rotating machines erection guidelines

Originator ALSTOM POWER SYSTEMS S.A..

Alstom Identification number TJN/40/M/----- -----/EG/013

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Owners dwg number T4-APD-B0-A-40104

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ALSTOM 2013. All rights reserved.

Table of Contents:

1. Objective ........................................................................................................................................................... 4 2. General requirements ..................................................................................................................................... 4

2.1. Logic diagram of operations .............................................................................................................................. 4 2.2. Reference documents ....................................................................................................................................... 6 2.3. General requirements concerning works ......................................................................................................... 6

3. Basement level preparation ........................................................................................................................... 6 3.1. Basement level inspection for erection purposes ............................................................................................ 6 3.2. Concrete basement level preparation .............................................................................................................. 6 3.3. Metal basement level preparation .................................................................................................................... 7

4. Installation ........................................................................................................................................................ 7 4.1. General ............................................................................................................................................................... 7 4.2. Installation tolerances ........................................................................................................................................ 7

5. Wedging ............................................................................................................................................................ 7 6. Alignment .......................................................................................................................................................... 8

6.1. Alignment chronology ........................................................................................................................................ 8 6.2. Execution of alignment ...................................................................................................................................... 8 6.3. Allowable alignment tolerances ........................................................................................................................ 8

7. Tightening of anchor pieces .......................................................................................................................... 9 8. Piping connection ......................................................................................................................................... 10

8.1. Erection of pipes .............................................................................................................................................. 10 8.2. Jointing ............................................................................................................................................................. 10 8.3. Connection of the main pipes ......................................................................................................................... 10

9. Inspections ..................................................................................................................................................... 11 9.1. Inspections of the basement level "for erection" ............................................................................................ 11 9.2. Equipment installation inspection ................................................................................................................... 11 9.3. Alignment checking before jointing of pipes ................................................................................................... 12 9.4. Checking of main pipes jointing ...................................................................................................................... 12 9.5. Alignment checking after piping connection................................................................................................... 12 9.6. Alignment checking after final setting of pipe elastic supports ...................................................................... 12 9.7. Checking of auxiliary mechanical equipment erection .................................................................................. 12 9.8. Checking of instrumentation and control installation ..................................................................................... 12 9.9. Miscellaneous .................................................................................................................................................. 12

10. Attachment 1: Alignment of rotating machines ........................................................................................ 12 10.1. Measuring instruments .................................................................................................................................... 12 10.2. Alignment procedures ..................................................................................................................................... 13 10.3. Marking of the reference points ...................................................................................................................... 13 10.4. Adjustment of the distance between shaft ends ............................................................................................ 14 10.5. Adjustment of parallelism ................................................................................................................................ 14 10.6. Adjustment of concentricity ............................................................................................................................. 16



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11. Attachment 2: Calculation of tolerances for semi-flexible coupling ..................................................... 18 11.1. Calculation of speed factor (Fv) values .......................................................................................................... 18



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1. OBJECTIVE

The present document collects the general recommendations and/or requirements concerning the erection of rotating machines and particularly:

motor-driven feedwater pumps miscellaneous motor-driven pumps Given the wide range and diverse nature of the equipment concerned and especially the particular requirements relating to some major components (such as feedwater pumps) the present document can be amended or completed by specific rules mentioned in the Erection Instructions (EI) and/or Erection Quality Control Plan (EQ).

2. GENERAL REQUIREMENTS

2.1. Logic diagram of operations

The extent of the works and inspections to be performed for erection of rotating machines is shown by the following logic principle diagram:



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Miscellaneous mechanical

Inspection of basement

Placing of equipment

level for erectionPreparation of basement level

machines not arranged on a

Alignment checking after main

(coolers, pipes, ...)

Prealignment of the rotating

Main piping connections

Installation of instrumentation

common frame

"Equipment location" inspection

Alignment with anchor boltstightened to their rated torque

jointing

Jointing of main piping

Alignment checking after final adjustment of the elastic

Installation of auxiliarymechanical equipment

Alignment checking prior to pipe

Checking of main piping jointing

piping connection

Final adjustment of the elasticsupports of the main piping

equipment erection checking

and control equipmentInstrumentation and controlequipment erection checking

supports of main piping

X

X

Grouting



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2.2. Reference documents

The basic documents at the Erection Subcontractor's disposal are:

The civil works conformance report relating to basement level. The tolerances allowed for civil works execution (Erection Standard: EG 101) The equipment manufacturing drawing. The general arrangement drawing (GA) or the piping arrangement drawing (PA). The list of equipment and accessories for the equipment concerned and the corresponding

warehouse issue slip.

The erection instruction (EI) with erection drawings and documents. The erection quality control plan (EQ).

2.3. General requirements concerning works

The access and erection areas must be kept tidy and clean.

During erection, all necessary steps shall be taken to protect the surrounding equipment and the equipment waiting for erection.

3. BASEMENT LEVEL PREPARATION

3.1. Basement level inspection for erection purposes

The Erection Subcontractor performs the following operations:

Materialization on the basement level: - of the theoretical equipment installation axes - of a reference level.

Checking of: - location with regard to the theoretical axes - basement level geometry - surface conditions of basement level and anchor holes - location of anchor bars in anchor holes - visuel examination of foundations to search for apparent construction and erection defects

and faults (cracks, deformations, assembly of metal foundations, ...).

Once these inspections have been performed, the Erection Subcontractor:

gives his inspection report stamped "issued for erection" or transmits his observations with request for bringing the basement level to its final form (civil

works basement or metal support)

or proposes a new installation. 3.2. Concrete basement level preparation

Careful concrete surfacing at the shims

Checking of dimensions, flatness and horizontality of the supports thus arranged.



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3.3. Metal basement level preparation

Cleaning of basement levels

Elimination of the defects caused by any possible damage (shocks for instance).

4. INSTALLATION

4.1. General

Rotating machines can be delivered:

on rigid frames, mounted and set in workshop in separate elements with shaft line to be assembled on Site. Refer to the relevant Erection Instruction (EI) for:

location and orientation special instructions Equipment must be installed with respect to the theoretical reference axes of the installation building or area.

4.2. Installation tolerances

Tolerances to be adopted unless stated otherwise in the Erection Instruction (EI) concerned:

Installation with respect to the theoretical reference axes: - arrangement : 5 mm - level : 5 mm

Verticality (perpendicularity deviation) = 0.3 mm per meter Horizontality = 0.3 mm per meter

5. WEDGING

Arranged on each side of each anchor bolt, and as close as possible to the anchor holes (or bolts in case of metal foundations)

Wedging height on concrete foundations: above 30 mm

Reduce to the minimum the number of wedges to be stacked while respecting the stipulated height

The wedges shall be dimensioned (length x width) as specified on the documents attached to the construction package cleaned and burred.

The temporary wedges (screws jacks for instance) provided to make final wedging easier, must imperatively be removed before the anchor bolts are tightened to their rated torque.

The jacks-wedges definitely embedded in grouting mortar shall be blocked by tack-welds after the last alignment checking and before the grouting mortar is poured.



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6. ALIGNMENT

6.1. Alignment chronology

Considering the type of the machine, all or some of the following alignments must be carried out.

Prealignment: only for the machines not installed on a common frame. Alignment prior to pipe jointing:

- before pouring the grouting and wedging mortars - after tightening of the anchor bolts to their rated torque.

Alignment after pipe connection Alignment after final adjustment of the elastic supports of the main pipes.

6.2. Execution of alignment

Alignment comprises 3 types of operation:

adjustment of the distance between shaft ends or coupling plates, axial positioning of axes, radial positioning of axes. Appendix 1 details a method for aligning 2 axes.

Alignment is performed with "cold machines"

The cold position of shafts is defined in the relevant Erection Instructions (EI), when the shaft deformations and displacements affect the alignment.

NOTE: For spring mounted foundations ; shaft alignment is not affected by loading and adjustment of spring supports. Nevertheless it is recommended that the couplings stay open during these operations for control measurement.

6.3. Allowable alignment tolerances

Unless stated otherwise in the Manufacturer's drawing or Erection Instructions (EI), the tolerances are as follows:

Semi-flexible couplings with rubber inserts

For the same coupling, the allowable tolerances vary with the rotation speed.

The alignment is satisfactory if the 3 following conditions are met:

Parallelism: maxi angle difference (EA) = 16 Fv Od/10000 Concentricity: maxi radius difference (ER) = 16 Fv Od/10000 Maxi (EA + ER) = 16 Fv Od/10000 Where Fv is the speed factor calculated by means of the abacus of Appendix 2, Od is the outside diameter of the half coupling.

Rigid couplings



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Parallelism : 0.01 mm max. on a diameter of 100 mm (i.e 1/10000) Concentricity : 0.02 mm max. Flexible couplings

Parallelism : 0.05 mm max on a diameter of 100 mm (i.e 5/10000) Concentricity : 0.20 mm Tooth couplings

Parallelism - Max.: 0.025 mm for n = 1 800 rpm max. on a diameter of 100 mm (i.e 2.5/10000) - Min. : 0.015 mm for n > 1 800 rpm on a diameter of 100 mm (i.e 1.5/10000)

where n = number of revolutions per minute.

Concentricity (tolerance in event of misalignment): - Max.: 0.05 mm for n = 1 800 rpm max. - Min.: 0.03 mm for n > 1 800 rpm.

Clearance between the coupling hubs: 0.5 mm

NOTE: Before measuring the clearance between hubs, make sure that:

The possible axial rotor locking device has in fact been removed, The free rotor of an electric motor is in the correct position with a 0.3 mm tolerance.

7. TIGHTENING OF ANCHOR PIECES

Nuts: mounted lubricated

Tightening torque to be adopted tolerances 5 % if the erection instruction (EI) or its appendices specify no special value.

bolt mm 14 16 18 20 22 24 27 30 33 36

Torque value m daN 3,5 5,5 7,5 10,5 14 18,5 27 33,5 50 64

Tighten all anchor bolts progressively.



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8. PIPING CONNECTION

8.1. Erection of pipes

The pipes absolutely must be erected by starting from the fixed point of the piping so as to end in the machine pipe. In no case shall erection be started by fixing the piping onto the machine.

When designing the piping execution and prefabrication, extra-lengths are to be provided so as to adjust the pipe sections arranged as close as possible to the machine in the 3 planes.

8.2. Jointing

Before beginning any jointing operation, check that the protecting covers have in fact been placed on the machine pipes to prevent any foreign matter from entering the machine.

Jointing is satisfactory only if:

All the welds on the piping jointed to the machine are made (up to the first fixed point support, at least)

All hangers between the fixed point and the machine are free and set on "cold piping" position, in conformity with the instructions shown on the supports drawings

The flange facings are parallel and centered, taking account of the tolerances given hereafter. The clearance between the flange facings complies with the type of connection to be made

(flanges or welds)

Flange-type jointing

During the checking of the jointing, the flange/pipe weld must be totally carried out and checked. Unless specified otherwise in the erection instruction (EI), the preliminary connection tolerances

to be complied with are the following: - Parallelism : < 0.1 mm for pipe < 12"

< 0.3 mm for pipe 12" < < 24" < 0.5 mm for pipe > 24"

- Concentricity : The flange fixing bolts must be put into place manually without forcing and particularly without applying any load or thrust on the pipe whatsoever.

Weld-type

The preliminary connection tolerances are those applying to butt-welding and specified in the Piping Welding Standards or in the relevant Erection Instructions (EI).

8.3. Connection of the main pipes

Before connection check that the piping preliminary connection complies with the instructions specified in item 82,

To prevent any risk of electric striking between the various machine internals during the welding operations, make sure that:

The grounding terminal is well connected to the general grounding circuit of the Power Plant The grounding connector is well fastened to the machine frame. Welds are made in conformity with the Piping Welding Rules. The machine-to-pipe heterogeneous welding processes shall be specified in the Erection Instructions (EI).



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For connections by welded joints:

Realize only one joint at a time on the same shaft line Check the alignment before proceeding to any welded connection of main pipes Take all necessary arrangements to prevent any deformations of the machine, e.g. realize the

weld according to the method of the "Quarters opposite" to 2 welders

Make sure that the machine has not undergone any deformation during welding, so that the adequate measures can be taken as soon as a deformation is detected.

The inspection points specific to the machine are defined in the erection instruction (EI). The corrective actions selected shall receive the approval of the erection supervision department.

9. INSPECTIONS

The following list is not exhaustive. It defines the minimum inspection to be performed by the Erection Subcontractor. In addition to these inspections, the Erection Subcontractor must take all the necessary steps to ensure erection quality.

The inspections specified hereafter shall be detailed in the Erection Quality Control Plan (EQ) which may be completed or amended by the Erection Instructions (EI).

9.1. Inspections of the basement level "for erection"

Visual examination to detect the visible defects

Layout and materialization of the theoretical equipment axes

Basement level altitude

Horizontality of the basement upper part

Dimensions of the basement(s) (geometry)

Installation of the basement(s) with respect to the theoretical equipment axes

Anchoring or fixing holes (number, location, dimensions, installation and location of the anchor bars)

Chipping of the basement surface.

9.2. Equipment installation inspection

Surface conditions, dimensions, flatness, horizontality of base levels for metal wedges

Position of the theoretical axes of the equipment or of a set of elements connected one to another

Horizontality and verticality

Orientation of equipment with respect to the reference axes of the building

relative position of the machines

preliminary alignment of the independant machines.



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9.3. Alignment checking before jointing of pipes

Torque load of anchor bolts

Alignment.

9.4. Checking of main pipes jointing

Erection of pipes up to the first fixed point with setting of supports

Characteristics of each jointing and in particular:

Parallelism of flanges Centering of the pipe on the nozzle Clearance between the sides to be assembled.

9.5. Alignment checking after piping connection

Checking of connecting welds on machines

Alignment.

9.6. Alignment checking after final setting of pipe elastic supports

Filling of the pipes conveying water

Complete thermal insulation of pipes

Unlocking of elastic supports

Alignment.

9.7. Checking of auxiliary mechanical equipment erection

Refer to the Erection Standards relative to the corresponding equipment (fabricated components, piping, ...).

9.8. Checking of instrumentation and control installation

Refer to the Construction Data Package for Instrumentation.

9.9. Miscellaneous

Protection of the equipment being erected and of the surrounding equipment as well.

Inner and outer cleanliness of equipment after erection

10. ATTACHMENT 1: ALIGNMENT OF ROTATING MACHINES

10.1. Measuring instruments

Miscellaneous measuring instruments can be used for the alignment operations and, in particular:

For alignment truing (preliminary alignment): - fitter setting gauge



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- set of adjusting shims

For alignment: - comparators - set of shims (normal or oblique)

These instruments are supplied by the Subcontractor charged with realizing or checking the alignment.

10.2. Alignment procedures

Alignment is to be ensured by a qualified fitter perfectly familiarized with the usual procedures associated with this king of work.

Alignment and prealignment include 3 checkings of:

distance between both shaft ends parallelism concentricity When defining the concentricity corrections, do not forget to take account of the possible shaft line shifting defined in an Appendix to the relevant Erection Instructions (EI).

Before performing the various alignment measurements, make the machines provided with journal bearings rotate a few turns so as to get an oil film

The various alignment measurements require the simultaneous rotation of both shafts as if they were connected.

10.3. Marking of the reference points

4 fixed points to be marked on the body of one of the machines (12 o'clock,

3 o'clock, 6 o'clock and 9 o'clock) according to 2 perpendicular axes (one vertical axis and one horizontal axis - see fig. 1 hereafter).

2 diametrally opposed A and B generatrices to be marked on both half-coupling sleeves (see figure 1 hereafter).



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FIGURE 1

10.4. Adjustment of the distance between shaft ends

The distance between the coupling hubs must be adjusted according to the Manufacturer's drawing so as to respect the functional axial clearances.

Distances shall be checked only after adjustment of the rotors within their respective axial clearances.

10.5. Adjustment of parallelism

Use one or two comparators (normal mounting or mounting with return level). If the measurement cannot be made by means of a comparator, sets of shims may, exceptionally, be used.

Make both machines rotate simultaneously and after each quarter-turn, read the "a" and "b" values at the vertical marks 12 o'clock and 6 o'clock or at the horizontal marks 3 o'clock and 9 o'clock.

See figures 2, 3 and 4 hereafter, for information.

FIGURE 2 FIGURE 3 FIGURE 4



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Driven rotor Driving rotor

D

Driven rotor Driving rotor

D

12 o'clock

9 o'clock 3 o'clock

6 o'clock

a

b

Calculate the average of the "a" and "b" values at the 12 o'clock, 3 o'clock, 6 o'clock and 9 o'clock points.

See figure 5 hereafter, for information.

FIGURE 5

12 o'clock a = 5.00b = 8.00 Average = 6.5 mm

9 o'clock 3 o'clock

6 o'clock

a = 6.75a = 6.25

a = 7.00

b = 7.25 b = 3.75

b = 6.00

Average = 6.75 mm Average = 5.25 mm

Average = 6.5 mm

This example points out that the "a" and "b" measurements made at the same place are not identical. This is of minor importance for the measurement interpretation as an average of both these values is made.

Interpret these averages. The difference between both averages of points facing one another (either vertically or horizontally) gives the parallelism differences.

See figures 6 and 7 hereafter, for information.

FIGURE 6 FIGURE 7

12 o'clock

6 o'clock Difference : 0

Difference : 0

9 o'clock 3 o'clock

Difference : + 0.5 mm Difference : 0

In this example, it will be observed that:



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Parallelism is correct in the vertical plane Parallelism is defective (0.5 mm clearance on 9 o'clock side) in the horizontal plane. The parallelism differences must be less than those allowed for this machine.

Otherwise, corrections shall be made util acceptable values are reached.

In the example mentioned above, one of the machines is to be moved in the horizontal plane for:

Decreasing the 0.5 mm measure at 9 o'clock Increasing the 0.5 mm measure at 3 o'clock.

10.6. Adjustment of concentricity

The comparator is to be arranged on the generatrix marked A.

Make the machines rotate simultaneously and after each quarter-turn, read the "c" value at the 12 o'clock and 6 o'clock vertical marks and at the 3 o'clock and 9 o'clock horizontal marks.

See figures 8, 9 and 10 hereafter for information.

FIGURE 8 FIGURE 9 FIGURE 10

C

C

12 o'clock

9 o'clock 3 o'clock

6 o'clock



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Interpret these measurements

See figures 11, 12 and 13 hereafter, for information.

FIGURE 11 FIGURE 12 Measurement readings Vertical distance and correction

12 o'clock

9 o'clock 3 o'clock

6 o'clock

2c = 4.85 mm

2c = 5.00 mm

2c = 5.60 mm

2c = 5.75 mm

12 o'clock

Correction : 0.30 mim.

6 o'clock

Distance : 0

Distance : + 0.60 mm

towards 12 o'clock

FIGURE 13

Horizontal distance and correction

9 o'clock 3 o'clock

Distance : 0

Correction : 0.45 mm towards 9 o'clock

Distance :- 0.9 0 mm

The concentricity differences must be less than those allowed for this machine.

Otherwise, corrections shall be made on the machine on comparator needle side until acceptable values are reached.

In the example mentioned above, the rotor axis is to be moved even if the relevant Erection Instructions (EI) does not specify any shaft line difference between "cold" and "hot" positions.

0.30 mm (vertically) from 6 o'clock to 12 o'clock 0.45 mm (horizontally) from 3 o'clock to 9 o'clock.



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11. ATTACHMENT 2: CALCULATION OF TOLERANCES FOR SEMI-FLEXIBLE COUPLING

11.1. Calculation of speed factor (Fv) values

Example:

For a coupling with an outside diameter of 300 mm, with spacer, rotation speed of 3000 rpm:

Fv = 0.53

whence the following alignment tolerances:

EA max. =

16 0 53 30010000x x,

: 0.25 mm at the outside diameter of the half couplings.

ER max. = 0.25 mm

(EA + ER) max. = 0.25 mm

rotating machines erection guidelines

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