Novel Shaft Coupling Alignment Method For Critical Machinery Trains Has

Laser Moves & Reverse Dial Check

By Abdulrahman Alkhowaiter: Saudi Aramco Oil Company June-2019

Introduction:
This Best Practice describes an innovative shaft coupling alignment method developed at Saudi Aramco which drastically simplifies reverse dial
indication methods while achieving higher accuracy and reliability. It applies Laser like correction moves to the machinery footing with high
accuracy and minimum of calculations. It was first formalized in year 2010 and has been applied to twenty machinery trains ranging from 1000
HP to 32,000 HP with direct driven and gearbox trains including steam turbine trains. These installations achieved reduced vibration levels below
historical with at least 25% vibration reduction attributed to improved coupling alignment compared to past historical records. Some achieved
up to 75% reduction in inboard shaft displacement or bearing housing seismic overall vibration amplitude. In addition to this report, the author
encourages readers to study the third edition of Shaft Alignment Handbook, by John Piotrowski.

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 Novel Shaft Coupling Alignment Method For Critical Machinery Trains Has
Laser Moves & Reverse Dial Check
By Abdulrahman Alkhowaiter: Saudi Aramco Oil Company June-2019

The present Shaft Coupling alignment methods utilized on turbomachinery around the world are the Rim and Face using dials, the Reverse Dial
indicator method, and the modern Laser Alignment method which is well known to be the most accurate. Most machinery require alignment
offset at cold position to compensate for thermal growth and shaft movement. For Cold to Hot alignment measuring techniques, it can be said
that Laser Alignment has improved greatly due to development and is now a highly accurate tool for performing cold alignment and capturing
actual hot alignment figures during operation through active lasers mounted on bearing housings or by laser heads installed on hubs immediately
after shutdown with sweep. Another accurate tool capturing cold to hot alignment is the proximity probe method of measuring hot alignment
which was developed in the 1970’s.

The new improved method in this report uses Reverse dial indicators, but only for initial zero-zero alignment of couplings and as a final alignment
quality control check method after all feet moves have been completed. The Author has worked extensively with the above three methods in
the past 25 years, and has found that many users while realizing the accuracy of modern laser equipment tend to prefer manual methods which
are easier to remember and do not have to follow specific software guidelines which can be forgotten. For this reason in the Petroleum-
Petrochemical industry, the primary technique of shaft alignment is still the Reverse Dial indicator method because of its simple robust tools:
Alignment bracket, Dial Indicators, and Sketching paper with calculator. The following is an explanation of the deficiencies of Reverse dial
indicator alignment:

Human Factor Problems with the Reverse Dial Indicator Method

1. Confusing Logic of Reverse Dial Readings: A machine set high is measured by dial indicator as a negative value, while a low machine is given
a positive value. From this situation it is easy to make incorrectly reversed readings causing wrong alignment and high vibration. The new
method starts machines from a zero-zero alignment condition.
2. Complicated Alignment process takes a long time as movements are trying to achieve a fixed reading and not zero-zero. The process is not
a simple, and logical procedure.
3. Does not have the simplicity of direct calling for adding-removing shims as in Laser Shim Moves. To generate actual shim corrections at
feet, the as found dial indicator readings found at couplings have to be transformed into the feet movements through calculation formulas.
It can also be performed graphically but the graphing is complicated still requiring many formulas and causes frequent user errors.
4. Does not have a hot analysis method unless Alignment bars with Indicator proximity probes are utilized and these are more complicated
than Laser systems. The conventional hot shutdowns method can also be used but this does not give correct operating condition because it
takes considerable time to install which then allows machines to cool and lose thermal growth.
5. Reverse dial can be inferior to modern lasers for accuracy due to alignment bar sag, reading errors and reduced hot alignment capability.
6. The graphical plotting method of conventional reverse dial is complicated and not intuitive.
7. Advantage of Reverse Dial to lasers is that it does not require learning specific laser alignment software and does not need laser hardware.

From the above it’s clear that the superiority of Laser alignment is in its accurate laser heads which have no reading errors, its logical moves
which are straight forward; and the complicated formulas of reverse dial are replaced with internal software that calculates the necessary final
corrections at each feet. This is a long and tedious process with Reverse dial methods. However, the before mentioned complication of learning
and refreshing software skills in Laser tools can be daunting unless used frequently.

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 Novel Shaft Coupling Alignment Method For Critical Machinery Trains Has
Laser Moves & Reverse Dial Check
By Abdulrahman Alkhowaiter: Saudi Aramco Oil Company June-2019

The author wanted to find a new method to resolve these deficiencies: Is it possible to get the simplicity and accuracy of Laser Moves, without
the complication of Reverse dial plotting and calculations and difficult understanding of the angular and parallel corrections necessary to obtain
the desired cold readings? The answer was yes after four years of study and development.

The New Innovative Method of Reversed Dial Alignment with Laser Moves

This report describes the newly developed Simplified Shaft Alignment Method that simplifies alignment using reverse dial gauges only for
measurement and zero-zero setup. Note: In this method there is no need to measure feet distances or plot machinery on graph when thermal
growth is non angular, meaning parallel hot rise. However for angular growth it is necessary to plot the machine rise. New Innovative Procedure:

1. Alignment Note: This method does not use previously prepared or plotted alignment readings. It starts the alignment process from a clean
sheet of paper.
2. First step is to perform a full Pre-alignment process on the machinery skid. This is required for any professional alignment.
3. Second step is to obtain actual running condition hot alignment data by measuring thermal temperatures and growth at all the machinery
train feet and any skid structural feet under the machine feet. Best time for this is spring time as this averages summer-winter conditions
but it can be also be calculated for any season. If the thermal growth cannot be measured at this point then it is possible to utilize the OEM
expected movement as a baseline for a future, more accurate alignment.
4. Third step is to combine the differential vertical and horizontal movement due to thermal growth and other sources on both machines
with any shaft movement in bearings and sum this up to get final vertical and horizontal readings at feet. This can be plotted easily see
attached growth plots. As in other alignment methods, the distances of feet to coupling hub flange, and to each other, is required for accurate
plotting of the machinery movement.
5. Horizontal check: Ensure no piping strain at machine flanges by releasing process flanges and removing strain on all piping of 2.0 inch and
greater. Then insure that pipe is properly supported so minimal movement incurs when pipes are hot and pressurized. One solution to hot
piping expansion forces at machine nozzles is to apply a cold gap at piping flanges equal to half to full actual hot growth of piping toward
machine. This flange gap is only applied with flexible supported piping such as spring hanger support.
6. This Alignment method strongly advises to rectify the sources of horizontal forces and movement, and not try to solve symptoms by using
horizontal offset unless offset is due to a gearbox horizontal thermal growth. In gearboxes, another source of horizontal movement is the
pinion shaft movement inside bearing. When gearboxes are used; in that case apply vendor figures for horizontal offset.

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 Novel Shaft Coupling Alignment Method For Critical Machinery Trains Has
Laser Moves & Reverse Dial Check
By Abdulrahman Alkhowaiter: Saudi Aramco Oil Company June-2019

7. First Alignment move sets machines to zero-zero vertical-horizontal condition: This is a major change compared to conventional reverse
dial methods. Using reverse dial indicators, move the movable machine until it is aligned to fixed machine hub to zero-zero condition in both
horizontal and vertical. Compensate for bracket sag and insure compliance after calculating sag to within 0.004 inch TIR. This movement
does not need calculations as it is possible for experienced technicians to achieve Zero-Zero readings once all Pre-alignment work is done
such as fixing soft feet, fixing piping strain, removing corroded shims and adding a light coating of Silicone grease on top of shim pack, under
machinery feet.
8. Horizontal Correction Moves: If the train has a gearbox then apply the OEM preset horizontal growth as a direct offset [not TIR] by moving
the machine using the horizontal jacking screws carefully. Apply dial indicators on the front and back feet to measure horizontal movement.
Typically such horizontal hot growth compensation figures are shown on the gearbox drawings as a detail. If no gearbox, then fix sources of
horizontal forces and make zero offsets.
9. The next step is to use the plotted growth plot on graphical paper to calculate the vertical movement shim correction thickness required at
each foot of the movable machine.
10. Application of Final Vertical Shim Corrections: Shims can easily be removed or added to movable machine. Lock all feet. Apply vertical shims
to each foot individually; each foot released one at a time until all feet have the correct shim added or removed underneath. By this method,
very limited error occurs at other feet due to machine movement.
11. Final Reverse Dial Indicator reading at coupling is a check to insure quality of alignment: Final reverse dial readings are taken to compare
final readings with desired. This will capture any errors in case the user movements were incorrect. If major deviation is found, repeat steps
six to ten.

Advantages of this new method:

1. The concept of first bringing two or more machines in a train to a zero-zero coupling alignment position is a logical concept that appeals to
technicians as a means for zero baseline before alignment.
2. The initial reverse dial alignment to bring two machines to zero-zero condition does not require complicated formula; any experienced
alignment technician can apply positive and negative shim correction to gradually achieve zero-zero alignment. This is easily accomplished
once a formal Pre-alignment work is applied to the skid to eradicate soft feet, piping strains, uneven footing, corroded base to feet and other
deficiencies.
3. The graphical plotting is extremely simple and understood by all due to logical approach.
4. Accurate cold to hot readings are used based upon actual skid operating growth data, not inaccurate OEM figures.
5. This method leaves no chance for errors by technicians and engineers interpreting the confusing reverse dial readings where all real world
movement becomes reversed [up movement of machine hub gives negative dial reading].
6. All moves are simple to understand since alignment method uses normal human logic.
7. Faster and simpler because no footing calculations are needed for parallel growth machines, no formula needed apart from thermal growth.
Machine Growth can be charted on graph similar to reverse dial.
8. For machines with angular vertical growth, then only machine feet distance dimensions to the coupling hubs is necessary in order to plot the
actual train thermal growth.
9. To further improve machinery alignment this method strongly emphasizes not to utilize horizontal offsets except for coupling Machinery to
large Gearboxes. All other sources of horizontal movement are not recommended as the source of horizontal forces and movement during
hot operation is required to be removed by proper pre-alignment.
10. Final quality control check of completed alignment is still applied by using reverse dials to take a final sweep reading.

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 Novel Shaft Coupling Alignment Method For Critical Machinery Trains Has
Laser Moves & Reverse Dial Check
By Abdulrahman Alkhowaiter: Saudi Aramco Oil Company June-2019

General Guidelines on Movement:

When two machines are being aligned, one is set as fixed and the second as movable. Select the easiest to move. When three machines are
in a train the central machine such as gearbox is best set as the fixed machinery. With four machines, again, if a gearbox is used that is set as
fixed and remaining are movable. By design gearboxes are supposed to be set with constant thickness shims under all feet to ensure gear
teeth mesh alignment. This shows criticality of perfectly flat foundation feet under the gearbox.

Horizontal Offset Alignment:

The Majority of machinery do not require horizontal offset at couplings except those with Gearboxes. All other machine trains experiencing
horizontal misalignment from cold to hot condition are exposed to high external horizontal forces that can and should be controlled and
minimized by design improvements to machinery footings, design improvements to piping systems, eliminating cold misalignment strain at
nozzles, and by thermal growth compensation of piping at machinery flanges.

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 Novel Shaft Coupling Alignment Method For Critical Machinery Trains Has
Laser Moves & Reverse Dial Check
By Abdulrahman Alkhowaiter: Saudi Aramco Oil Company June-2019

Case History: 32000 HP Steam Turbine Driven Compressor Train KT-221 UGP Jan-2019

The following is the application of the Innovative Simplified Reverse Dial Alignment for Turbomachinery. The machine train is a 32,000 HP Barrel
type compressor direct driven at 5800 RPM by a 625 PSI inlet steam turbine with 70 psi exhaust. This turbine has been a bad actor machine with
MTBF of 6 months due to high vibration. The machinists applied this method for the first time on this train after turbine major overhaul. The
comments were that it is more logical to follow and simple compared to Reverse Dial.
1. Fixed machine was compressor, this is non movable machine. See below drawings.
2. Perform full pre-alignment procedures. Minimize number of shims by using solid shims as much as possible. In this machine case, the skid
feet were machined flat by magnetic mounted field machining tools to remove soft foot and corrosion.

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 Novel Shaft Coupling Alignment Method For Critical Machinery Trains Has
Laser Moves & Reverse Dial Check
By Abdulrahman Alkhowaiter: Saudi Aramco Oil Company June-2019

3. Movable machine is the Turbine: Align its coupling hub Zero-Zero- baseline to compressor hub using Reverse Dials. Readings at hub vertical-
horizontal shall all be below 4 thou TIR maximum. Compensate readings for Alignment Bar sag.
4. Bar sag compensation: Simplest method is to adjust dial indicator at 12 clock position to read a positive number equal to actual bar sag
found. Normally it is zeroed at this position. This method automatically compensates for sag.
5. Horizontal corrections First: None, its direct drive with no gearbox. All horizontal forces arise from piping hot movement which must be
absolutely minimized during pre-alignment. Another source of horizontal forces may arise from the torque transfer to turbine flex-feet, but
this deflection has been reduced to almost zero by increasing flex feet thickness from existing 0.38 inch to 0.50 inch during the turbine
overhaul.
6. Train Vertical Growth corrections second: See drawings. These are based upon Thermal Growth measurements taken on actual machinery
train during operation. They were extrapolated to springtime ambient temperatures.
7. Apply the vertical feet corrections at turbine as shown in drawing after locking turbine feet horizontally using jacking screws.
8. Steam Piping Exhaust flanges cold gap to compensate for hot growth: The Exhaust steam piping at 70 psig has a Delta-T of 300 DegF from
cold ambient to operation temperature. The total Growth vertical length includes casing growth from split line until the flange at top of
turbine, and the growth from flange to elbow. This total length is 116 inches above turbine casing splitline. So total growth at piping is: 300
F x 116 inch x 0.000007 inch/inch DegF= 0.245 inch. Conclusion: Set cold gap at flanges to 0.25 inch after installing gasket. Adjust piping
spring hanger.
9. For Inlet 625 psi steam piping: An axial growth of 0.25 inch occurs from casing growth towards piping, and piping growing towards casing.
Using 0.25 inch cold gap will compensate for piping axial hot growth toward turbine because free growth length is shorter than exhaust
piping but temperature is higher. Delta-T is 600 F, with total growth length of 2 Ft casing + 3 Ft piping = 60 inches. Growth= 600x 60 inch x
0.000007= 0.25 inch.
10. Turbine Front Feet: Do not add or remove shims from front feet after reaching initial zero-zero condition.
11. Turbine Rear Feet: Add 0.005 inch shims to rear feet after reaching initial zero-zero reading at coupling. This compensates to allow turbine
rear shaft centerline to meet the hot growth line of non-movable machine shown in vertical alignment graph.
12. Perform final Reverse Dial check alignment to obtain final alignment figures.
13. Start Machine and monitor for eight hours until normal operational temperatures are achieved. By this time vibration will drop to low levels.
14. Result of innovative alignment at startup: When coupled, the maximum vibration recorded at full speed-load on steam turbine was inboard
vibration 0.60 mills and outboard of 1.1 mills. All vibration was at 1X with no multiples and 1X orbit circular.

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Novel Shaft Coupling Alignment Method For Critical Machinery Trains Has
Laser Moves & Reverse Dial Check
By Abdulrahman Alkhowaiter: Saudi Aramco Oil Company June-2019

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