular misalignment. Ideally, the shaft may be pivoted about any point on the shaft. \ By Convention, it is usually pivoted about a point on the outside dian- eter of the shaft or coupling, or about the center of rotation of the shaft or coupling. Both methods give the same results as will be explained. In the following discussion, because of the relatively ° large radius and small movements involved, it will be assumed that when the shaft is pivoted, it moves in a straight line rather than on arc. CASE 1 (Fig. #12 : The rim check is good, which means that the projection of the rim of Shaft #1 is concentric with the rim at the end of Shaft #2, but the face check is bad; the axes of rotation are not in the same vertical plane. From Fig. #12, it can be seen that the coupling is “open® +050" on the left, which is the algebraic difference of the left and right readings (.050-0 = .050). The faces are parallel from top to bottom as the algebraic difference of these readings equal 0. To correct this misalignment, point "8" would be pivoted about point “A® +050" toward Shaft #1. The same results would be obtained by pivoting point "A: one-half the total misalignment about point "C" (at center of rotation) in a counter clockwise direction. These both give the same result because in the first case the ratio of movement is the total misalignment to the diameter of the shaft and in the second case it's one halfFIGURE 11 Shaft 1 I A Shaft 2 t best nop View } » Right pH is js Side View Bottom Shaft End View A v 0 q +.028 R Ind. +.020 Mounted B on Shaft 1 oCShaft 1 Ind. Mounted on Shaft 1 FIGURE 12 Point’A Point B Shaft 2 Point C Left wo Shaft 1 Ind. Mounted Shaft 1 on Shaft 1 oR FIGURE 13 ——==— RIM Top View Side View X" Dia. Top View Side View 24" Coup. Dia WDthe misalignment to the radius. CASE 2 (Fig. 13 The rim check is good (all readings equal 0). The face check shows the coupling open on the left and the bottom. From Fig. #13, it can be seen that the coupling is open .030" on the left (algebraic difference of left and right readings), and it is open .020" on the bottom (.025 - .005 = .020) which is the algebraic difference of the top and bottom readings. To correct this misalignment, point B on Shaft #2 would have to be pivoted CCW .030" about point A in the horizontal plane and point D would have to be pivoted CW .020" about point C in the vertical plane. After the alignment data has been analyzed and the magnitude and direction of the move determined at the coupling, it now becomes nec- essary to calculate the move in relation to the number and locations of the shaft supports which until now have been ignored. In the following examples, the correct alignment will be calculated to be achieved in one horizontal move and one vertical move. It should be noted, however, that practical considerations may cause this procedure to be extended to-several moves. The principles and procedures remain! the same. i Rim reading corrections are accomplished by straight vertical and/or horizontal moves in which an equal amount of shims are added or sub- tracted from each support or each support is moved latterly an equal | amount. Referring to the example in Fig, #11, the correction is to add .010" of shims under the shaft supports and to move the shaft .018 to the left (see Fig. #14). | Movement of a shaft to correct for face readings is more involved than correcting for rim readings because the shaft supports are moved un- equal amounts. Referring to the example accompanying Fig. #13, both horizontal and vertical pivotal moves must be made, The amount of these moves at the supports is calculated by equation 1 on Fig. #15. The shaft must be pivoted as mentioned earlier by these calculated amounts to the left and down. The shaft is moved down by removing . i}Shaft 1 — 7. 4 77 WTTT7 A B Support T oO Ind. Mounted On Shaft 1) 3p R 7 +20 B Shaft 2 Vertical Horizontal FIGURE 14 sup. 1 sup. 1 +.010 +2018 Shaft 2 Side View Sup. 2 Sup. N x" Coup. Dia, FACE READINGS: SLIDING PARALLELS B + MICROMETER sup. 2 Sup. N +010 +.010 +018 +.018 13shims from under the various supports. This type of correction where “step shimming" is involved lends itself very well to solution on a slide rule or by graphical means, In the graphical method, appropriate scales are marked off and the slope of the line is given by the ratio ®yy or C/A (see Fig. #15). See Fig. #158 for the solution of this example by graphical means. The most involved alignment problem is one in which both a rim and face correction must be made. In this type of problem a tabulation of the moves, both magnitude and direction, must be kept so as not to become confused when making the final vector additions for the “single move" correction. In actual practice, one would be wise to first make the verticle move at each support as calculated, with dial indicators set up to measure any horizontal movement. The horizontal move can then be made, taking into account any side movement that may have occurred during the vertical move. See Fig. #16 for the solution of this type of problem. From the rim readings, it can be seen that Shaft #2 is .008" low and..006" to the left (1/2 of the algebraic difference between the readings) which’ means a the correction would be to move Shaft #2 up .008" and .006" to the | right. The face readings show that the coupling is open .012" on the left and .020" on the bottom (the algebraic difference between these readings). The face reading corrections are calculated using | equation 1 (Fig. #15). Shaft #2 will be pivoted to the left and - down. The actual vectors are entered on a chart and the total move determined as illustrated in Fig. #16. | In conclusion, when dealing with shaft alignment. problems, correct | for one move at a time and enter the moves on a chart from which the total move can be deduced, remembering to move the shaft one-half of. | the algebraic difference of the im correction, and the total algebraic difference when making a face correction. Field Engineering Development Center fs () DOUGLAS LEMMO : ~~. 21 Sept. 1976 } “6FIGURE 15 Bi. dL. 02. YCR "Ry TTR C = Diameter of Coupling or Shaft A = Amount Shaft Must Pivot At the Face D = Distance From Coupling Face To Support EQUATION #1 X = Amount Support Must Move Horizontal or Vertical R = Radius of Coupling or Shaft ¥ = 1/2A = 1/2 Shaft Movement | From Fig. 13 6 lo" N Shaft 1 Side View ) Shaft 2 ae iu Ind. Ot). ata aioe olR 24" coup. Dia. | Mounted on FACE READINGS: | Shaft 1. ey SLIDING PARALLELS + ‘ a MICROMETER | VERTICAL CORRECTION HORIZONTAL CORRECTION 24 72, 192, Ne192 24 = 22 = 192. mei92 020 * ¥ ¥ X, -T50 ¥ ¥ ty Fay Ny yy Ney | xy, 7 060% 7 090" i C X, = .160"% Ky = .240 | ay 2H Xy = 2020 (N+192)) Xy_ = 2030 _(192+N) | —a ig 7 20 [Seenseyour-310ddng 03 aoeg SuTTdnoy wor; eoueasta OGT O8T OLT O9T OST OFT OET OZT OTT COT 06 08 o£ 09. 0S oF of oz ot zoqourta Buttdnoy 1 q10ddng| ‘quowenon BuzTdnop z 3z0ddng < 6 wor309r709 a TeOTA TOA, 2 5 g EB ‘uot3091709 [eqUOZ TION ioe oe 6S e S$ SF A e a = 3Yeueaow 3z0ddng jo junowy ee el i) ib 'snoY, 4 < ° e 8 ySuy ue zo Syapul e ovz NoILnTos 7 rHawia o9z 6FIGURE 16 o ? r FACE READINGS: =e SLIDING PARALLE + +014 [% RIM RJ. 002 L[+.016 +,004 R MICROMETER Indicator Mounted On Shaft 1 B Fr0I6 B Coupling : Dia. = le" 6 lot N shaft 1 \ Shaft 2 | sup. sup. sup. A B Z H EQUATION 1: Horizontal 18 _ 72 _ 192 _ 1924N , Correction 012 ~ x, * x) aH lH FACE Vertical 1g 72, 192 | 1924n CORRECTIONS Correction .020 " ¥,_ "Xj ~ “x yoy ON r Support 1 Support 2 Support W HORIZ. VERT. vortz. | verr. || worrz. VERT. RIM CORRECT. ‘+.006 +008 =| +006 | +.008 +006 | +.008 j FACE CORRECT. +.048 +080 +128 ++213 || +.022(292+n) | +.020(292+0 | Te | | ‘TOTAL =.042 $072 ~.122 ¥.205 | +).012(1924N) 9) MOVE | / t Te 17-005. | | | i + (2020092400) 5 999T6=190 (SHEET 7A) (5-72) , COUPLING ALIGNMENT CUSTOMER TURBINE SERIAL SECTION, coDE DATE____ FOREMAN’S SIGNATURE. DATE_____INSPECTOR’S SIGNATURE. DATE _____ INSTALLATION SUPV’S SIGNATURE, DATE ENGINEER'S SIGNATURE. PERIPHERY PERIPHERY NOTE: CHECK TO BE TAKEN LOOKING TOWARD GENERATOR, ENTER AVERAGE OF FOUR 90 COUPLING eee COUPLING BRACKET BRACKET OR INDICA OR INDICA- TOR MOUNTED “TOR MOUNTED ON. SIDE SIDE OF COUPLING OF COUPLING i NOTE: CHECK TO BE TAKEN coo’ LOOKING TOWARD GENERATOR. ENTER AVERAGE OF FOUR 90° COUPLING CHECKS. Eure COUPLING BRACKET OR INDICA- TOR MOUNTED ON. SIDE OF COUPLING BRACKET OR INDICA: TOR MOUNTED ON___SIDE OF COUPLING Couplings to be aligned in accordance with bea bolted. Refer to coupling assembly instructions for individual unit. yment diagram, and with all upper half casings assembled and 2. Periphery checks must be within .002" of expected value shown on the bearing alignment drawing. Faces ore to be aligned parallel horizontally within 001" only to be made with engineering approval. 3, Rotor position changes 10 favor coupling alignment 18EMI1910] Page 4 of 4 ae Jen. 1, 1979, 1&SE FIELD ENGINEER'S MANUAL —LST- Fitting Instructions— ‘TURBINE : Bearing Ring to Pedesi a! to the pedestal in the areas of ring pad pedestal fit. Assemble the bear ing and ring assembly tothe pedestal and rotate the bearing ring slightly. Remove the assembled bearing and ring from the pedestal and inspect the markings of the ring pads. If there is a minimum of 75% contact per pad, the fit is satisfactory. Pads containing oil feed and drain holes should have contact completely around the hole circumference. If ‘some additional scraping and shim- ming is required to improve contact, it is not to.be done in a manner that would effect the alignment es- tablished. (See Fig. 2 for typical mis- alignment conditions that occur in which shimming and/or scraping will be required). 7 Note After the rotors are installed and it A is found necessary to make a final . bearing alignment change, it will not be necessary to re-check the contact on the pads if the rotor is moved-10 mils or less. | ‘Add or remove shim on each pad equal to amounts given in ‘Table A. For pads on the vertical centerline (O°), the shim change equals the vertical shift. To. ralee 08 Inch ‘0055 inch shim. i ‘To lft right .006 Inch ad¢ .004 Inch shin, Tolal of ebove - add .0086 inch shim, Fig 6 GENERAL @® ELECTRIC .008 inch add'.0085.Jach shim. . {right .006 inch remove .008 ineh shim, 1 of bore = ad COIS Iaeh shin, “The pad angles referred to in the fol- \ lowing ables ae always measured from ’ the vertical center line. The tes are based on the following mathematical 1 felaion, whore the pad angle fs" 6" Shim change : Shim change TABLE A o “TABLE B “Amount of Shits] __ Shim Change for Pad on the “Amount of Shite] Shim Chang fin Mis) Following Angles (in Ba) tin Ms) Following 18 [jsoe Pase- [25° = ase | 30°) rhe ff yo = [a a 2 fa pomp Ta ala a 3 papa ais Spinal Paneer woe 1 pels 4 toe) Peo) ae ghd es 5 5 a fail wes =- fatal saad s te Ton [eta ahaa F nals ta] 6 7 7 |e [Ps = U7 = [sials [a We a Ee ET 3 2 [4p smal So vials [eal - sk = [al eials ory 9 Bay 7 awa 10 aya 5 7 10 Table A — Toshi Bearing Vertcaly Tbe 8 — To Shit Bearing Horizontal ves) Remove shim from side in direction’ of motion and add it to ' the corresponding pad on the ether side ip amounts given in Table B. 1%This manual contains information prepared for, and considered confidential to, the General Electric Company, and is restricted to use by General Electric Company employees only. This manual is not to be read by, copied for, or otherwise released to non-General Electric Company personnel, such as customer personnel, architect-engineering consultants, contractor personnel, service competitors, etc., or otherwise used directly or indirectly in any way detrimental to the interests of the General Electric Company. FIELD ENGINEERS MANUAL VOLUME I AND II ENGINEERING MANUAL LARGE STEAM TURBINE AND GENERATOR BM2160: SOLID RING EXPANSION JOINT MAINTENANCE (MARCH 2, 1992 INTRODUCTION INTRODUCTION Solid ring expansion joints serve. a twofold purpose. First, they pipe steam from one shell to another. Second, they accommodate differential (em between the shells. ost designs have a pipe or snout with stellite hardfacing on the oD gliding fits. The pipe fits in a series of sliding solia rings which | Scconnodate lateral movement. Fig. 1, HP inlet pipe (not typical), shows ,an expansion joint assembly on a HP inlet pipe. |The most common field problems with ring-type expansion joints include loose retaining rings, tight seal rings, snouts frozen in the rings, and ‘cracked stellite. | ‘this article will cover the recommended repairs and modifications of ring expansion joints. Consultation with Product Service Component Engineering is required before any of the work is undertaken. fies , [toose REVAINING RINGS ” renasonaliy, reports are received on turbines where the retaining rings for the locking rings have loosened up to the point of falling off. These retaining rings lay around the pipes. Fortunately, the locking ring segments are kept in place by the snout. Retaining ring looseness is a problem reported only on the Type A design (Fig. 2) and on modifications 3 of the Type A design (types B and C -- Fig. 2) where the retaining ring rests against the shell or nozzle box. If the retaining ring is assembled too deeply into the shell or nozzle box, or if the retaining ring is machined incorrectly, differential thermal expansion can push out the peening or crack the welds, loosening the retaining ring 70 eliminate the possibility of the ring assembly coming loose, the designs of the locking and retaining rings have been changed. In the new modification, axial forces caused by differential expansion are resisted by the groove in the shell or nozzle box, avoiding the wear on the small welded or peened area which occurred in the previous design. Types D and B (Fig. 2) illustrate this design, with retaining rings welded directly to ) locking rings. Our current design, Type E, has its locking rings also welded to the shell or nozzle box’ to eliminate the need for peening and an anti-rotation pin (Refer to Type D -- Fig. 2. Fig. 2. Various types of retaining and locking rings) Welds on the Type E are made at a Page 1 Tue Oct 31 18:16:05 1995 ‘ 20