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
 11. The retention capacity is the total operation (2) An emergency oil pump 4. Oil Sight Flow Indicators: Installed in
LUBRICATION volume below
operating level.
the minimum 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
API 614
12. Retention time is the time allowed (3) Able to supply additional 20% of 5. Solenoid Valves: Act as a pilot valve
for disengagement of entrained air normal oil flow for transient requirement to pneumatic valves, hydraulic
Oil Reservoir:
or gas. (4) Check valves shall be provide on valves, or equivalent alternate valve
1. Manway shall be located on top of
13. The rundown capacity is the volume each pump discharge to prevent arrangement
reservoir
between the rundown level and the backflow of oil through standby pump 6. Pressure Limiting Valves
2. Oil return line shall be located away
maximum operating level 7. Control Valves: Maintain system
from pump suction line to avoid
14. The working capacity is the volume Pressure Regulating Valves: Regulate pressure, reduce pressure, regulate
disturbance of flow
between the minimum operating pressure to prevent fluctuation of the oil flow, or maintain a differential
3. Baffle or internal piping can be put
level and the suction-loss level. pressure to the equipment when both the pressure
in-place to avoid turbulence that can
15. A low-level alarm shall actuate at main and the standby pump are in
cause foaming
the minimum operating level. operation or either the main or the Oil Demister: (1) For oil recovery from
4. Drain connection shall be located at
16. The working capacity between Level standby pump is in operation and the mist (2) Create a certain level of vacuum
the lower point of the slope
C and Level D shall be sufficient for other pump is started or stopped at the top of lube oil tank
at least 5 minutes of normal flow.
17. The minimum retention capacity Coolers: (1) Shall be of shell and tube
shall be calculated based on 8 type unless specified – Fin fan coolers
minutes of normal oil flow. can be used (2) Oil side (shell) operating
18. The rundown capacity shall allow for pressure must be higher than the water
all of the oil contained in all of the side (tube) operating pressure to prevent
components, such as bearings and oil contamination
seal housings, overhead seal tanks,
rundown tanks, accumulators, Filters: (1) Replaceable elements /
control elements, and vendor- cartridge (2) Located downstream of
furnished piping that drain back to coolers (3) Water and corrosion resistant
the reservoir. (4)
5. The rundown level (Level A) is the 19. The rundown capacity shall also
highest level that oil in the reservoir allow for at least an additional 10 Transfer Valves: (1) Switch coolers or
may reach when the entire system percent of these volumes for the filters if fouling or clogged occurs (2) Are
is shut down. purchaser’s inter-connecting piping not intended to be used as tight shut-off
6. The maximum operating level (Level 20. A temperature indicator is installed devices for the maintenance of coolers
B) is the highest level that oil will at reservoir to ensure right and filters
reach during normal operation of the temperature (540C – 710C) for
equipment. correct lube oil viscosity during Accumulators: Needed to maintain
7. The minimum operating level (Level startup control oil pressure during servo-control
C) is the lowest level that oil will 21. Heater is provided in the reservoir to transient or to maintain lube or seal oil
reach during normal operation of the provide oil at the correct pressure while standby pump accelerates
equipment. temperature for start-up from idle condition to operating speed –
8. The suction-loss level (Level D) is 22. N2 is supplied to oil reservoir as the control pressure shall be maintained
the level above the pump section blanket to avoid gas contact with oil above the equipment manufacturer’s
level (Level E) at which the pump vapor. minimum specified supply pressure at all
begins to lose prime. The pump operating conditions (including transient)
suction level is defined by the pump Heaters: Induce heat in order to achieve
suction vortex and net positive / maintain minimum oil start-up Instrumentation, Control and
suction head requirements. temperature Electrical Systems:
9. The charge capacity is the total 1. Temperature Indicators
volume below the rundown level. Pump and Drivers: (1) Equipped with a 2. Thermocouples and Temperature
10. The normal operating range is any main oil pump and a standby oil pump Resistance Detectors
level between the maximum and installed with flooded suction – shall be 3. Pressure Indicators: Shall not be
minimum operating levels. identical and suitable for continuous 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)

Copper Lead 5. Taper roller bearings and spherical 1. Hot oil bath heaters are used to
BEARING



Bronzes
Aluminum
roller bearings will take radial load
as well as axial load 2.
heat bearings and housings.
Dry bearing heaters are electric or

Silver (over-plated) Advantage: Coefficient of friction is low gas air ovens – used only for small
Bearings: Any kind of support for a
compared with plain bearings especially bearings.
rotating shaft or spindle or guide of a
Tilting Pad Bearings: (1) Consist of at low speeds - lower power loss (2) 3. Induction heaters operate the
piece of equipment which slides across
three or more pads located around Wear is negligible if lubrication is correct fastest of all bearing heaters
another – use in equipment and
circumference (2) Each pad able to tilt in (3) Much shorter than plain bearings and 4. Dry ice or freezer can be used for
components that moves
order to assume most effective working take up less axial space (4) Because of tight fit installation in housings – are
position extremely small clearance they permit often too large to be heated when
Functions of Bearings: (1) To carry /
more accurate location (5) Self-aligning an outer race is installed
support weight / loads (radial, thrust and
Installation types permit angular deflection of the
combination) subjected on rotor (2)
1. Split Half bearings are installed with shaft and misalignment. Removal of Anti-Friction Bearing
Maintain correct radial clearance
the ends of the bearings are pushed Disadvantage: (1) Outside diameter is 1. To remove bearings with press fits,
between rotor and casing (3) Permit
together, and the bearings are large (2) Noise is greater than for plain a bearing puller is used
smooth movement between surfaces –
forced (‘Bearing Crush’ – complete bearings, especially at high speeds. 2. When a bearing driver or a press is
reduce friction that can induce heat and
contact of the bearing back with the (3) Greater need of cleanliness when used, put the force on the inner race
wear rate
bearing bore and prevent rotation of fitted to achieve correct life (4) More or outer race.
the bearing in the bore) into the expensive for small quantities but 3. Force must not be put on balls,
Type of Bearings: (1) Hydrodynamic
bearing bore relatively cheap when produced in large rollers, or the bearing cage. This will
bearings – plain bearings, journal
2. Sleeve bearings are normally quantities (5) Failure may be catastrophic cause damage to the bearings.
bearings (2) Anti-friction bearing
installed with a press fit using a
bearing driver – if a sleeve bearing Angular Contact Ball Bearing Bearing Maintenance
Plain Bearings
has an oil hole, the hole must be in 1. Must be kept clean and correct
1. Solid bearings use the principle of
alignment with the oil hole in the lubrication.
sliding action
part into which the bearing is 2. When bearings are serviced, your
2. Shaft turns on the bearing surface
installed hands must be clean and dry.
made of soft metal (to minimize
3. Do not spin the bearings or dry
danger of scoring / damage of rotor 1. Back-to-back is a very stiff
Bearing Repair: Can be repaired by them with air pressure.
shaft) arrangement
reconditioning its inside surface – 4. If the bearing is to be used at a later
3. A thin layer of oil separates the 2. Face-to-face the shaft can tilt
machine smooth or relining time, put oil on all of the bearing
bearing surface and the shaft 3. Tandem - higher axial load only one surfaces, and wrap it in clean paper.
4. Categorized into ‘Split Half’ type and direction
Anti-Friction Bearings 5. Do not remove the paper from any
‘Sleeve’ (one piece) type
1. Parts: Inner race, outer race, ball / bearing until the time of installation.
5. Oil hole and oil groove are made for Thrust Ball Bearing
roller, cage and seal 6. Dirt in an anti-fraction bearing can
rapid supply of oil around bearing
cause the bearing to lock – rolling
surface
components will not move, this can
Advantage: (1) Support large radial load
cause the shaft to turn in the inner
(2) Less radial space required (3) Quieter
race or the outer race to turn in the
in operation (4) Less likely to be
bore.
damaged by contaminating particles (5) 1. Carry axial load in one direction only
Better resistance to unexpected overload 2. Can’t carry radial load Causes Bearing Failures: (1) Mounting
and shock conditions
2. The term ‘rolling bearing’ refers to errors (2) Faulty lubrication (3)
Disadvantage: (1) Good lubrication is Thrust Washers / Plates
both ball (point of contact) and roller Contamination (4) Shaft or housing
necessary bearings (line of contact) 1. Thin solid bearing used for thrust seating errors / misalignment (5)
3. Ball bearings are used for radial loads only. Vibration
Characteristics of Plain Bearing 2. Used on shafts next to gears and
loads but will take a considerable
Material: (1) Score resistance (2) Load axial load – may also be used for other bearings. Symptoms: (1) High Vibration (2)
capacity (3) Fatigue strength (4) 3. Most common materials are bronze
thrust bearings Excessive heat (3) Abnormal noise
Conformability (5) Embedability (6) and steel, aluminum and steel or
4. Roller bearings of the same size of
Corrosion resistance ball bearings can be subjected to lead and tin.

Babbitt (tin-base, lead-base) – melt
higher radial load but will not take
about 1100C Installation of Anti-Friction Bearing
axial load
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.
 that it requires a large axial displacement Advantages of Inside Installation: Advantages of Face-to-Face
SEALING to effect a relatively small force change.
(2) A corrosion allowance can be built
Better cooling, less space requirement
and low leakage
Installation: Can accommodate reversal
pressure
API 682
into larger cross section wire. Advantages of Outside Installation: Advantages of Back-to-Back
Disadvantages: Shaft rotation is a big Ease in maintenance Installation: Ideal for highly corrosive
Purpose of Sealing: Prevent leak of
factor in single-spring seal applications. service
pumped product from leakage and
The spring should be placed in a retainer Tandem Mechanical Seal:
escaping to atmosphere
to resist unwinding. The retainer is large Quench System: Quenching involves
and heavy, introducing a balance and the introduction of a medium, usually
Type of Sealing: (1) Face / mechanical
vibration problem. water, nitrogen or steam, on the
seal (2) Non-contact seal
atmospheric side of a mechanical seal
Multiple Springs assembly. Quenching is normally applied
Basic Mechanical Seal Component: (1)
Advantages: (1) The multiple-spring if the material being sealed is noxious,
Primary seal – rotating and stationary
design has a shorter axial stuffing box (1) Use for toxic and flammable flammable, oxidizes, polymerizes, or will
face (2) Secondary seal - ‘O’-ring,
space requirement than a single coil application (2) Consist of two mechanical crystallize when dried. Quenching can
gaskets or packing (3) Hardware –
spring (2) Face loading (about 30 lb/f) seals – primary and back-up (3) Primary also be used for heating or cooling. The
spring, retainer and etc.
can be more readily varied simply adding seal is flushed by any selected seal flush gland plate is equipped with a throttle
or subtracting springs (4) Multiple-springs plan (4) Back-up seal is provided with bushing to prevent moisture or steam
also resist unwinding from centrifugal flush system incorporating a safe, low leakage from a quenched seal from
forces to a much higher degree than flash point liquid (5) A pressure alarm is entering the bearing housing and
single coil springs, since the forces act provided to actuate on increase stuffing contaminating the lubricating oil, and to
differently and the springs are caged in box pressure between the primary and maximize containment of the quench
retainers. back-up seal indicating primary seal fluid.
Disadvantages: (1) The small cross failure
Design and Selection: Chemical section of the wire can corrode easily - Vacuum Condition: Mechanical seal
properties of liquid being seal put high stainless steels and Hastelloy can Double Mechanical Seal: should not be subjected to vacuum
constraint upon the type of seal compensate for much of this condition
arrangement, material of construction disadvantage (2) The small springs are
and seal design (1) Product – pressure more likely to clog from debris. Mechanical Seal Failure: (1) Heat check
temperature, lubricity, abrasion, corrosion – a pattern of parallel cracks at seal
and toxicity (2) Environment (3) Seal Lubrication and Cooling: Pumped contact surface (2) Blistering – crescent
arrangement (4) Equipment product is injected into the seal chamber shaped cracks or craters on carbon
and a small amount passes through the graphite seal face (3) Spalling – voids on
Principle of Face Seal / Mechanical interface of the mating surfaces the outside diameter or back surface of
Seal: (1) Mechanical force from spring (1) Use for toxic and flammable carbon-graphite seal face (4) Face
(single or multiple) or metal strip bellow Seal Configuration: (1) Single application – cannot be tolerated under distortion – intermittent and uneven wear
that keep two flat polished mating face Mechanical Seal (2) Tandem Mechanical any circumstances such as H2S, track pattern (5) Thermal distress –
together to perform sealing effect (2) A Seal (3) Double Mechanical Seal Hydrofluoric Acid Alkylation or Sulfuric elastomer charred and flaky, ‘O’-ring has
very thin oil film (3 – 5 micron) formed in Acid (2) Leakage of the pumped fluid to taken the shape of the groove (6) Cuts,
between the faces as lubrication to Single Mechanical Seal: the atmosphere is positively prevented by tears and Splits – ‘O’-ring flattened out,
reduce friction and overheating (3) A providing a sealing system, whose liquid torn and split (7) Fretting corrosion –
secondary seal such as ‘O’-ring, gaskets is compatible with pumped liquid, that pitted or shiny area on the shaft or sleeve
or packing is put in place to prevent continuously provides a safe barrier liquid at the location of the dynamic gasket (8)
leakage around faces back – for high at a pressure higher that the pumped Drive pin wear – excessive wear on
temperature application above 4000C fluid (3) Seals are usually identical in torsional drive pins, slots and lugs.
‘Graphoil’ or Kalrez material is used (4) design with exception that one seal
Seal Leak depends on the pressure drop incorporates pumping ring to provide Pre-Installation Check: (1) Check shaft
across the faces continuous flow of liquid to cool the seals run-out (2) Check shaft endplay (3)
(4) Can be installed Face-to-Face or Check radial deflection (4) Stuffing box to
Single Spring: (1) Use for non-toxic and non-flammable Back-to-Back shaft perpendicularity (5) Stuffing box
Advantages: (1) Variations in face application (2) Can be installed inside or concentricity
loading can be attained with a single coil outside
spring, but the rate of deflection is such
 Plan 52 (Low Temperature Product Buffer Fluid: (1) Fluid between two seal
SEALING Flush / Buffer System): face use as lubricant (2) Lower pressure
compared to product
API 682

Flush Plan: A means to provide sealing

with continuous clean and abrasive free
Non-Contact Seal: (1) Labyrinth Seal (2)
lubricant to prevent seal failure such as
Ring Seal – fixed and floating type
wear of seal faces and cooking of
elastomer due to heat
Labyrinth Seal:
Plan 11 (Clean Product Systems):

Consist of a tandem seal with buffer

liquid between them. External reservoir
Recirculation from pump discharge providing buffer liquid for the outer seal.
through a flow control orifice to the seal. During normal operation, circulation is
The flow enters the seal chamber maintained by an internal pumping ring.
adjacent to the mechanical seal faces, The reservoir is usually continuously
flushes the faces, and flows across the vented to a vapor recovery system and is (1) Simple configuration as compared to
seal back into the pump. maintained at a pressure less than the mechanical seal – more reliable (2) Can
pressure in the seal chamber. be categorized to dynamic (as part of
Plan 13 (Product Flush System): rotating part) and static (as part of
Plan 53 (Toxic and Flammable Product casing) (3) A series of circumferential
Flush / Barrier System): 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
Recirculation from pump seal chamber seal land (6) High tolerance to dirt
through a flow control orifice and back to
the pump suction. Use primarily in Ring Seal:
vertical pumps applications because it
provides positive venting of the stuffing
box.

Plan 23 (High Temperature Product

Flush):
Consist of a dual seal arrangement with
barrier liquid between them. Pressurized
external barrier fluid reservoir supplying
clean fluid to the seal chamber. (1) A series of sleeves in which the bores
Circulation is by an internal pumping ring. forms a small clearance around the shaft
Reservoir pressure is greater than the (2) Arrange in a stuffing box – a type of
Recirculation from a pumping ring in the process pressure being sealed. Inner gland seal used to prevent leakage of
seal chamber through a cooler and back seal leakage will always be barrier fluid, such as water or steam, between
into the seal chamber. This plan can be leakage into product. sliding or turning parts of machine
used on hot applications to minimize the elements.
heat load on the cooler by cooling only Barrier Fluid: (1) Fluid between two seal
the small amount of liquid that is use for complete isolation of product to
recirculated. environment (2) Higher pressure
compared to product
 SEALING
API 682

Simplify Seal Oil Schematic:

 1. Lay a straight across coupling rims axis of the driven and driver
ALIGNMENT 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
Alignment: Procedure by which the shaft
Soft Foot Check straight edge touches all the way 3. Formula:
centerlines of one machine is adjusted to
Alternately loosening hold down bolts across both couplings or gap FRONT =
L1× ( Rim ⋅ TIR1 + Rim ⋅ TIR2) Rim ⋅ TIR2
+
be co-linear with the center line of
and checking that a maximum differential between coupling faces is 2d 2
another equipment shaft at operating
rise of .002 of an inch is not exceeded. approximately equal all around
temperature and speed – shaft position L2 × ( Rim ⋅ TIR1 + Rim ⋅ TIR2) Rim ⋅ TIR2
Advantage: Fast – rough alignment, BACK = +
changes due to operating condition i.e. 2d 2
Guidelines of Alignment: (1) Pre- suitable close coupling and low rpm
thermal growth, pipe strain
Alignment (2) Rough Alignment (3) Final equipment
alignment Disadvantage: Trial and error, many Note: No reading taken on the face of the
Purpose of Alignment: (1) Maintain coupling because both the angular and
factors that may affect accuracy,
performance level of equipment by parallel misalignment is corrected by
Pre-Alignment
minimizing forces transmitted to the computing the readings taken on the rim
1. Lock-Out-Tag-Out (LOTO) in place Rim and Face Dial Indicators
equipment internals (bearing, seals etc.) of two couplings
2. Select method of alignment Preferred for DBSE < 1/2 coupling length
when equipment is connected (2) Advantage: Precision alignment, axial
3. Prepare necessary tool and shims
Increase bearing life and rotor stability (3) float will not affect readings
(stainless steel)
Reduce power consumption – 5% Disadvantage: Difficult to read direction
4. Check foundation from void
savings (4) Minimize amount of wear in of moves from dial gauge, coupling
5. Check existing shims – change if
coupling (5) Maintain proper internal backlash
necessary
clearance (6) Lower vibration level
6. Loosen vertical and horizontal jack
bolts Laser (same as Reverse Dial
Misalignment: (1) Misalignment - 1. Set-up one dial gauge with the Indicators)
7. Decide which machine to move
deviation of shaft position from a co- plunger perpendicular to the shaft 1. Set-up the laser transmitter and
8. Ensure bearing are well lubricated
linear axis of rotation when equipment is axis – Rim detector on each shaft / coupling
before turning shaft
in operation – Parallel or Angular 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,
(2) 'Cold Offset' - Misalignment set on 3. Equipment properly leveled 4. Formula: capable of handling long spans between
purpose by the equipment manufacturer 4. Equipment aligned as per vendor L1 × Face ⋅ TIR Rim ⋅ TIR couplings, automated computing for
FRONT = +
to account for the different values of ‘Cold Offset’ value D 2 correction
equipment support growth from 'Cold' Disadvantage: Expensive
position to 'Hot' (running) position Final Alignment BACK =
L 2 × Face ⋅ TIR Rim ⋅ TIR
+
D 2 Sweep Reading Validity Rule:
1. Re-check Rough Alignment
Cause of Misalignment: (1) Improper Advantage: Precision alignment,
2. Re-check ‘Soft Foot’
foundation and base plate (2) Pipe stress Disadvantage: Disassembly of coupling, TOP
3. Install coupling according to vendor
(3) Thermal Growth (4) Soft foot (5) time consuming, trial and error in putting (0.00)
procedure and set proper axial face
Improper pipe support (6) Loose or shimming
gap based on Distance Between R+L=B ( ± 0.05mm)
broken foundation bolt (7) Shim problem Shafts End (DBSE) tolerance
(8) Inadequate knowledge in performing Reverse dial indicators
4. Confirm piping to machinery bolting
alignment Preferred for DBSE > 1/2 coupling length
is properly torque LEFT RIGHT
(0.60) (0.30)
Symptoms of Misalignment: (1) Pre- Methods of Alignment: (1) Straight
mature bearing, seal, shaft, coupling etc. edge / Thickness gauge / Taper gauge
failure (2) Excessive radial and axial (2) Rim and Face dial indicators (3)
vibration (3) High Bearing temperature Reverse dial indicators (4) Laser (5)
(4) Loose coupling bolt or flexible Thread / String – for pulley and sprockets BOTTOM
element (5) Loose foundation bolt (6) Hot Straight edge / Thickness gauge / (0.90)
coupling after stop (7) Abnormal sound Taper gauge 1. Set-up two dial gauges with the
(8) Induced heat plunger perpendicular to the shaft
 density and finishes (3) Non-symmetry of Principal Inertia Axis and phase angle of required correction
BALANCING design (4) Non-symmetry in use including
distortion, dimensional changes – due to
Center of Gravity
masses

rotational stresses Unbalance Correction Methods: (1)

Balancing: Procedure by which the
Addition of prefabricated correction
mass distribution of a rotor is checked
Balancing Machine: (1) Necessary to masses of different sizes at a number of
and if necessary adjusted in order to
detect, locate and measure unbalance – Unbalance locations identified (2) Removal of mass
ensure that the vibration of the journals
data furnished by balancer permits (1) Exist when the central principal axis – drilling (most effective method in
and / or forces on the bearings at a
changing the mass distribution of a rotor of inertia is not parallel to or intersecting production balancing), milling and
frequency corresponding to the service
(2) Balancer only measure unbalance, the shaft axis (2) Most frequently grinding (trial and error)
speed are within specified limit
never balance occurring type (3) Can only be corrected Note: The select correction method
by mass correction in two planes should ensure that there is sufficient
Purpose of Balancing: (1) Increase
Types of Unbalance (ISO 1925): (1) perpendicular to the shaft axis capacity to allow correction of the
bearing life (2) Minimize vibration (3)
Static Unbalance (2) Couple Unbalance maximum unbalance which may occur
Minimize audible and signal noises (4)
(3) Dynamic Unbalance (4) Quasi Static Balancing Methods: (1) Gravity
Minimize operational stress (5) Minimize
Unbalance balancing machines (2) Centrifugal Balance Quality Grade for Rigid Rotor:
power losses
balancing machines (3) Field balancing (1) The product of specific unbalance and
Static Unbalance: equipment the maximum angular speed of the rotor
Unbalance: (1) Excess mass on one
– ISO 1940 (2) The higher the service
side of a rotor – due to centrifugal force
Gravity Balancing Machines: speed the smaller should be the residual
exerted by m during rotation the entire
Advantage taken of the fact that a body unbalance
rotor is pulled in the direction of F
free to rotate always seeks position in
which its center of gravity is lowest
(1) Force unbalance (2) Exist when the
principal axis of inertia is displace parallel Centrifugal Balancing Machines (Soft
to the shaft axis (3) Found in narrow, disc Bearing and Hard Bearing)
shaped parts such flywheels and turbine 1. The amplitude and phase of
wheels (4) If large enough can be motions or reaction forces caused
detected with conventional gravity type by centrifugal forces resulting from
balancing method – on a knife edge level unbalance are sensed, measured
(2) Condition which exists in a rotor when and indicated by appropriate means
rotor will turn until the heavy or
vibratory force or motion is imparted to its 2. Direction of rotation is unimportant
unbalance spot reaches the lowest Allowable Residual Unbalance:
bearing as result of centrifugal forces (3) except for bladed rotors in which the
position
Unbalance in just one rotating direction with least turbulence Acceptable ⋅ Re sidual ⋅ Unbalance × 10
component of an assembly may cause 3. High Speed Balancing is balancing Radius × Number ⋅ of ⋅ Plane
Couple Unbalance:
the entire assembly to vibrate – include at speed passing critical speed or at
structure running speed (especially for Rigid Rotor: A rotor is considered rigid
flexible rotor) while Low Speed when it can be corrected in any two
Units of Unbalance: Mass multiplied by Balancing is balancing at below planes and after that correction, its
the distance from shaft axis operating speed or less than 3000 unbalance does not significantly exceed
RPM the balancing tolerances at any speed up
4. Balancing speed should be as low to maximum service speed
as possible to decrease cycle time,
(1) Moment unbalance (2) Exist when the horsepower requirement, wind, Pre-Balancing Check:
principal axis of inertia intersect the shaft noise and danger to balancing 1. Assemble all rotating parts –
axis at the center of gravity (3) Arises machine operator inclusive coupling hubs
when two equal unbalance masses are 2. Check rotor weight
position and spaced 180 degrees apart Field Balancing Equipment 3. Check rotor rotation
(4) Each end will vibrate in opposite Provide sensing and measurement
directions instrumentation only while rotor runs in its
Cause of Unbalance: (1) Tolerance in
own bearing and under own power –
fabrication (2) Variations within materials
Dynamic Unbalance: convert vibration readings to magnitude
such as voids porosity, inclusions, grain,
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

The vendor shall consult with the Hold Point and Final Inspection:
REPAIR Inspection: owner on material selection and the
Owner and Vendor to define

Conduct dimensional check – shaft owner shall approve the material. whether an Factory Acceptance
REFURBISHMENT run-out, clearance
Shaft areas can be restored by the Test (FAT) is required
API 687
Conduct visual inspection for following processes as per the
Vendor to issue preliminary repair
physical damage; clearly procedures report and final inspection report for
Guideline for Rotor Repair and photograph in detail; and note on a
Tungsten Inert Gas (TIG) owner acceptance prior to shipment
Refurbishment: sketch the size, location, and Process.
1. Develop Initial Scope of Inspection / orientation (including any required
Submerged Arc Welding Preparation for Shipment Shipping /
Repair / Upgrades physical reference point) of any (SAW) Process. Storage Container Documentation:
2. Select Vendor Shop erosion, corrosion and any unusual
High Velocity Oxygen Fuel
Rotors and components for all
3. Transport to Vendor Shop appearances or other damage (HVOF) Process. classes shall be placed in
4. Receiving Inspection resulting in loss or displacement of
High Velocity Liquid Fuel containers with covered tops. The
5. Phase 1 Inspection of Assembled material, deposits, and buildup. (HVLF) Process. basic differences in these
Rotor Standardized sketches, forms, and
Intermittent Combustion containers are the material and the
6. Hold Point and Scope Evaluation tabulations are desirable. Process design for long term storage.
7. Phase 2 Inspection of
Vendor shall clean the rotor to
Damaged shaft area can be turned
Rotor retainers shall be used at the
Disassembled Rotor remove dirt, rust and other foreign down resulting in an undersize cradles to prevent any movement
8. Hold Point and Scope Evaluation material using a procedure shaft. during transit – do not support rotors
9. Repairs / modifications appropriate for the Non-Destructive on bearing, probe or seal areas and
10. Reassembly and Balancing Examination (NDE) methods to be Reassembly and Balancing: at any exposed rotor blades or gear
11. Hold Point and Final Inspection used.
Rotors to be balanced shall be teeth.
12. Preparation for Shipment Shipping /
Performed NDE on component rotated in a direction that is “normal”
Rotor shall be protected with a
Storage Container Documentation
Radiographic to reduce “windage” effects on the corrosion barrier. Critical shaft areas
13. Post Shipment Review
Ultrasonic, components mounted on the rotor- such as journals, end seal areas,

Magnetic Particle and Liquid blading, vanes, etc. probe target areas, and coupling fit
Develop Initial Scope of Inspection / Penetrant Inspection
Rotating components shall be multi- areas shall also be protected by a
Repair / Upgrades: Scope shall at least plane dynamically balanced during separate barrier material to protect
include the Phase 1 Inspection Hold Point and Scope Evaluation: assembly with the shaft against incidental mechanical

Owner and Vendor to define hold
High-speed balancing should be damage.
Vendor Shop: The repair shop should point in which both parties have to Considered which may include, but
be selected on the basis of the shop’s agree to proceed with repair or not not be limited to, the following: Example: Frame-7 DLN Gas Turbine
ability to perform the scope of repair. This
Scope of repair and components
Rotors which have exhibited Parts Send for Repair
depends upon the repair shop’s: replacement must be reviewed and high vibration as they pass Frame-7 DLN
Expected Numbers of
Life Repair

Facilities. accepted by Owner prior to through their critical speeds. Combustion Liner 36k 2

Engineering capability and support. commencement of repair activity
Rotors which accelerate slowly End Cover 36k 2

Experience repairing similar through their critical speeds. Fuel Nozzle 36k 2
equipment. Repairs / Modifications:
Rotors which are running on or Crossfire-Tubes 36k 2
Transition Piece 36k 2

Having a quality system in place
New material used for the repair of near a critical speed. 1st Stage Bucket 72k 1
similar to that recommended by API existing parts or the manufacture of
Rotors which are sensitive to 1st Nozzle 72k 1
replacement parts shall be equal to unbalance. 1st Shroud 72k 1
Transportation: Rotors being returned or better than the original for the
Rotors for equipment in
for repair shall be adequately preserved intended service. Compatibility of extremely critical services.
to prevent from any damage or the materials and the process in
Rotors going to inaccessible
environmental deterioration. which they serve must be verified. locations, such as offshore.

All drawings procedures and
Very long, flexible rotors.
Receiving Inspection: Vendor to record processes used in the repair or
Places where a critical rotor
the condition of the shipping container, manufacture of any component shall cannot be run in its intended
skid, box, etc., photographed to clearly be available and agreed owner casing prior to installation.
show details of any damaged areas and review.
Rotors that have previously
immediately reported to carrier, vendor been high speed balanced and
representative and owner representative have not been disassembled.
 will, in turn, affect the and possible modifications to Plasma Spray: The plasma spray
REPAIR temperature of the powder. the remaining components of process feeds a powder and gas mixture

The base metal may be cooled the coupling assembly due to into a high energy electric arc producing
REFURBISHMENT by air, carbon dioxide, the shaft to shaft dimension a molten metallic stream. The resulting
API 687 nitrogen, etc. This will keep the being modified. impact of the metal powder has low bond
part from distorting due to heat,
Process seals – seals may strength. Plasma spray is not
Consideration for Repair: but may also have an affect on have to be redesigned due to recommended for shaft repair

Determination of the base material the quality of the coating, the smaller shaft.
and the restoration material depending on which coating
Other areas – turned down

Limitations of the processes medium is used. dimension may affect the
(thickness; environment of the part
The powder may be injected in mating component
chemical, thermal compatibility; different locations in the flame
Torque capabilities
machinability; mechanical bonding stream to vary the amount of
The modification may affect the
capabilities; velocities of steam / heat to which the powder is spare rotor, spare parts and
gas) subjected. component delivery due to the

Concerns of using the technique for
The type of fuel may vary. non-standard dimensions.
the application
Mass flow meters may be used
The preferred method is

Durability / economics / risk rather than pressure drop type grinding

Time constraints flow meters to control powder,

Experience using the technique in fuel and oxygen flow rates. Shaft Restoration by Plating: When
that shop and user’s reference list specified, components may be restored

Qualification of repair procedure to original design size by chrome or
and people Intermittent Combustion Processes: nickel type plating. The application

Quality control procedures Oxyacetylene powder method firing a method, procedure, thickness, quality
very high velocity stream of particles control checks, and acceptance criteria
Repair Methods: Weld repair, thermal
Oxygen, acetylene, and powdered should be mutually agreed upon
spray, reducing ‘Turning Down’ the shaft, coating material suspended in
plating, shaft straightening, metallizing, nitrogen are metered into the Shaft Straightening: When specified,
and plasma spray combustion chamber the restoring of the shaft straightness

A spark detonates the mixture to may be attempted by stress relieving,
High Velocity Fuel Processes: create a hot, high-speed gas stream peening, or cold or hot straightening.
Generates a velocity of molten metallic which makes the particles plastic Shaft straightening is not preferred due to
stream. while hurling them from the the following situations:

Metal powder impacts the item applicator
Low success rate for all diameters
being sprayed with high energy
Successive detonations build up the
Shaft does not always maintain this

The metal powder bonds with the desired thickness restored straightness while in
base metal. The powder particles operation under load and
flatten as they impact the surface Reducing (Turning Down) the Shaft: temperature
and the coating is built-up, layer by Reduction of a diameter on a shaft and
Smaller diameter shafts are more
layer, to achieve a fully dense leaving the shaft at the reduced diameter difficult to straighten than larger
structure. – no build-up to the original diameter is to diameters

HVOF process uses gas as the fuel occur.
and HVLF process uses liquid as
It is important to understand that the Metallizing: The metallizing process
the fuel. reduction of the shaft diameter may generates a low velocity molten metallic

HVOF / HVLF processes differ in affect items such as: stream. Since the kinetic energy varies
their application methods in the
Bearing journals - The journal, by the square of the velocity, the
following ways: thrust bearing, and / or seal resulting impact of the metal powder has

The applying device may be rings for the bearing housing comparatively lower energy resulting in
cooled by a different medium may have to be redesigned low bond strength and high porosity.
(air, water, etc.) This will affect due to the smaller shaft. Metallizing is not recommended for shaft
the flame temperature which
Coupling shaft end – coupling repair
hub may have to be replaced
 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)