06-20-05 MIKE MITSWEAS INSTALLATION AND ALIGNMENT PROCEDURES Installation Procedure for Installing Kop-Flex Dry Flexible Couplings Between Driving and Driven Equipment Shafts. Alignment Procedure for Aligning Driving and Driven Equipment using Kop-Flex Dry Flexible Couplings and Alignment Tool Number FR@meeeeeKX, F767/07 AUD FTCTO8 CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 General Information Installation of Half Couplings Alignment Alignment Terminology Axial Alignment Procedure Bore and Face Alignment Procedure Compute Horizontal and Vertical Offsets Axial Check and Shim Adjust Final Assembly 10.0 RemovalInstallation & Alignment Procedures, (Created: 27235 Revieed: 314/95 4.0 GENERAL INFORMATION The Kop-Flex disc coupling is dynamically balanced and must be assembled with all parts in the positions specified by the match marks on the coupling. Each coupling assembly has a unique serial number marked on every major component. Make sure the serial numbers match exactly ‘on every component used for the complete coupling. The spacer bolts and nuts are individually weight balanced so any nut may be used on any bolt. Only bolts and nuts supplied by Kop- flex are to be used. If serial number of coupling is known, individual nuts and bolts can be ordered to replace lost or damaged ones without ordering an entire set. Kop-Flex disc couplings are supplied in factory preassembled units. Do not attempt to disassemble the half couplings. Do not tighten or loosen the disc pack bolts and nuts. Prior to installation, inspect the coupling for any signs of damage during shipment. Check that all parts are on hand and are as ordered. Components should be cradied or supported during handling to avoid damage and should be wrapped for protection. Flanges and rabbets should be kept free of nicks and burrs. 20 INSTALLATION OF HALF COUPLINGS 24 SPLINED HUB MOUNTING Before installation, check the hub spline and shaft for nicks and burrs and dress if necessary. When completed make sure the hub spline and shaft are clean. Heat the entire half coupling to expand the bore; Do Not allow the half coupling temperature to exceed 450°F (230°C). Do not apply an open flame to the disc packs. An oil bath or oven is recommended. Place the half coupling in the proper position on the shaft. Hold in place as it cools and install the shaft retaining nut or bolts if required. 2.2 KEYED HUB MOUNTING Before installation, check bore and shaft for nicks and burrs, dress if necessary. Make sure the hub bore and shaft are clean. For keyed taper bores, check the fit of the bore to the shat Keys must be precisely fitted to the keyways in the shaft and hub. Each key should have a tight fit on the sides and with a slight clearance on top. To maintain dynamic balance, the keys should fill he keyways exactly and not be too short or too long. Clean the hub bore and shaft. Record the position of the hub on the shaft as the “start” position for advancing keyed taper bored couplings. Heat the entire half coupling to expand the bore; Do Not allow the coupling temperature to exceed 450°F (230°C). Do not apply an open flame to the disc packs. An oil bath or oven is recommended. Place the half coupling in the proper position on the shaft. For keyed taper bored hubs, the hub must be advanced the correct amount as specified by the machine manufacturer or as given on the coupling drawing. Hold the hub in place as it cools. For keyed taper bores, verify the hub advance and install the shaft retaining nut. 2.3. HYDRAULIC (KEYLESS) HUB MOUNTING Specific instructions for hydraulic mounting of coupling hubs are given by the manufacturers of the connected equipment. The following general instructions onInstallation & Alignment Procedures. (Created: 2/23/95 Revised: 3/14/95 mounting are given for reference. Make sure the equipment manufacturer's instructions are supplied and are followed. ‘Check the hub bore and shaft for nicks and burrs, dress if necessary. when completed make sure the hub bore and shaft are clean. Check the fit of the bore to the shaff, at least 85% contact is required. Make sure there are no O-rings or backup rings in the oil seal grooves. Do Not lap the hub on the shaft to obtain the required contact, use special gauges. Record the position of the hub on the shaft as the "start" position of for advancing. Clean the hub bore and shaft and install the O-rings and backup rings (if used). Place the half coupling on the shaft and install the necessary hydraulic mounting equipment. Place the hub in the "start" position and inject oil to pressurize the bore and expand the hub. Check for leaks. Push the coupiing onto the shaft to be specified advance. Keep the proper pressure in the bore. Do Not exceed the maximum allowable assembly pressure specified on the coupling general arrangement drawing or on equipment manufacturers installation instructions. 3.0 ALIGNMENT Cold alignment compensates for the thermal growth of operating equipment by correctly offsetting the driving and driven equipment. The offset allows equipment to grow into alignment at normal operating conditions. The correct offset is determined from the thermal growth of the equipment by making hot alignment checks during factory testing. The fixed equipment is the starting point shown in the Mechanical installation drawing and is mounted on the package base frame and doweled into place. Subsequent field alignment is made by positioning other equipment with respect to the fixed starting point. Cold alignment face and bore measurements are made at the locations given on the mechanical installation drawing. These measurements are compared to the alignment requirements in the mechanical installation drawing. The illustration in the mechanical installation drawing identifies the station number of the face plane for each piece of equipment being aligned. 4,0 ALIGNMENT TERMINOLOGY Axial alignment is the axial position of the driving equipment half coupling sleeve flange face relative to the driven equipment half coupling sleeve flange face. This is termed calculated flange to flange distance. Face alignment is the angular position of the driving equipment shaft centeriine relative to the driven equipment shaft centertine. Bore alignment or bore offset is the Parallel position ofthe diving equipment shaft centertine relative to the driven equipment shaft centertine. Bore and face relationships are determined by mounting the required field tool with dial indicators to the equipment that you are aligning from at the location shown on the mechanical installation drawing. Dial indicators should be positioned to sweep the bore and fave of the equipment that you are aligning to at the location given on the mechanical installation drawing. The field tool is slowly rotated and measurements are taken at 90-degree intervals. See Fig. 1 Ensure equipment bearings are lubricated prior to alignment.Installation & Alignment Procedures (Created: 2723/95, Revised: 314/95 44 BORE OFFSET ‘The bore offset or parallel offset is represented by a parallel line in respect to the center line of the driven shaft. Bore left (BL) and bore right (BR) represent a parallel line to the right and left of that center line, Bore top (BT) is above and bore bottom (BB) is below the center line. When BR and BL are swept the reading indicates a vertical displacement. See Fig. 2. 4.2. FACE OFFSET Face alignment is represented by the centerline of the driving shaft which intersects the centerline of the driven shaft at an angle. When face top (FT) and face bottom (FB) are ‘swept the reading indicates a vertical angular displacement. When face right (FR) and (FL) are swept the readings indicate a horizontal angular displacement. See Fig. 3. 4.3 COMBINATION BORE AND FACE ALIGNMENT. Combination bore and face offset is indicated when both face and bore are swept. The bore offset indicates that the parallel centerlines are offset horizontally or vertically. The face offset indicates that the centerlines intersect at an angle. See Fig 4. AXIAL ALIGNMENT PROCEDURE 5.1 POSITION SHAFTS BEFORE AXIAL ALIGNMENT (Half Coupling Installed) Power Turbine: Thrust payer turbine sheft toward riven equipment. (AA Postion) Single Helical Gearbox: Pull input shaft out of gearbox until thrust surface is against the bearing. Align input shaft in this position. When axial alignment is completed on. input side of gearbox pull output shaft out of gearbox until thrust surface is against the bearing. Align output shaft in this position. Double Helical Gearbox: Measure axial travel between bearings on input shaft of gearbox. Divide axial travel in half and center input shaft between bearings. With input ‘shaft centered, lock and mark it's position. Without moving the input shaft axially, rotate the output shaft of gearbox until gears mesh. This positions the output shaft. Mark ‘output shaft position. Compressor: Thrust compressor rotor toward suction end. With equipment shafts thrust in their correct position, release red locking and yellow collapsing screws at both ends so the so the half coupling sleeve flange faces will rest in approximately the neutral position, allowing axial measurements to be taken from the half coupling sleeve flanges in this condition. See Fig. 5. Using an inside micrometer to align between half coupling sleeve flange faces, take an average of at least four (4) axial measurements between half coupling sleeve flange faces. Compare the average measured axial distance between half coupling sleeve flange faces to the calculated flange to flange distance and adjust the connected equipment accordingly to achieve the required calculated flange to flange with an initial required tolerance of plus or minus .010. See Fig. 6| > CTS NY 88 Fa SORE MEASUREMENTS FACE MEASURENENTS, Figure No. 1 - Alignment Terminology SHAET A a Se — SHAFT a Figure No. 4 - Combination Bore and Face AlignmentInstallation & Alignment Procedures (Created: 223/95, Revised: 9/1495 Calculated” Flange to Flange Distance Equals Design Flange-To-Flange Distance plus Prestretch Design Flange to Flange Equals ‘Spacer Plus One Shim-Pack Prestretch Accommodates Thermal and Initial Axial Misalignment 6.0 BORE AND FACE ALIGNMENT PROCEDURE Proceed with bore and face alignment when axial alignment is completed and the axial measured distance is within plus or minus .010 of the calculated flange to flange distance. Remove the red locking screws while storing for future use and tighten the yellow collapsing ‘screws equally to collapse the disc pack and pull the half coupling sleeve flanges apart allowing clearance for the spacer rabbits allowing installation of the spacer. Tighten screws progressively and in small increments. Before installation of the spacer install the red locking screws to the half coupling on the equipment aligning from making the disc pack and half coupling ridged and non flexible. This must be done progressively and in small increments. See Fig. 5. Place the coupling spacer without shim pack between the two half couplings and push the ‘spacer/sleeve fianges together at the half coupling aligning from and instal flange bolts and Nuts to every other hole in the bolt circle of the half coupling aligning from and tighten. See Fig. 7. lot Attach bore half and face half of alignment tool FT674l9* XXX (dash no. on mechanical installation drawing) as shown in Figure 8 using tapped holes in unconnected end of spacer flange. Bore half of tool is mounted 180° from face half and both halves must be adjusted to sweep the bore and face of equipment aligning to at the location shown on the mechanical installation drawing. CAUTION: While pulling or pushing the shaft against a bearing face to take up end play, Rotate equipment shafts in normal direction of rotation. Reverse rotation of the equipment can cause seal damage. 2. Equipment mounting bolts must be tight during bore and face measurements. 3. When dial indicators are set to zero, a minus indicator reading represents an extended dial indicator shaft and a plus indicator reading represents a compressed dial indicator shaft. 6.1 MEASURE FACE ANGULAR OFFSET ‘To measure the face alignment dimensions set face indicator to read zero at the face top (FT) position. See Fig. 1. Sweep alignment tool 360 degrees to verify test setup. Rotate dial indicator slowly in the normal direction of rotation, to the face right (FR) position (Fig. 1). Observe and record dial indicator reading in Table 1 Rotate dial indicator slowly in the normal direction of rotation, to the face bottom (FB) Position (Fig 1). Observe the record dial indicator reading in Table 2 Rotate dial indicator slowly in the normal direction of rotation, to the face left (FL)43 sHiveina sczeus tthe cansenevs tay anche SF Stacie) SH ia’ 09 NOT TIGHTEN of LOOSEN THe Ose PACE eoLTs aA nuts THe" tse Be Figure No. 5 Red Locking and Yellow Collapsing Screws SHIPPING SCREWS -satpning ScacwS : Geo Lecsing Ser staevs) TRE ca Getine carseacvs) MEASUREO FLANGE Zo FLANGE OISTANCE 5 eae « ; Figure No. 6 Four (4) Axial Measurements Ss, For Axial Alignment Figure No. 7 ‘Spacer to Sleeve Flange Installation for Bore and Face Alignment Figure No. 8 ‘Alignment Tool FT87104-XXX Installation ¢ for Bore and Face Alignment =Installation & Alignment Procedures (Created: 2723/95, Revised: 3/1495 position (Fig 1). Observe and record dial indicator reading in Table 1. 6.2 MEASURE BORE ANGULAR OFFSET To measure the bore angular offset dimensions set bore indicator to read zero at the bore top (BT) position. See Fig 1. Sweep alignment tool 360 degrees to verify test setup. Rotate dial indicator slowly in the normal direction of rotation, to the bore right (BR) position (Fig 1.) Observe and record dial indicator reading in Table 1. Rotate dial indicator slowly in the normal direction of rotation, to the bore bottom (BB) position (Fig. 1). Observe and record dial indicator reading in Table 2. Rotate dial indicator shaft slowly in the normal direction of rotation, to the bore left (BL) position (Fig 1). Observe and record dial indicator reading in Table 1 7.0 COMPUTE HORIZONTAL AND VERTICAL OFFSETS ‘Compute the horizontal and vertical offsets using Tables 1 and 2 respectively. If the horizontal offset is not within tolerance, adjust the engine position according to Horizontal Alignment Adjustment Procedures in Step 1 below. If the vertical offset is not within tolerance, adjust the engine position according to Vertical Alignment Adjustment Procedures in Step 2 below. 7.4 STEP 4- Adjust horizontal alignment as follows: Loosen all engine mounting bolts and back off horizontal adjustment screws opposite the direction of travel. ‘Adjust the engine side-to-side position using appropriate horizontal adjustment screws. Tighten all mounting bolts. Verify alignment in accordance with above mentioned face and bore angular offset dimensions measurement procedures. 7.2 STEP 2 - Adjust vertical alignment as follows: ‘Compute the total shim thickness required from Table 2. NOTE: If the total shim thickness is positive, remove required shims. If the total shim thickness is negative, add required shims. To raise or lower forward end of the engine Loosen all mounting bolts. Raise forward mount with vertical adjusting screws. ‘Adjust the number of shims under the mount bracket. Lower the forward mount with vertical adjusting screws Tighten all mounting bolts. Verify alignment in accordance with above mentioned face and bore angular offset dimensions measurement procedures. To raise or lower the aft end of the engineInstallation & Alignment Procedures (Crested: 272305 Revised: 31495 Loosen all mounting bolts. Raise forward mount with vertical adjusting screws. Adjust the number of shims under the mount. Lower the aft mount with vertical adjusting screws Tighten all mounting bolts. Verify alignment in accordance with above mentioned face and bore angular offset dimensions measurement procedures. 8.0 AXIAL CHECK AND SHIM ADJUST When the bore and face alignment have been completed, remove the alignment tooling from the spacer and the spacer from the half coupling. Remove red locking and yellow collapsing ‘screws at both ends so the so the half coupling sleeve flange faces will rest in approximately the neutral position, allowing axial measurements to be taken from the half coupling sleeve flanges in this condition. See Fig. 5. Using an inside micrometer to align between half coupling sleeve flange faces, take an average of at least four (4) axial measurements between half coupling sleeve flange faces. Compare the measured axial distance between half coupling sleeve flange faces to the calculated flange to flange distance this time using a required tolerance of plus or minus one (1) shim pack thickness. If calculated flange to flange distance minus measured flange to flange distance is. within tolerance (one shim pack thickness) shim adjust accordingly. See Fig. 6. WARNING: Repeat axial alignment if not within the tolerance of one shim pack thickness. ‘The axial shim adjust can be represented by: ‘Shim Adjust Equals "Calculated" Flange to Flange Distance minus Measured Flange to Flange Distance If SHIM ADJUST is zero, place one shim pack between the half coupling sleeve flange and the spacer and store the second shim pack. If SHIM ADJUST is a negative number, remove shims equal in thickness to SHIM ADJUST from one pack and put the remainder of the pack between the half coupling sleeve flange and the spacer (store the remioved shims and the second pack) If SHIM ADJUST is a positive number, place one shim pack between this half coupling sleeve flange and this spacer and remove shims equal in thickness to SHIM ADJUST from the second pack and place them on the other end between the half coupling sleeve flange and the spacer (store the remainder of the second pack). WARNING: DO NOT put more than one shim pack between any half coupling sleeve flange and spacer. "Calculated" Flange to Flange Distance Equals Design Flange-To-Flange Distance plus Prestretch Design Flange to Flange Equals ‘Spacer Plus One Shim-Pack Prestretch Accommodates Thermal and Initial Axial Misalignment.Installation & Alignment Procedures (Created: 22395 Revised: 9/14/95 9.0 FINAL ASSEMBLY ‘With the red locking screws removed tighten the yellow screws equally; this collapses the disc pack and pulls the sleeves apart to allow clearance of the spacer rabbets. Tighten the screws progressively and in small increments; Do Not tighten them one at a time. See Fig. 5. Place the coupling spacer with the correct amount of shim between the two half couplings match marks are the same. Release the collapsing screws; this must be done progressively and in small increments Do Not loosen them one at atime. Store the yellow collapsing screws for future use. See Fig. 5. Line up the match marks exactly and push the spacer/sleeve flanges together, pressing lightly or tapping together. Do Not use excessive force. Install the flange nuts and bolts so that if possible nuts are always on the spacer side. The proper tightening torque is marked on the spacer and sleeve flange for reference. 10.0 REMOVAL Remove the spacer bolts and nuts and break the flanges apart using the jacking screw holes located between the spacer bolt holes. Install the yellow collapsing screws in the clearance holes in the sleeve and tighten them equally to collapse the disc packs. The collapsing screws must be tightened progressively and in small increments; Do Not tighten them one at a time. This operation will pull the sleeves wey from the spacer and allow the rabbets to clear so tht the spacer can be removed. See Fig. KEYED OR SPLINED - Install a puller on the hub using the tapped holes provided in the hub face; pull the hub off the shaft. Do not pull on the sleeve or disc pack. HYDRAULIC - Install the hydraulic equipment and remove the hub from the shaft, reversing the installation procedure. Do Not exceed the maximum allowable assembly pressure specified on ‘the coupling general arrangement drawing, or on equipment manufacturers installation instructions. WARNING: If heat is used in removing the half coupling from the shaft, apply it directly to the hub. Do Not use extreme temperatures. Do Not apply direct flame to the disc pack. If direct flame is required to remove the half coupling, the disc pack Must be protected with insulating wool or flame resistant material. Excessive heat on the disc pack will destroy the disc coating and reduce the service life of the coupling.Table 1 Computational of Horizontal Offset Measured Value | In-tierence,” | Near Foot NF) “Par Foot (FF) DI= 1 D2= ‘Mechanical Installation Drawing Reference Values BL, FL= (ee eee Face Diameter (FD) Record Bore and Face Measurements BL= FU= BR, = FR,= Horizontal Bore Offset Horizontal Face tect HB = 1/2 (BL, - BL,) HE = Total Indicator Reading Toate Sit Toe NF = HB + D1/FD x HE FF =HB + D2/FD x HF Table 2 Computational of Total Shimming for Vertical Offset Measured Value | In-Line Machine Out-Of-Line Machine Reference Near Foot (NF) Far Foot (FF) D1= D2= Mechanical Installation Drawing Reference Values BT, = FT,= BB, = FB, = Face Diameter (FD) Record Bore and Face Measurements BT, = FT,= BB, = FB, = Vertical Bore Offset (Bore Error) Vertical Face Offset (Face Error) VB = 1/2 (BB, - BB,) VF = Total Indicator Reading Total Shim Calculation ‘Near Foot (NF) Total Shim Calculation Far Foot (FF) NF = VB + D1/FD x VF FF = VB + D2/FD x VF 10SANIGUNL UV IVS (Br ASVL DVI WY LUE ras vow oe (Ly YOLVOION! 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