PT.

Truba Jaya Engineering 1

SUPERVISOR TRAINING

1. TITLE
Rotating Equipment Knowledge

2. SCOPE
This document is described about Static & Rotating Equipment knowledge and guidelines
for general installation and alignment for Supervisor.

3. OBJECTIVE
This is to giving the general knowledge & guidelines for each mechanical supervisor related
to the Static & Rotating Equipment, which will be applied to PT. Truba Jaya Engineering
project.

4. REFERENCE
4.1 Truba Jaya Engineering Quality Manual.
4.2 International Standard reference.
4.3 Recommended Procedure which prepared by equipment manufacturer.

5. EQUIPMENT
Mostly the equipment divided to become 2 (two) categories :
a. Static Equipment
What is the included in static equipment like : Vessels, Tanks, Heat Exchangers, drums,
compressor skid, etc. ( See attached dwg ).
b. Rotatic Equipment
What is the included in static equipment like : Pumps (centrifugal & axial), Steam
Turbine & Generator, Gas Turbine & Generator, Mixer, etc. ( See attached dwg ).
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Sample Drawing of Static Equipment

Fig 5-1 : Drum Equipment

Fig 5-2 : Vessel (Horisontal Type )

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Fig 5-3 : Vessel (Vertical Type )

Fig 5-4 : Steam Boiler Package

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Fig 5-4 : Storage Tank

Sample Drawing of Rotating Equipment

Fig 5-5 : Pump

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Fig 5-6 : Steam Turbine & Generator (Front View)

Fig 5-7 : Steam Turbine & Generator (Plan View)

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Fig 5-8 : Pump (Front & Plan View)

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6. WHY ALIGNMENT
The biggest contribution of rotating system is to align the equipment correctly in the first
place, in order to avoid any problem to the equipment while operation after installation and
the cost cause of damage.
When misalignment the loading of shaft dramatically increases due the reaction forces
created within coupling.
The effect of misalignment :
a. Premature bearing, seal, shaft and coupling failures
b. High bearing and coupling temperatures & excessive vibration
c. Looseness of foundation bolts
d. High power consumption
To eliminates or reduce of misalignment the precision alignment of equipment have to be
done in the correct way or follow the manufacturer instruction.
7. ALIGNMENT BASIC
Kinds of misalignment :
a. Parallel (Radial) Misalignment
b. Angular (Axial) Misalignment
c. Parallel & Angular Misalignment

Fig 7 – 1 : Misalignment
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8. ALIGNMENT TOOLS
a. Dial Indicator h. Auto Level Sets
b. Filler Gauge i. Theodolite Sets
c. Micrometer j. Hydraulic Jack
d. Caliper
e. Straight Edge
f. Dial Gauge Stand with magnetic Base
g. Laser Alignment

Fig 8 – 1 : Dial Indicator , Stand & Magnetic Base

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Fig 8 – 2 : Caliper & Outside Micrometer

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Fig 8 – 3 : Inside Micrometer

Fig 8 – 4 : Feeler Gauge

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Fig 8 – 5 : Theodolite (Total Station)

Fig 8 – 6 : Auto Level

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Fig 8 – 7 : Laser Alignment Equipment

9. ALIGNMENT METHOD
a. Straight Edge Indication
Alignment by using Straight Edge Ruler, Caliper, Feeler Gauge Tool, which alignment
accuracy is low (depend on the limited resolution of human eye).

Fig 9 – 1 : Straight Edge Indication

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b. Rim & Face Indication ( Axial & Radial Alignment )

Measurement method conducted in 4 (four) different point by turned around of the shaft
driver. Which by using the Dial Indicator, and from the measurement result taken by
average value.

Fig 9 – 2 : Rim (Radial) Indication

Fig 9 – 3 : Face (Axial) Indication

c. Reverse Indication
Alignment needing with high accuracy and usually conducted at the equipment with
long spacer. This alignment is combine between Rim and Face Alignment. Calculation
and user must be highly experience.
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Fig 9 – 4 : Reverse Indication

Method of alignment beside using the simple way like Straight Edge Indication, Rim & Face
Indication which by using dial indicator, there is any other way of more highly accurate that
is by Laser Alignment System. But the method still same as above mentioned.
Advantages of Laser Alignment :
1. Error free, fasted, accurate and reliable measurement with optimally result.
2. No human uncertainties that can be influence to reading error.
3. Universal precision brackets designed for quick and rigid set up.
4. Automatic computation and quick of horizontal and vertical alignment result, which
quick on screen display.
Compared to alignment by used Dial Indicator System, Laser alignment system more
accurate, quick and efficiencies.
Below is how accurate are Dial Indicator Reading?
1. Mechanical linkage bracket ( long, big, not strong enough) can be influence to the
reading error.
2. Sometimes the dial gauge must be tapped in order the dial indicator needle is settle
on its final value.
3. The simple human error that occur when the dial indicator must be read under
poorly condition and severe constrains.
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4. Tilted the indicator because dial gauge not be mounted perpendicular to the
measurement surface, so that part of the displacement reading is lost.

10. ROTATING EQUIPMENT INSTALLATION & ALIGNMENT

The basic document for equipment erection :
a. The civil works report relating to the equipment basement or foundation level.
b. Equipment manufacturing and general arrangement drawing.
c. The erection instruction including erection drawing & documents.
d. Erection quality control plan and etc.
General requirement for concerning works is the access and erection area must be clean,
free from other materials, and all necessary steps shall be taken to protect the
surrounding equipment or waiting for erection.

10.1 Basement Level Preparation

Checking the basement or foundation level :
a. Mark out of equipment and anchor holes center line on the concrete foundation.
b. Surface condition of foundation level and anchor holes.
c. Visual examination of foundations to search for apparent construction and erection
defects and faults (crack, deformations, etc). And inspection have been performed.

10.2 Concrete Basement Level Preparation

Checking of dimensions, flatness and horizontality and chipping the whole of equipment
foundation are to be grouted. Most of design chipping thickness is 30 mm. Performed of
chipping by using a pneumatic or electric hammer.

10.3 Metal Basement Level Preparation (Subsole Plate)

Cleaning the basement level or foundation surface from any materials (oils, dust, etc).
Mark the setting position of the subsole /padding plate on the foundation surface.
Put the grouting materials onto setting positions and depress the subsole plate on it and
adjust the level of subsole plate. Adjusting the level shall by precision level equipment
like Auto level or theodolite. Make sure that adjusting level shall follow the
manufacturer tolerance.
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Fig 10 – 1 : Basement Plan View

10.4 Installation of Equipment

Rotating equipment can be deliver :
- On rigid frames, mounted and set in workshop.
- In separate elements with shaft line to be assemble at site.
Installation of equipment as following :
a. Preparation of correct lifting equipment and lifting tools as required during erection.
b. Unpack the package equipment.
c. Pre-position of equipment to the foundation and put on to foundation, measure and
match the equipment center to the foundation center marks.
d. Put and arranged on each of anchor bolt, and as close as possible to the anchor holes.
e. The temporary wedges or hydraulic jack provided to make final adjusting easier, and
shall be removed before the anchor bolts are grout and tightened. Most of jack
wedges embedded in grouting mortar and shall be block by tack welds after the last
alignment checking and before the grouting mortar is poured.

10.5 Alignment of Equipment

Measure the level of rotating equipment using precision level gauge (dial gauge), if
required the level shall adjusted using shim liner which put on the subsole plate.
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Measuring point are 4 points of upper, right, lower, left directions with turning driver &
driven interval 90 degree.
Consider the type of the equipment, all or some of the following alignment must be
carried out
- Pre-alignment : Only for the machine (driver & driven).
- Alignment prior to pipe joining : centering, clearance to the pipe connection.
- Final alignment after the supports and the pipe connection : complete piping
installation and connection.

10.6 Inspection
Inspection shall be performed by erector quality control and must take all the necessary
steps to ensure erection quality.
a. Inspections of the basement level as following
- Visual examination to detect the visible defect.
- Basement or foundation level altitude.
- Dimension of the equipment basement or foundation.
- Anchoring and fixing holes (number, locations, etc).
- Chipping the basement surface.
b. Equipment Installation Inspections (Pre-alignment)
- Surface condition, dimensions, flatness, horizontality of basement levels.
- Position of theoretical axes of the equipment and orientation with respect to the
reference.
- Preliminary alignment of the independent machines.

10.7 Grouting
After the final alignment the equipment will be fully grout., by install the temporary
wooden board for grouting to beside foundation. Before grouting cleaning of concrete
surface should be by air blow and water blasting. Grouting materials shall refer to the
manufacturing or specification standard.
Mixing and application of cement grout shall strict accordance with the instructions of
the manufacturer.
After hardening the mortar the tightening of the all anchor bolts. Tightening the bolts
shall refer to the torque standard.
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Same steps for the Laser Alignment as shown the figure below:

Fig 10 – 2 : Laser Alignment

Fig 10 – 3 : Laser Alignment

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Fig 10 – 4 : Laser Alignment

Thank you for your attention, and wish can be applicable

Regards
Hery Setiawan