Best Practice

SABP-G-003 Special Purpose Steam Turbines Dynamic Analysis Factory Acceptance Test Document Responsibility: Consulting Services Dept. 31 October, 2004

Saudi Aramco DeskTop Standards

Table of Contents 1 2 3 4 5 6 7 8 Introduction.................................................... 2 References.................................................... 2 General.......................................................... 3 Definitions...................................................... 3 Vibration Detectors........................................ 5 Shop Verification of Unbalanced Response Analysis....... 6 Tests Procedure............................................ 6 FAT Acceptance Criteria................................ 8

Previous Issue: New Next Planned Update: 1 November, 2009 Revised paragraphs are indicated in the right margin Primary contact: Khaleel M. Al-Hussain on 873-0311

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Document Responsibility: Consulting Services Dept. Issue Date: 31 October, 2004 Next Planned Update: 1 November, 2009

SABP-G-003 Special Purpose Steam Turbines Dynamic Analysis Factory Acceptance Test

Introduction 1.1 Purpose The purpose of this Practice is to establish guidelines in reviewing the dynamic analysis of special purpose steam turbines during Factory Acceptance Test (FAT). 1.2 Scope This Best Practice gives general guidelines for reviewing vibration instrumentation requirements, test procedure and acceptance limits during the Factory Acceptance Test and does not include performance test criteria. 1.3 Disclaimer This Best Practice is being provided for the general guidance and benefit of Saudi Aramco engineers attending special purpose steam turbines Factory Acceptance Test (FAT). The use of this Best Practice during factory acceptance test, however, does not relieve the manufacturer from his responsibility or duty to confirm or to verify the accuracy of any information presented or from his contractual liability to perform an accurate FAT that conforms to Mandatory Saudi Aramco Engineering Requirements. The use of the information or material contained herein will not guarantee that the resulting product satisfies the applicable requirements of Saudi Aramco Standards. Saudi Aramco assumes no responsibility or liability whatsoever for any reliance on the information presented herein or for FAT performed by manufacturer in accordance with this Best Practice document. Moreover, this Best practice is intended only to provide guidelines for Saudi Aramco engineers attending the Factory Acceptance Test and shall not be considered as a replacement for the Mandatory Saudi Aramco Engineering Requirements. Saudi Aramco is a registered trademark of the Saudi Arabian Oil Company. Copyright, Saudi Aramco, 2004. 1.4 Conflicts with Mandatory Standards In the event of a conflict between this Best Practice and other Mandatory Saudi Aramco Engineering Requirement, the Mandatory Saudi Aramco Engineering Requirement shall govern.

References This Best Practice is based on the below referenced standard: 2.1 Saudi Aramco References
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Document Responsibility: Consulting Services Dept. Issue Date: 31 October, 2004 Next Planned Update: 1 November, 2009

SABP-G-003 Special Purpose Steam Turbines Dynamic Analysis Factory Acceptance Test

Saudi Aramco Engineering Standard SAES-K-501 Steam Turbines (30 September, 2003)

Saudi Aramco Materials System Specifications 32-SAMSS-010 34-SAMSS-625 2.2 Special Purpose Steam Turbines (30 September, 2003) Machinery Protection Systems (30 June, 2002)

Industry Codes and Standards American Petroleum Institute API STD 612 Special Purpose Steam Turbines for Petroleum, Chemical and Gas Industry Services, 4th Edition Machinery Protection Systems, 4th Edition

API STD 670 3 General

This best practice gives general guidelines for the vibration instrumentation requirements, test procedure and acceptable limits during special purpose steam turbines factory acceptance test. The attendee should review the rotordynamic analysis prior the test. At least 6 weeks before the first scheduled test, the vendor shall submit to the purchaser, for review and comment, detailed procedures for all tests, including acceptance criteria for all monitored parameters. (API STD 612/ P 4.3.1.2) A minimum of 14 days advance notice shall be provided for any observed or witnessed testing. (32-SAMSS-010 / P 4.1.4). Provisions shall be made for ready access (not requiring removal of the case) for field balancing between the bearings. The number and location of these points shall be mutually agreed upon by the purchaser and the vendor. (API STD 612 / P 2.6.15). 4 Definitions Acceptance Level: This is the vibration level (displacement, velocity, or acceleration) at which a machine can run indefinitely without inducing vibration related maintenance. Factory Acceptance Test (FAT): is a test conducted at a factory to ensure that the turbine meets its required performance and mechanical integrity.

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Document Responsibility: Consulting Services Dept. Issue Date: 31 October, 2004 Next Planned Update: 1 November, 2009

SABP-G-003 Special Purpose Steam Turbines Dynamic Analysis Factory Acceptance Test

General purpose steam turbines: are those turbines used to drive equipment that are spared or not critical to plant operation. General purpose steam turbines shall not be used for applications requiring a rated power exceeding 2,250 kW (3,000 HP), a maximum continuous speed exceeding 5,000 RPM or for steam conditions exceeding a pressure of 4,800 kPa Gauge (700 psig) and a temperature exceeding 400C (750F). (32-SAMSS-009 / P 1.1.1.1). Special purpose turbines: are those turbines used to drive equipment that is usually not spared, is relatively large in size (power), or is in critical service. This category is not limited by steam conditions or turbine speed. Special purpose turbines shall be used for all applications not covered by the above general purpose steam turbines. (API STD 612/ P 1.1.2.2 & SAES-K-501 / P4.2.1). Hydrodynamic bearings: Bearings that use the principles of hydrodynamic lubrication. Their surfaces are oriented so that relative motion forms an oil wedge to support the load without journal-to-bearing contact (API STD 612 paragraph 1.4.8). Maximum continuous speed (revolutions per minute): is the speed at least equal to 105% of rated operating speed (see API STD 612 Figure 5). (API STD 612 / P 1.4.14). Mechanical running test: is a test of a steam turbine to demonstrate mechanical integrity of the turbine package and functionality of the instrumentation. This test is normally performed uncoupled and under no load. (API STD 612 / P 1.4.21). Slow roll: is the speed recommended by the vendor (typically 400-500 revolutions per minute) for warm-up and initial check of equipment integrity prior to full operation. (API STD 612 / P 1.4.31). The speed governor system: is the primary system necessary to match the turbine speed to the application. The governor includes those elements which are directly responsive to speed and which position or influence the action of other elements of the governing system to maintain the operating speed within the specified limits. (API STD 612 / P 1.4.32 & 3.4.3.1). Trip speed (expressed in revolutions per minute): is the speed at which the independent overspeed shutdown system operates to shut down a prime mover. Trip speed shall be at least 115% of the maximum continuous speed (see API STD 612 Figure 5). (API STD 612 & 32-SAMSS-010 / P1.4.36).

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Document Responsibility: Consulting Services Dept. Issue Date: 31 October, 2004 Next Planned Update: 1 November, 2009

SABP-G-003 Special Purpose Steam Turbines Dynamic Analysis Factory Acceptance Test

API STD 612 Figure 5 Overspeed Trip Requirements 5 Vibration Detectors Vibration detection equipment shall be provided as per the below Table-1: Table-1: Required Vibration Instrumentation for Special Purpose Steam Turbine
Machine Train Applicable Standard Relative Measurement Radial Thrust Key Seismic Measurement Reading at the monitor Velocity Acceleration (RMS)

Special Purpose Steam Turbine

32-SAMSS-010

X&Y

Dual

Yes

Vibration detectors shall be provided, installed and calibrated in accordance with 34-SAMSS-625.

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Document Responsibility: Consulting Services Dept. Issue Date: 31 October, 2004 Next Planned Update: 1 November, 2009

SABP-G-003 Special Purpose Steam Turbines Dynamic Analysis Factory Acceptance Test

Shop Verification of Unbalanced Response Analysis 6.1 Shop verification of unbalanced response analysis shall be performed as part of the mechanical running test and the results shall be used to verify the analytical model (API STD 612 / P2.8.3.1). The method to conduct the shop verification test is described in API STD 612 & 32-SAMSS-010 section 2.8.3. The results of the verification test shall be compared with those from the original analytical model. The vendor shall correct the model if it fails to meet any of the following criteria (API STD 612 / P2.8.3.2.2): a) b) c) 6.3 The actual critical speeds shall not deviate from the predicted speeds by more than 5%. The predicted amplification factors shall not deviate from the actual teststand values by more than 20%. The actual response peak amplitudes, including those are critically damped, shall be within 50% of the predicted amplitudes.

6.2

When the test data does not meat the requirements of API STD 612, paragraph 2.8.3., additional more stringent testing is requires as per API STD 612, paragraph 2.8.3.4. The purpose of this additional testing is to determine on the test stand that the machine will operate successfully.

Tests Procedure 7.1 The Vendor shall demonstrate the compatibility of the contract probes and his test stand readout equipment. The contract axial position probes and oscillator demodulators shall be used during the shop test. (32-SAMSS-010 / P4.3.3.1.7). Shop test facilities shall include instrumentation with the capability of continuously monitoring and plotting revolutions per minute, peak-to-peak displacement and phase angle. Presentation of vibration displacement and phase marker shall also be by oscilloscope. (API STD 612 / P4.3.3.1.8). When seismic test values are specified, vibration data (minimum and maximum values) shall be recorded and located (clock angle) in a radial plane transverse to each bearing centerline (if possible), using shop instrumentation during the test. (API STD 612 / P4.3.3.1.10). As a minimum, the FFT spectra range shall cover a frequency range from 0.25-8 times the maximum continuous speed but not more than 1500 hertz. (API STD 612 / P 4.3.3.3.2).
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7.2

7.3

7.4

Document Responsibility: Consulting Services Dept. Issue Date: 31 October, 2004 Next Planned Update: 1 November, 2009

SABP-G-003 Special Purpose Steam Turbines Dynamic Analysis Factory Acceptance Test

7.5 7.6

Tape recordings shall be made of all real-time vibration data. (API STD 612 / P 4.3.3.3.5). Plots showing synchronous vibration amplitude and phase angle versus speed for deceleration shall be made before and after the 4-hour run. Plots shall be made of both the filtered (one per revolution) and unfiltered vibration levels. When specified, these data shall also be furnished in polar form. The speed range covered by these plots shall be from the specified trip speed to 400 revolutions per minute. (API STD 612 / P 4.3.3.3.7). Bearing housing overall velocity should be measured in in/sec (mm/sec) RMS and shaft vibration in mils (m) pk-pk. The combined total electrical and mechanical runout is presented in Table-2 (for more detail refer to API STD 612 & 32-SAMSS-010 paragraph 2.6.2.2): Table-2: Allowable Total Runout

7.7 7.8

Probes Location Radial

RPM 1800 > 1800

Applicable Standard 32-SAMSS-010 (Sec. 2.6.2.2 a) 32-SAMSS-010 (Sec. 2.6.2.2 a) API STD 612

Allowable Total Runout (TR)

TR 9 m pk-pk

(0.35 mils pk-pk)

TR 6 m pk-pk (0.25 mils pk-pk)

Axial

All

(Sec. 2.6.2.2 b)

whichever is greater TR 0.25 x maximum allowed pk-pk vibration amplitude TR 13 m pk-pk (0.5 mils pk-pk)

Note:

If the vendor can demonstrate that electrical or mechanical runout is present and the total runout is within the limit specified in Table-2, then the runout may be vectorially subtracted from the vibration signal measured during the factory. (API STD 612 & 32-SAMSS-010 / P2.8.5.8)

7.9

Electrical and mechanical runout shall be determined and recorded by rolling the rotor in V-blocks at the journal centerline while measuring runout with a noncontacting vibration probe and a dial indicator at the centerline of the probe location and one probe-tip diameter to either side. (API STD 612 / P 2.8.5.6). Accurate records of electrical and mechanical runout, for the full 360 degrees at each probe location, shall be included in the mechanical test report. (API STD 612 / P 2.8.5.7). The mechanical running test shall verify that lateral critical speeds conform to the requirements of API STD 612 paragraph 2.8.2 and 2.8.3. The first lateral critical speeds shall be determined during the mechanical running test and

7.10

7.11

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Document Responsibility: Consulting Services Dept. Issue Date: 31 October, 2004 Next Planned Update: 1 November, 2009

SABP-G-003 Special Purpose Steam Turbines Dynamic Analysis Factory Acceptance Test

stamped on the nameplate followed by the word test. (API STD 612 / P 4.3.3.3.3). 8 FAT Acceptance Criteria During the mechanical running test, the mechanical operation of all equipment being tested, including all casing joints and connections, and the operation of the test instrumentation shall be satisfactory. The measured vibration shall not exceed the limits in Table-3 and shall be recorded throughout the operating speed range. This table content is a combination of API STD 612 4th edition and 32-SAMSS-010 exceptions. The below steps 1 to 3 specify the FAT vibration values that need to be checked. 1. The overall vibration at the maximum continuous speed or at any other speed within the specified operating speed range shall not exceed the overall limit specified in Table-3. The frequency spectrum at the maximum continuous speed and at other speeds that may have been specified in the test agenda should be checked to identify the highest amplitude (excluding the running speed) and ensure that it does not exceed the maximum limit for discrete frequency amplitude specified in Table-3. At any speed grater than the maximum continuous speed, up to and including the trip speed of the driver, the vibration should not exceed 150% of the maximum value recorded at the maximum continuous speed. (API STD 612/ P 2.8.5.5). Table-3: Vibration Limits for Special Purpose Steam Turbines
Location of vibration Measurement Item

2.

3.

Vibration On Inboard & Outboard Bearing Housing

Turbine Shaft (adjacent to bearing)

Overall (i) Maximum continuous speed or at any other speed within the specified operating speed range

Vu 2.5 mm/sec RMS * (0. 10 in./sec RMS)*

whichever is less Au (5.16X106 /N)05 m pk-pk ((8000/N)05 mils pk-pk)

Au 50 m pk-pk (2.0 mils pk-pk)

Discrete frequencies (other than N)

Vf 0.5 mm/sec RMS (0.02 in./sec RMS) (API STD 612 / P 4.3.3.3.2)

20% of the above allowable overall limit Af 0.2 x Au (API STD 612 / P 4.3.3.3.2)

(ii) Vibration limits at any speed greater than the maximum continuous speed, up to and including the trip speed

150 % of the recorded value at maximum continues speed

150 % of the recorded value at maximum continues speed

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Document Responsibility: Consulting Services Dept. Issue Date: 31 October, 2004 Next Planned Update: 1 November, 2009
Notes:

SABP-G-003 Special Purpose Steam Turbines Dynamic Analysis Factory Acceptance Test

(*) These specifications are from 32-SAMSS-010 paragraph 2.8.5.5 not API STD 612. Where: Vu = unfiltered vibration velocity. Au = unfiltered displacement determined by FFT. Vf = discrete frequencies, non-synchronous, velocity. Af = discrete frequencies, non-synchronous, displacement determined by FFT. N = rotational speed (RPM).

31 October, 2004

Revision Summary New Saudi Aramco Best Practice.

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