Centrifugal Pumps Design and Application 2nd ed - Val S. Lobanoff, Robert R. Ross (Butterworth-Heinemann, 1992)
Alignment 510 parallelism/perpendicularity. The T 4- B vs. S 4- S test, which is described in Murray [6], will detect inclined-plane error if this is present. Numerical Examples Numerical examples will not be given here due to lack of space to give proper coverage. Those wishing to examine a variety of such examples are urged to see Murray [6]. Thermal Growth When machines are operating, their temperatures usually change from that at which they were aligned. In most cases they get hotter, although the opposite is occasionaly true. In the case of pumps, turbines, and compressors, the temperature of the connected piping also changes. These temperature changes cause expansion or contraction in the metal. In most cases, this expansion or contraction is not uniform and differs significantly for driver and driven machines. Their relative positions therefore change during operation, causing changes in the alignment relationship. In addition to temperature effects, torque, hydraulic effects, and oil film thickness may contribute to alignment changes. Because of these factors, a coupled machine train with good alignment in its "cold" or non-operating state may have less precise alignment under operating conditions. For a pump that operates at conditions subject to little temperature variation and aligned at an ambient temperature that also varies little, the relationship between cold and hot alignment will be constant and repeatable. If the amounts and directions of growth can be determined, they can be used in the form of thermal offsets to include a deliberate misalignment when the machines are aligned. Then, under operating conditions, the growth will act equal and opposite to this misalignment, causing the machines to become aligned during operation. So much for the theory. We live in an imperfect world, and things do not usually behave exactly as we might wish. The best laid plans of mice and men oft go astray, and thermal growth offsets are a good example of this. There are two common approaches. One, favored by certain authorities, is to use formulas or rules of thumb involving fluid or metal temperatures, coefficients of thermal expansion, and machine geometric measurements to calculate predicted growths. These are then converted to offsets and incorporated into the initial machine alignment. If the machine runs well, with low vibration and without premature failure, the offsets are assumed to be correct, and are used thereafter. If the machine does not run satisfactorily, and the problem is attributed to misalignment caused by thermal growth other than that used to derive the offsets, the
520 Centrifugal Pumps: Design and Application growth is then measured by some means, and the offsets are revised accordingly. The other approach, favored by this author for most pumps (but not necessarily for large turbomachinery), is simpler. This is to say that formulas and rules of thumb are unreliable because they fail to account for piping growth effects that may influence machine movement more than the growth of the machines themselves. The formulas also fail to account for uneven temperature rises in different parts of the machine frames, which is quite common. In effect, formulas are unlikely to give good figures for amounts of relative growth and are equally unlikely to get the directions of such relative growths correct. This being the case, our most conservative course of action, as well as the easiest, is to align everything to zero offset, cold. Then, at least, the machines are starting from a good alignment condition, and relative growth in one direction is no more harmful than in another. If alignment-related vibration and reliability prove satisfactory, as they do about 90% of the time, we have simplified our alignment task by eliminating offsets. In the other 10% of the cases, the growths should be measured, not calculated, and offsets applied. Several methods of growth measurement are described in Table 19-5. Table 19-5 Methods for Determining Thermal Growth Offsets for Machinery Alignment Method Advantages Disadvantages Manufacturers' When available, these Recommendations require little effort to obtain. Sometimes they give good results. Calculations based on temperatures, thermal expansion coefficients, and machine geometry, using formulas and rules of thumb. Shut down and "quickly" take alignment measurements. Easy to obtain, and very scientific-looking. Makes the measurer feel he is doing something worthwhile. Often not available, and often unreliable when they are available. Unreliable. Likely to do more harm than good by getting the relative growth direction wrong and thus increasing the misalignment. Formulas fail to account for nonuniform temperature rise in machines and effects of temperature rise in connected piping. Utterly useless and self-deceiving. The majority of the thermal movement occurs during the first
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520 <strong>Centrifugal</strong> <strong>Pumps</strong>: <strong>Design</strong> <strong>and</strong> <strong>Application</strong><br />
growth is then measur<strong>ed</strong> by some means, <strong>and</strong> the offsets are revis<strong>ed</strong> accordingly.<br />
The other approach, favor<strong>ed</strong> by this author for most pumps (but not<br />
necessarily for large turbomachinery), is simpler. This is to say that formulas<br />
<strong>and</strong> rules of thumb are unreliable because they fail to account for<br />
piping growth effects that may influence machine movement more than<br />
the growth of the machines themselves. The formulas also fail to account<br />
for uneven temperature rises in different parts of the machine frames,<br />
which is quite common. In effect, formulas are unlikely to give good figures<br />
for amounts of relative growth <strong>and</strong> are equally unlikely to get the<br />
directions of such relative growths correct. This being the case, our most<br />
conservative course of action, as well as the easiest, is to align everything<br />
to zero offset, cold. Then, at least, the machines are starting from a<br />
good alignment condition, <strong>and</strong> relative growth in one direction is no<br />
more harmful than in another. If alignment-relat<strong>ed</strong> vibration <strong>and</strong> reliability<br />
prove satisfactory, as they do about 90% of the time, we have simplifi<strong>ed</strong><br />
our alignment task by eliminating offsets. In the other 10% of the<br />
cases, the growths should be measur<strong>ed</strong>, not calculat<strong>ed</strong>, <strong>and</strong> offsets appli<strong>ed</strong>.<br />
Several methods of growth measurement are describ<strong>ed</strong> in Table<br />
19-5.<br />
Table 19-5<br />
Methods for Determining Thermal Growth Offsets for Machinery<br />
Alignment<br />
Method Advantages Disadvantages<br />
Manufacturers' When available, these<br />
Recommendations require little effort to obtain.<br />
Sometimes they give good<br />
results.<br />
Calculations<br />
bas<strong>ed</strong> on<br />
temperatures,<br />
thermal<br />
expansion<br />
coefficients,<br />
<strong>and</strong> machine<br />
geometry,<br />
using formulas<br />
<strong>and</strong> rules of<br />
thumb.<br />
Shut down <strong>and</strong><br />
"quickly" take<br />
alignment<br />
measurements.<br />
Easy to obtain, <strong>and</strong> very<br />
scientific-looking.<br />
Makes the measurer feel he<br />
is doing something<br />
worthwhile.<br />
Often not available, <strong>and</strong><br />
often unreliable when they<br />
are available.<br />
Unreliable. Likely to do<br />
more harm than good by<br />
getting the relative growth<br />
direction wrong <strong>and</strong> thus<br />
increasing the misalignment.<br />
Formulas fail to account for<br />
nonuniform temperature rise<br />
in machines <strong>and</strong> effects of<br />
temperature rise in<br />
connect<strong>ed</strong> piping.<br />
Utterly useless <strong>and</strong><br />
self-deceiving. The majority<br />
of the thermal movement<br />
occurs during the first