Download - Rotating Machines erection guidelines
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Originator ALSTOM POWER SYSTEMS S.A..
Alstom Identification number TJN/40/M/----- -----/EG/013
Rev. A
Date 04.04.2013
Lang. En
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Owners dwg number T4-APD-B0-A-40104
Rev A
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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Originator ALSTOM POWER SYSTEMS S.A..
Alstom Identification number TJN/40/M/----- -----/EG/013
Rev. A
Date 04.04.2013
Lang. En
Sheet 3/18
Owners dwg number T4-APD-B0-A-40104
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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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Originator ALSTOM POWER SYSTEMS S.A..
Alstom Identification number TJN/40/M/----- -----/EG/013
Rev. A
Date 04.04.2013
Lang. En
Sheet 4/18
Owners dwg number T4-APD-B0-A-40104
Rev A
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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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Originator ALSTOM POWER SYSTEMS S.A..
Alstom Identification number TJN/40/M/----- -----/EG/013
Rev. A
Date 04.04.2013
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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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Originator ALSTOM POWER SYSTEMS S.A..
Alstom Identification number TJN/40/M/----- -----/EG/013
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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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Originator ALSTOM POWER SYSTEMS S.A..
Alstom Identification number TJN/40/M/----- -----/EG/013
Rev. A
Date 04.04.2013
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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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Originator ALSTOM POWER SYSTEMS S.A..
Alstom Identification number TJN/40/M/----- -----/EG/013
Rev. A
Date 04.04.2013
Lang. En
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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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Originator ALSTOM POWER SYSTEMS S.A..
Alstom Identification number TJN/40/M/----- -----/EG/013
Rev. A
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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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Originator ALSTOM POWER SYSTEMS S.A..
Alstom Identification number TJN/40/M/----- -----/EG/013
Rev. A
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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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Originator ALSTOM POWER SYSTEMS S.A..
Alstom Identification number TJN/40/M/----- -----/EG/013
Rev. A
Date 04.04.2013
Lang. En
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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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Originator ALSTOM POWER SYSTEMS S.A..
Alstom Identification number TJN/40/M/----- -----/EG/013
Rev. A
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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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Originator ALSTOM POWER SYSTEMS S.A..
Alstom Identification number TJN/40/M/----- -----/EG/013
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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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Originator ALSTOM POWER SYSTEMS S.A..
Alstom Identification number TJN/40/M/----- -----/EG/013
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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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Alstom Identification number TJN/40/M/----- -----/EG/013
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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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Originator ALSTOM POWER SYSTEMS S.A..
Alstom Identification number TJN/40/M/----- -----/EG/013
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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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Originator ALSTOM POWER SYSTEMS S.A..
Alstom Identification number TJN/40/M/----- -----/EG/013
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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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Originator ALSTOM POWER SYSTEMS S.A..
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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