Shop Order/Serial Number F602328

INSTALLATION AND OPERATING MANUAL

 Elliott Company
901 North Fourth Street
Jeannette, PA. 15644-1473
Phone; 724-527-2811
http://www.elliott-turbo.com/

-WARNING-
Read this entire Instruction and Operation Manual
prior to installing, operating, or servicing this
equipment. Follow all plant and safety instructions.
Failure to comply can cause personal injury and/or
damage to property.

Installation and Operating Manual

Revision: 0
Date: 06/21/2017

Shop Order / Serial Number F602328

Purchaser: PT OMETRACO ARYA SAMANTA

INDONESIA

User: RSPI POM

INDONESIA

Customer Purchase Order Number: C.325/CIE-EC/I/2017

Elliott Company General Order Number: F16045P
Turbine Tag Number: 159-16-069

Equipment Shop Order / Serial Number Frame / Model

YR Turbine F602328 DYRUG III

Form 3053 (9/30/02)

 Table of Contents
YR Turbine, UG Governor System

TABLE OF CONTENTS
YR Turbine, UG Governor System

Customer Order Information

Limitations, Warranty, and Safety
Equipment Data

CHAPTER 1 – GENERAL INFORMATION

PAGE NO.

INTRODUCTION ............................................................................................................ 1-1

GENERAL DESCRIPTION ............................................................................................. 1-2
Turbine Casing .................................................................................................... 1-2
Packing Cases and Carbon Rings ...................................................................... 1-2
Sentinel Valve ..................................................................................................... 1-2
Nozzle Ring and Reversing Blade Assembly ...................................................... 1-5
Bearing Housings and Supports ......................................................................... 1-5
Governor System ................................................................................................ 1-5
Journal Bearings ................................................................................................. 1-5
Rotor Locating Bearing ....................................................................................... 1-5
Overspeed Trip System ...................................................................................... 1-5
Rotor ................................................................................................................... 1-5
Steam Chest ....................................................................................................... 1-6
FACTORY TESTS .......................................................................................................... 1-6
SHIPMENT ..................................................................................................................... 1-6
UNPACKING ................................................................................................................... 1-6
HANDLING ..................................................................................................................... 1-6
STORAGE ...................................................................................................................... 1-7
RECOMMENDED SPARE PARTS ................................................................................. 1-9
FIELD SERVICES ........................................................................................................... 1-9
FACTORY REPAIR ........................................................................................................ 1-9

CHAPTER 2 – INSTALLATION

INTRODUCTION ............................................................................................................ 2-1

FOUNDATION ................................................................................................................ 2-3
Foundation Preparation ....................................................................................... 2-6
CHOCK BLOCKS ........................................................................................................... 2-7
Chock Block ........................................................................................................ 2-7
GROUTING ..................................................................................................................... 2-11
SETTING THE EQUIPMENT ON FOUNDATION ........................................................... 2-13
COUPLING INSTALLATION ........................................................................................... 2-14
Installing a Straight Bore Coupling ...................................................................... 2-14
Installing a Taper Bore Coupling ......................................................................... 2-15
SHAFT ALIGNMENT ...................................................................................................... 2-16
Shaft Alignment Map Instructions ....................................................................... 2-20
Rim and Face Method of Alignment .................................................................... 2-24
Reverse Indicator Method of Shaft Alignment ..................................................... 2-27
Hot Alignment Check .......................................................................................... 2-29
Realign as Necessary ......................................................................................... 2-33

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YR Turbine, UG Governor System

PAGE NO.
CHAPTER 2 – INSTALLATION
(Continued)

TURBINE PIPING RECOMMENDATIONS ..................................................................... 2-33

STEAM BLOW DOWN .................................................................................................... 2-34
TURBINE STEAM SUPPLY ............................................................................................ 2-35
TURBINE ATMOSPHERIC RELIEF VALVES ................................................................ 2-35
Condensing Turbines .......................................................................................... 2-35
Non-condensing Turbines ................................................................................... 2-36
MISCELLANEOUS PIPING CONNECTIONS ................................................................. 2-36
VACUUM BREAKER FOR CONDENSING TURBINES ................................................. 2-40
CONNECTING TURBINE TO CONDENSER ................................................................. 2-40
TURBINE INSULATION .................................................................................................. 2-41
Turbine Jacketing ................................................................................................ 2-41

CHAPTER 3 – OPERATION

INTRODUCTION ............................................................................................................ 3-1

STEAM SUPPLY ............................................................................................................ 3-1
SAFETY PRECAUTIONS ............................................................................................... 3-2
PREPARING THE TURBINE FOR INITIAL START-UP ................................................. 3-3
INITIAL START-UP ......................................................................................................... 3-6
ROUTINE START-UP ..................................................................................................... 3-9
OVERLOAD HAND VALVES .......................................................................................... 3-11
TURBINE SHUTDOWN .................................................................................................. 3-13
OPERATION OF EMERGENCY AND STANDBY TURBINES ....................................... 3-13

CHAPTER 4 – MAINTENANCE

INTRODUCTION ............................................................................................................ 4-1

SCHEDULED MAINTENANCE ....................................................................................... 4-1
TURBINE CASING and MISCELLANEOUS JOINTS ..................................................... 4-3
PACKING CASE (SHAFT SEALING GLAND) and CARBON RING SERVICE .............. 4-5
Packing Case Disassembly ................................................................................. 4-6
Carbon Ring ........................................................................................................ 4-6
Removal .................................................................................................. 4-6
Replacement ........................................................................................... 4-7
Clearances .............................................................................................. 4-7
Adjustments ............................................................................................. 4-7
Labyrinth Seal (BYRHH Turbine Only) ................................................................ 4-8
Removal .................................................................................................. 4-8
Replacement ........................................................................................... 4-8
Clearances .............................................................................................. 4-8
Adjustments ............................................................................................. 4-8
Packing Case Assembly ..................................................................................... 4-10
TURBINE CASING ................................................................................................... 4-10
Disassembly ........................................................................................................ 4-10
Assembly ............................................................................................................. 4-11

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 Table of Contents
YR Turbine, UG Governor System

PAGE NO.
CHAPTER 4 – MAINTENANCE
(Continued)
BEARING LINERS .......................................................................................................... 4-11
Disassembly ........................................................................................................ 4-11
Clearances .......................................................................................................... 4-12
To Check the Bearing Liner Clearances ............................................................. 4-12
Dimensional Method ................................................................................ 4-12
Plastigage Method ................................................................................... 4-12
Lift Check Method ................................................................................... 4-13
Adjustments ........................................................................................................ 4-13
Assembly ............................................................................................................. 4-13
WATER COOLED BEARINGS ....................................................................................... 4-14
Disassembly ........................................................................................................ 4-15
Adjustments ........................................................................................................ 4-15
Assembly ............................................................................................................. 4-15
ROTOR ASSEMBLY ....................................................................................................... 4-15
Removal .............................................................................................................. 4-15
Clearances .......................................................................................................... 4-16
Adjustments ........................................................................................................ 4-17
Replacement ....................................................................................................... 4-17
EXHAUST PEDESTAL REPLACEMENT ....................................................................... 4-17
Disassembly ........................................................................................................ 4-17
Clearances .......................................................................................................... 4-18
Adjustments ........................................................................................................ 4-18
Replacement ....................................................................................................... 4-18
STEAM BEARING HOUSING REPLACEMENT ............................................................. 4-19
Disassembly ........................................................................................................ 4-19
Clearances .......................................................................................................... 4-19
Adjustments ........................................................................................................ 4-19
Replacement ....................................................................................................... 4-20
EXHAUST PEDESTAL AND STEAM BEARING HOUSING ALIGNMENT .................. 4-20
To Check the Bearing Housing Alignment .......................................................... 4-20
To Correct any Misalignment .............................................................................. 4-22
ROTOR LOCATING BEARING....................................................................................... 4-22
Clearances .......................................................................................................... 4-22
Disassembly ........................................................................................................ 4-23
Adjustments ........................................................................................................ 4-23
Assembly ............................................................................................................. 4-23
NOZZLE RING and REVERSING BLADE ASSEMBLY .................................................. 4-23
Disassembly ........................................................................................................ 4-24
Clearances .......................................................................................................... 4-24
Adjustments ........................................................................................................ 4-24
Assembly ............................................................................................................. 4-25
SHAFT SLEEVE SEALS ................................................................................................. 4-25
Disassembly ........................................................................................................ 4-25
Replacement and Adjustment ............................................................................. 4-26
Clearances .......................................................................................................... 4-26
OVERSPEED TRIP SYSTEM ........................................................................................ 4-26
Disassembly, Standard YR Overspeed Trip Mechanism .................................... 4-27
Trip Body Removal .............................................................................................. 4-28
Plunger Assembly Replacement ......................................................................... 4-28
Trip Body Replacement ....................................................................................... 4-28
Assembly, Overspeed Trip Mechanism............................................................... 4-29

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Table of Contents
YR Turbine, UG Governor System

PAGE NO.
CHAPTER 4 – MAINTENANCE
(Continued)

Adjusting the Trip Pin and Plunger Clearance .................................................... 4-31

Adjusting the Turbine Trip Speed ........................................................................ 4-31
Disassembly, Trip Valve ...................................................................................... 4-32
Guide Bushing Replacement .............................................................................. 4-32
Assembly, Trip Valve .......................................................................................... 4-33
Backseating the Trip Valve ................................................................................. 4-33
Trip System Linkage ........................................................................................... 4-35
Trip System Clearances ...................................................................................... 4-35
GOVERNOR VALVE....................................................................................................... 4-36
Disassembly ........................................................................................................ 4-36
Clearances .......................................................................................................... 4-36
Adjustments ........................................................................................................ 4-36
Assembly ............................................................................................................. 4-37
OVERLOAD HAND VALVE ............................................................................................ 4-39
Disassembly ........................................................................................................ 4-39
Adjustments ........................................................................................................ 4-39
Assembly ............................................................................................................. 4-39
TIGHTENING BOLTS ..................................................................................................... 4-50

CHAPTER 5 – LUBRICATION

INTRODUCTION ............................................................................................................ 5-1

BASIC OIL REQUIREMENTS......................................................................................... 5-1
CARE OF OIL ................................................................................................................. 5-1
METHODS OF LUBRICATION ....................................................................................... 5-2
RING OILED LUBRICATION .......................................................................................... 5-2
To Change Oil in Bearing Housing Reservoir ..................................................... 5-4
PRESSURE LUBRICATION ........................................................................................... 5-5
Lubrication System Flushing ............................................................................... 5-5
Normal Maintenance .......................................................................................... 5-7
Turnaround Maintenance .................................................................................... 5-7
SELECTING LUBRICATING OILS ................................................................................. 5-7

CHAPTER 6 – UG GOVERNOR SYSTEM

INTRODUCTION ............................................................................................................ 6-1

GENERAL DESCRIPTION ............................................................................................. 6-1
LUBRICATION ................................................................................................................ 6-3
Governor Oil Requirements ................................................................................ 6-3
Governor Drive Lubrication ................................................................................. 6-3
OPERATION ................................................................................................................... 6-5
Principle of Operation .......................................................................................... 6-5
Initial Start-Up ..................................................................................................... 6-5
Routine Start-Up ................................................................................................. 6-6

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 Table of Contents
YR Turbine, UG Governor System

CHAPTER 6 – UG GOVERNOR SYSTEM

(Continued)
PAGE NO.

MAINTENANCE ............................................................................................................ 6-6

Routine Maintenance ........................................................................................ 6-6
Governor Disassembly ...................................................................................... 6-6
Governor Removal ............................................................................................ 6-6
Worm Wheel Replacement ............................................................................... 6-7
Governor Installation ......................................................................................... 6-7
Worm Wheel Tooth Contact Adjustment ........................................................... 6-7
Worm Wheel Backlash Adjustment ................................................................... 6-8
Turbine Shaft Driven Oil Pump Removal........................................................... 6-8
Pump Installation ............................................................................................... 6-9
Overspeed Trip Plunger Replacement .............................................................. 6-9

CHAPTER 7 – TROUBLESHOOTING

INTRODUCTION........................................................................................................... 7-1

CHAPTER 8 – ACCESSORIES

INTRODUCTION........................................................................................................... 8-1
ACCESSORY LIST ....................................................................................................... 8-3

CHAPTER 9 – SERVICE/PARTS/SALES

INTRODUCTION........................................................................................................... 9-1
SPARE PARTS............................................................................................................. 9-1
Spare Parts List................................................................................................. 9-1
Ordering ............................................................................................................ 9-2
Storage ............................................................................................................. 9-2
Returning Parts to the Factory .......................................................................... 9-3
FIELD SERVICE ASSISTANCE ................................................................................... 9-3
CUSTOMER TRAINING................................................................................................ 9-3
TECHNICAL MANUAL COMMENT SHEET .................................................................. 9-3
APPENDIX “A” - SPARE PARTS LIST
APPENDIX “B” - SALES AND SERVICE OFFICE LOCATIONS
APPENDIX “C” - TECHNICAL MANUAL COMMENT SHEET
APPENDIX “D” - ELLIOTT TECHNICAL TRAINING 2017

CHAPTER 10 - TECHNICAL DRAWINGS

INTRODUCTION........................................................................................................... 10-1
NOMENCLATURE AND USE OF ASSEMBLY DRAWINGS ........................................ 10-1
DRAWING LIST ............................................................................................................ 10-3

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Table of Contents
YR Turbine, UG Governor System
FIGURE NO. LIST OF FIGURES PAGE NO.

1-1 Typical CYR, DYR Turbine ......................................................................... 1-3

1-2 Typical BYRH/BYRHH Turbine .................................................................. 1-4
1-3 Lifting the Turbine....................................................................................... 1-7

2-1 Typical Baseplate Mounting Arrangement ................................................. 2-3

2-2 Suggested Anchor Bolt Arrangement ......................................................... 2-5
2-3 Typical Soleplate Mounting Arrangement .................................................. 2-5
2-4 Typical Baseplate Mounting Arrangement ................................................. 2-6
2-5 Typical Chock Block ................................................................................... 2-7
2-6 Preferred Location of Chock Blocks ........................................................... 2-8
2-7 Preferred Location of Chock Blocks ........................................................... 2-9
2-8 Alternate Location of Chock Blocks............................................................ 2-9
2-9 Typical Chock Block Arrangement ............................................................. 2-10
2-10 Flexible Couplings/Tapered and Straight ................................................... 2-15
2-11 Types of Shaft Misalignment ...................................................................... 2-18
2-12 Axial Separation ......................................................................................... 2-19
2-13 Axial Separation-Diagram Coupling ........................................................... 2-19
2-14 Shaft Alignment Map Example ................................................................... 2-21
2-15 Pictorial of Note 3 on Alignment Map ......................................................... 2-22
2-16 Pictorial of Note 4 on Alignment Map ......................................................... 2-22
2-17 Blank Alignment Map ................................................................................. 2-23
2-18 Measuring Angular Misalignment ............................................................... 2-25
2-19 Angular Displacement ................................................................................ 2-25
2-20 Measuring Parallel Offset ........................................................................... 2-26
2-21 Reverse Indicator Readings ....................................................................... 2-27
2-22 Typ. Displacement of Benchmarks on Foundation and Bearing Housing .. 2-30
2-23 Graphical Determination of Shaft in Hot Position Rel. to Cold Position ..... 2-31
2-24 Suggested Steam Piping Arrangement ...................................................... 2-36
2-25 Miscellaneous Piping Connections............................................................. 2-38
2-26 Suggested Piping Arrangement for Water Cooled Bearing Housings ........ 2-39
2-27 Suggested Piping Arrg’t For Water Cooled Bearing Housings And Caps .. 2-39
2-28 Suggested Sealing Steam Piping Arrg’t for Condensing Turbines ............. 2-40
2-29 Turbine Recommended Insulation Metal Jacketing ................................... 2-41

4-1 Horizontal Joint Detail ................................................................................ 4-4

4-2 Packing Case Arrangement ....................................................................... 4-5
4-3 Carbon Ring Seal Assemblies .................................................................... 4-5
4-4 Schematic View, Water Cooled Bearing Housing ...................................... 4-14
4-5 Rotor Disk Arrangements ........................................................................... 4-16
4-6 Journal Bearing and Rotor Shaft Contact ................................................... 4-21
4-7 Nozzle Ring and Reversing Blade Arrangement ........................................ 4-24
4-8 Overspeed Trip System .............................................................................. 4-30
4-9 Backseating the Trip Valve ......................................................................... 4-34
4-10 Governor Valve Packing Arrangement ....................................................... 4-38
4-11 Overload Hand Nozzle Valve Assembly ..................................................... 4-40
4-12 Typical YR Turbine ..................................................................................... 4-43
4-13 Steam Chest Assembly .............................................................................. 4-46
4-14 Cold Clearance Diagram for CYR, DYR, DYRM and DYRN Turbines ....... 4-47
4-15 Cold Clearance Diagram for BYRH and BYRHH Turbines ........................ 4-48
4-16 Reversing Bucket Holder ............................................................................ 4-49

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 Table of Contents
YR Turbine, UG Governor System

LIST OF FIGURES
(Continued)

FIGURE NO. DESCRIPTION PAGE NO.

5-1 Ring Oiled Lubrication ................................................................................ 5-3

5-2 Glass Oiler.................................................................................................. 5-3

6-1 Governor System Arrangement .................................................................. 6-2

6-2 Typical Oil Flow Schematic Diagram for YR Turbine ................................. 6-4
6-3 Self Lubricated Governor Drive Arrangement ............................................ 6-4
6-4 UG Governor System ................................................................................. 6-11

LIST OF TABLES

TABLE NO. DESCRIPTION PAGE NO.

3-1 Overload Hand Valves ............................................................................... 3-12

4-1 Scheduled Maintenance Guidelines ........................................................... 4-2

4-2 Min./Max. Carbon Ring Dimensions for Operating
Exhaust Temperatures to 750 ºF (400 ºC)
CYR, DYR, DYRN, and DYRM Turbines.................................................... 4-9
4-2-1 Min./Max. Carbon Ring Dimensions for Operating
Exhaust Temperatures to 750 ºF (400 ºC)
BYRH and BYRHH Turbines ...................................................................... 4-9
4-3 Bolting Torque Requirements ..................................................................... 4-50

5-1 Oil Level Range, Capacities and Figure ’A’ Dimension .............................. 5-4
5-2 Guidelines for Selecting Lubricating Oils.................................................... 5-8
5-3 Operating Limits for Turbines ..................................................................... 5-9
5-4 Bearing Temperature Limits ....................................................................... 5-10

7-1 Troubleshooting Guide ............................................................................... 7-3

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Limitations, Warranty, and Safety

LIMITATIONS, WARRANTY, AND SAFETY

LIMITATIONS
It is to be noted that none of the drawings or printed material contained in this Technical
Manual in any way add to, detract from, void or alter any of the conditions of the contract.
Such drawings and/or printed materials are for descriptive purposes only and are not to be
construed as determining the scope of supply or the performance of the equipment.
Please consult your contract to determine those particulars.

Such drawings shall be deemed to be and remain Elliott Company’s proprietary property,
and reproduction, distribution or disclosure of any part of the contents is expressly
forbidden without written consent.

WARRANTY
Should any part of the machinery prove, under normal use and service, to have been
defective in material or workmanship, when shipped, the Company warrants, so far as said
part of its own manufacture, that it will repair or replace said part f.o.b. the Company
Works provided the Purchaser discovers said defect within eighteen months after date of
shipment or twelve months from date of start-up and notifies the Company in writing
thereof within five days after such discovery and on request of the Company returns the
part claimed to be defective, transportation prepaid, to the Company’s Works for
inspection. There are no other warranties, expressed or implied, except of title. The
Company shall not be liable for any damages or delays caused by defective material or
workmanship. No allowance will be made for repairs or alterations made by others without
the company’s written consent or approval. The company does not warrant that any part
of the machinery will resist the action of erosive or corrosive gases or liquids and no part
shall be deemed to be defective by reason of its failure to resist such action, unless
expressly agreed otherwise herein. The Company assumes no responsibilities for
damage to machinery caused by improper installation or by operation above its rated
capacity, intentional or otherwise, or by improper handling or maintenance. The foregoing
are Elliott Company’s standard terms and conditions of warranty. Please consult your
contract for any clarification, alterations and/or modifications thereto.

SAFETY
It is assumed that the safety department of the end user has an established safety
program based upon a thorough analysis of industrial hazards. Before installing and
operating or performing maintenance on the turbine, it is suggested that you review this
program to be certain that it covers the hazards arising from rotating machinery in general
and turbines in particular.

It is important that due consideration be given to those hazards developing from the
presence of electrical power, hot oil, high pressure and temperature steam, toxic gases,
and flammable liquids and gases. Proper installation and continued maintenance of
protective guards, shutdown devices and over pressure protection are also necessary for
safe turbine operation. The turbine should never be operated by bypassing, overriding or
in any way rendering inoperative, guards, protective shutdown equipment or other safety
devices.

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 Limitations, Warranty, and Safety

It is also essential that the turbine be isolated from all utilities to prevent the possibility of
applying power or steam to the turbine when internal maintenance work is in progress.
When performing internal turbine maintenance, always ensure that isolating valves in the
steam inlet and exhaust lines are locked closed and tagged, and all drains opened to
depressurize the turbine casing and steam chest. Precautions must also be taken to
prevent possible turbine rotation due to reverse flow through the driven machinery.

In general, you should be guided by all of the basic safety rules associated with the
turbine, driven equipment and plant process.

The turbine must not be modified in any way without Elliott Group's approval. This is to
ensure that the safety, reliability, and performance of the turbine and associated systems
are not compromised.

-WARNING-
THE ELLIOTT COMPANY CAN NOT ASSUME ANY
RESPONSIBILITY FOR DAMAGES OR PERSONAL
INJURY RESULTING FROM OPERATION OF THIS
EQUIPMENT WITH SAFETY AND/OR SHUTDOWN
DEVICES BEING ISOLATED, DISABLED, OR
BYPASSED.

-WARNING-
Read this entire Instruction and Operation Manual
prior to installing, operating, or servicing this
equipment. Follow all plant and safety instructions.
Failure to comply can cause personal injury and/or
damage to property.

IMPORTANT DEFINITIONS

-WARNING- indicates a potentially hazardous

situation that could result in personal injury or death.

CAUTION indicates a potentially hazardous situation

that could result in damage to equipment.

SPECIFIC WARNINGS / CAUTIONS

CAUTION
Ensure that all threaded fasteners, joints, and piping
are tight. These connections may come loose during
shipment. Check all connections prior to startup.

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Limitations, Warranty, and Safety

-WARNING-
The turbine surface is hot and can cause severe burns.
Extreme caution must be taken to prevent contact with
exposed surfaces.

-WARNING-
All rotating surfaces including the shaft, coupling, and
all other rotating parts must be guarded to prevent any
contact.

-WARNING-
This turbine may have hydraulic or pneumatic
powered mechanisms that may move without warning
and create pinch points. Coming in contact with these
areas may result in serious injury.

-WARNING-
This turbine is equipped with an overspeed trip system
that is designed to stop the turbine in the event of a
turbine over-speed. It is extremely important that this
system be maintained in operating condition.

-WARNING-
Do not exceed the steam conditions (pressures and
temperatures) specified on the turbine nameplate.
Exceeding these conditions can result in serious
injury and/or damage to the turbine.

-WARNING-
Ensure all exhaust valves are open prior to starting the
turbine.

-WARNING-
The sentinel valve is an overpressure audible warning
device only. An atmospheric relief valve must be
installed for over-pressure protection. Check for
proper sizing and setting.

CAUTION
Ensure proper lifting

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 Limitations, Warranty, and Safety

OVERLOADING OF TURBINES

From the turbine standpoint, greater loads than contract commitments can usually be
carried without exceeding permissible variations in design steam conditions. This is
particularly true when provision is made to extract large quantities of steam at rated load
or to develop rated load under emergency initial steam conditions, and/or back-pressure
above design values. Such an increase represents an overload introducing increased
maintenance expense, reduction of useful life and the possibility of physical damage to the
machine.

Any operation of a turbine beyond the capacity specified in the contract is undertaken by
the purchaser at his own risk and responsibility.

WET STEAM

Many factors that affect the life of turbine nozzles, disks, and blades are beyond the
control of the Elliott Company and prevent the Elliott Company from assuming any
warranty obligations for corrosion or erosion.

Nozzle, disk and blade erosion and corrosion increases with increasing steam moisture
content. The inlet steam pressure, the inlet steam temperature and the exhaust pressure
fundamentally determine moisture content. Skill in the boiler operation and the installation
and maintenance of moisture traps affect the steam moisture content as well.

The presence of non-condensable gases such as carbon dioxide, hydrogen sulfide, sulfur
dioxide, etc., in the steam will affect the acidity and, therefore, the corrosiveness of the
steam. Industrial steam systems with high percentages of “make-up” water frequently
have high concentrations of these non-condensables. Boiler feed water treatment is the
responsibility of the user and is out of the realm of the Elliott Company’s responsibility.

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Limitations, Warranty, and Safety

Corrosion will occur if vapor is allowed to enter the machine when it is idle. When shutting
down for standby, be sure that the trip and throttle valve or inlet valve has a tight seat and
that an open drain valve is provided between the inlet valve and the steam chest. Also be
sure that all casing drains are open.

ALLOWABLE VARIATIONS FROM RATED STEAM PRESSURE AND TEMPERATURE

The following variations are intended to allow for transient operating conditions only. To
eliminate the possibility of voiding the guarantee, steps should be taken to minimize their
occurrence and operate at design conditions.

INLET PRESSURE

The initial pressure at rated load shall average not more than rated pressure over any 12-
month operating period.

The turbine is capable of operating without damage at less than rated steam flow with an
average pressure of 105% of rated pressure. (This permissible variation recognizes the
increase in pressure with decrease in steam flow encountered during operation.)
The initial pressure shall not exceed 110% of rated pressure in maintaining these
averages except during abnormal conditions.

During abnormal conditions, the initial pressure may swing momentarily to 120% of rated
value. The aggregate of such swings shall not exceed 12 hours per 12-month operating
period.

INLET TEMPERATURE

The steam temperature at the turbine inlet flange shall average not more than rated
temperature over any 12-month operating period. In maintaining this average, the
temperature shall not exceed rated temperature plus 15°F (8°C) except during abnormal
conditions. During abnormal conditions, the temperature shall not exceed rated
temperature plus 25°F (14°C) for more than 400 hours per 12-month operating period, nor
rated temperature plus 50°F (30°C) for swings of 15 minutes duration or less, aggregating
no more than 80 hours per 12-month operating period.

EXHAUST PRESSURE FOR NON-CONDENSING TURBINES

The exhaust pressure shall average not more than rated exhaust pressure over any 12-
month operating period.

The turbine shall be capable of operating without damage at less than rated steam flow to
the turbine, provided that the exhaust pressure shall not exceed 110% nor drop below
80% of rated exhaust pressure.

EXHAUST PRESSURE FOR CONDENSING TURBINES

Any anticipated variations in the exhaust steam pressure should be specified by the user
so that it can be taken into consideration in the design of the turbine.
________________________________________________________________________

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 Limitations, Warranty, and Safety

COPYRIGHT
The information contained in this technical manual is the property of Elliott Company, and is furnished for use
by the assigned recipient only. Reproduction, disclosure or distribution of any part of the contents of this
manual is expressly forbidden without written consent of Elliott Company.
© ELLIOTT COMPANY 2008

Elliott Company
901 North Fourth Street
Jeannette, PA 15644
Phone Number 724-527-2811
FAX Number 724-600-8442
http://www.elliott-turbo.com

PRINTED IN THE U.S.A.

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 EQUIPMENT DATA INDEX
F602328

Turbine Operating Data

Turbine Customer Data Sheet, 5030256, Rev.0

 NON-CONDENSING TURBINE OPERATING DATA
SERIAL NUMBER/SHOP ORDER NUMBER F602328

FRAME: DYRUG III

SPEED:
Rated 4950 rpm
Maximum Continuous 4960 rpm
1st Calculated Critical 8850 rpm
Mechanical Overspeed Trip 5456 rpm
Trip Speed Range 5456 rpm to 5565 rpm

STEAM CONDITIONS - DESIGN CONDITIONS:

Inlet Pressure 305 psig 21 barg
Inlet Temperature 536 ºF 280.0 ºC
Exhaust Pressure 51 psig 3.5 barg

STEAM CONDITIONS - MAXIMUM CONDITIONS:

Inlet Pressure 700.5 psig 48.3 barg
Inlet Temperature 750 ºF 398.9 ºC
Exhaust Pressure 100 psig 6.9 barg

RELIEF VALVE SET: 75 psig 5.17 barg

SENTINEL VALVE SET: 75 psig 5.17 barg

ROTOR CLASS DESIGNATION: D-3

RATED POWER: 2138.9 HP 1595 KW

LUBRICATION SYSTEM: Pressure Lube

Type of Viscosity Grade ISO VG 32
Nominal Bearing Oil Pressure 7-9 psig 0.48 - 0.62 barg

TURBINE STEAM SEALS: Carbon Ring Seals

GOVERNOR TYPE: Woodward UG-12.8

Governor Valve Travel: 0.41 inches (Set at 0.50 inches maximum)
 JOB NO. ITEM NO. 159-16-069
PURCHASE ORDER NO. C.325/CIE-EC/I/2017
GENERAL PURPOSE STEAM TURBINE DATA SHEET NO. 5030256
DATASHEET REVISION NO. 0 DATE 6-Feb-17
SI UNITS (BAR) PAGE 1 OF 3 BY J.GREENE
 CHECKED N/A APPROVED N/A

1 APPLICABLE TO: PURCHASE APPLICABLE STANDARD: MANF STD. UNITS OF MEASURE: SI UNITS (BAR)
2 FOR RSPI POM UNIT
3 SITE INDONESIA NO. REQUIRED ONE
4 SERVICE DRIVEN EQUIPMENT Sychronous Generator
5 MANUFACTURER ELLIOTT MODEL DYRUG III SERIAL NO. F602328
6
7 OPERATING CONDITIONS
8 ABSORBED POWER, SPEED, OPERATING POINT / STEAM NO. HAND VALVES STEAM RATE
OPERATING POINT
9 KW RPM CONDITION OPEN KG/KW-HR
RATED / NORMAL
10 NORMAL 1595 4950 1 18.5
CERTIFIED STEAM RATE

OTHER / NORMAL
11 RATED 1595 4950 0 18.6
CONDITIONS

RATED @ MIN INLET & MAX

12 OTHER (6.1.4) 1196 4950 N/A N/A
EXHAUST
13 DUTY, SITE, AND UTILITY DATA
14 APPLICATION IS: SPARED
15 WIDE SPEED RANGE NO RAPID START NO APPLICABLE SPECIFICATIONS
16 SLOW ROLL REQUIRED NO HAND VALVES YES OTHER
17 OPERATION CONTINUOUS
18
19 CONSTRUCTION
20 LOCATION (6.1.14) OUTDOOR UNHEATED W/O ROOF TURBINE TYPE HORIZONTAL
21 AMBIENT TEMP MIN MAX C NO. OF STAGES 1 WHEEL DIA 711.2 MM
22 UNUSUAL CONDITIONS (6.1.14) ROTOR CONSTRUCTION BUILT UP
23 ARRANGEMENT BETWEEN BEARINGS
24 AREA CLASSIFICATION NONE (NON-HAZARDOUS) NONE (NON-HAZABLADING 2 ROW
25 CASING SPLIT AXIAL
26 CASING SUPPORT CENTER LINE
27 CONTROL POWER V 220 PH 1 HZ 50 VERTICAL JACKSCREWS FURNISHED YES
28 AUX MOTORS V PH HZ
29 COOLING WATER PRESS BARG DP BARG
30 FLOW LPM DT C TRIP VALVE INTEGRAL BODY
31 ALLOW. SOUND PRESS. LEVEL (6.1.12) dBA @ INTERSTAGE SEALS N/A
32 STEAM CONDITIONS (6.1.4) END SEALS CARBON RING
33 MAX NORMAL MIN
34 INLET PRESS 21.0 21.0 21.0 BARG
35 INLET TEMP 280 280 280 C TYPE RADIAL BEARINGS SLEEVE
36 EXHAUST PRESS 3.5 3.5 3.5 BARG TYPE THRUST BEARINGS ANTI-FRICTION
37 STEAM CONTAMINANTS LUBE OIL VISCOSITY ISO GRADE 32
38 TURBINE DATA LUBRICATION PRESSURE LUBE
39 ALLOW SPEEDS, RPM MAX 4960 MIN 4703 OIL MIST NO
40 MAX CONT SPEED, RPM 4960 OIL MIST SYSTEM N/A
41 TRIP SPEED, RPM 5456 BLADE TIP VEL. 201.5 M/S BEARING HOUSING OILER TYPE N/A
42 FIRST CRITICAL SPEED, RPM 8850 BEARING HOUSING SEAL SLEEVE (LABYRINTH)
43 EXH TEMP NORMAL 164 C NO LOAD 254 C SEAL SUPPLIER ELLIOTT
44 POTENTIAL MAX POWER 1651 KW CASING RATING INLET EXHAUST
45 MAX NOZZLE STEAM FLOW 34246 KG/HR MAX ALLOWABLE PRESS 48.26 6.89 BARG
46 ROTATION FACING GOVERNOR END COUNTER-CLOCKWISE MAX ALLOWABLE TEMP 400 371 C
47 VERTICAL DRIVEN EQUIPMENT THRUST N/A HYDRO TEST PRESS 98.25 12.06 BARG
48 VERTICAL TURBINE THRUST CAPACITY N/A
49 WATER PIPING REQUIRED NO
50 FURNISHED BY N/A REMARKS
51 OIL PIPING REQUIRED YES
52 FURNISHED BY OTHERS
53 AUTO DRAIN SYSTEM REQUIRED NO
54 FURNISHED BY N/A

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 JOB NO. ITEM NO. 159-16-069
PURCHASE ORDER NO. C.325/CIE-EC/I/2017
GENERAL PURPOSE STEAM TURBINE DATA SHEET NO. 5030256
DATASHEET REVISION NO. 0 DATE 6-Feb-17
SI UNITS (BAR) PAGE 2 OF 3 BY J.GREENE
 CHECKED N/A APPROVED N/A

1 MATERIALS (6.12) ACCESSORY EQUIPMENT BY VENDOR

2 HIGH PRESSURE CASING ASTM A-216 GRADE WCB REMOTE TRIP SOLENOID NO
3 TURBINE TRIPPED SIGNAL NO
4 EXHAUST CASING ASTM A-216 GRADE WCB VACUUM BREAKER NO
5 NOZZLES AISI 410 GRADE AUTOMATIC STEAM SEALING SYSTEM NO
6 BLADING AISI 403 GRADE SEALING STEAM N/A BARG N/A C
7 WHEELS AISI 4340 GRADE GLAND VACUUM DEVICE WITH: N/A
8 SHAFT AISI 4140 GRADE SENTINEL WARNING VALVE YES
9 SHAFT COATING UNDER PACKING INSULATION, TYPE: NONE
10 MATERIAL STAINLESS STEEL TACHOMETER TYPE SELF POWERED
11 APPLICATION METHOD FLAME SPRAY MFR. DYNALCO SPD-100
12 THICKNESS 0.5 MM MOUNTED BY ELLIOTT
13 GOV. VALVE TRIM D2, NI-RESIST THERMAL RELIEF VALVES NO
14 INLET STRAINER YES MESH SIZE #8 MESH
15 LOCAL GAUGE BOARD WITH PRESSURE GAUGES: NO
16 CONNECTIONS (6.4.2) THROTTLE STEAM NO FIRST STAGE NO
17 SIZE RATING FACING POSITION NOZZLE RING NO EXHAUST NO
18 INLET 6 600 RF RIGHT LIQUID FILLED GAUGES NO
19 EXHAUST 12 150 RF LEFT INSTRUMENT PANEL NO
20 DRAINS HP SEE PURCHASER'S CONNECTION DRAWING
21 DRAINS LP SEE PURCHASER'S CONNECTION DRAWING
22 EXTERNAL LUBE OIL SYSTEM
23 TYPE OF LUBE SYSTEM SUPPLIED
24 COUPLINGS (7.2) VENDOR FURNISH SYSTEM FOR
25 LOCATION TURBINE DRIVEN
26 MAKE OIL SYSTEM TO BE:
27 MODEL
28 RATING (HP/100RPM) REMARKS
29 LUBRICATION
30 LIMITED END FLOAT
31 SPACER LENGTH
32 SERVICE FACTOR VIBRATION AND POSITION DETECTORS (7.4.4.3)
33 COUPLING SPACER/HUBS MATL. FURNISH PROVISIONS FOR MOUNTING NON-CONTACTING
34 COUPLING DIAPHRAGMS (DISKS) MATL. VIBRATION PROBES NO
35 TURBINE VENDOR MOUNTS HALF COUPLING FURN. AXIAL POSITION PROBES NO NO. OF PROBES
36 COUPLING CONSTRUCTED TO MFR. MODEL
37 SEE SEPARATE DATA SHEET FURN. ONE EVENT PER REV PROBE NO
38 COUPLING BALANCED TO FURN. RADIAL PROBES NO NO. OF PROBES
39 TURBINE SHAFT STRAIGHT - SINGLE KEY MFR. MODEL
40
41 FURNISH BEARING METAL TEMP SENSORS FOR:
42 MOUNITNG PLATES RADIAL BEARINGS NO THRUST BEARINGS NO
43 TURBINE MOUNTED ON MAGNETIC SEISMIC PROBES NO
44 FURN. BY: PERMANENT SEISMIC PROBES NO
45 EQUIPMENT TO BE MOUNTED MFR. MODEL
46 TURBINE VENDOR SUPPLIES MONITORS
47 UNGROUTED BASEPLATE AXIAL AND RADIAL PROBES
48 BEARING TEMPERATURE SENSORS
49 SUBPLATES REQUIRED SEE SEPARATE DATA SHEETS FOR DETAILS
50 REMARKS
51
52 GEAR BOX
53 GEARBOX REQUIRED
54 FURN. BY:
55 APPLICABLE SPECIFICATION
56 GEARBOX DATA SHEET NUMBER

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 JOB NO. ITEM NO. 159-16-069
PURCHASE ORDER NO. C.325/CIE-EC/I/2017
GENERAL PURPOSE STEAM TURBINE DATA SHEET NO. 5030256
DATASHEET REVISION NO. 0 DATE 6-Feb-17
SI UNITS (BAR) PAGE 3 OF 3 BY J.GREENE
 CHECKED N/A APPROVED N/A
1 GOVERNING SYSTEM PREPARATION FOR SHIPMENT
2 GOVERNOR TYPE HYDRAULIC TURBINE, AUX. EQUIP. AND SPARE ROTOR PREPARED FOR:
3 GOVERNOR MANUFACTURER WOODWARD EXPORT BOX
4 GOVERNOR MODEL UG-12.8 OUTDOOR STORAGE NO LONGER THAN 6 MONTHS
5 SPEED RANGE OTHER 4,703 - 4,960 REMARKS
6 SPEED SETPOINT ADJUSTMENT
7 LOCAL HAND SPEED CHANGER
8 REMOTE SPEED SETPOINT
9 VARIABLE OPERATING RANGE CONTROL SIGNAL
10 SPEED TO RPM TO mA
11 SPEED TO RPM TO BARG
12 GOVERNOR POWER SUPPLY EXTERNAL TESTS (8.3) REQ'D. WITN. (8.1.1) OBSVD.
13 HYDROSTATIC YES NO NO
14 REMOTE TRIP INPUT TO ELECTRONIC GOVERNOR NO DYNAMIC BALANCE YES NO NO
15 ELECTRONIC GOVERNOR SUITABLE FOR SLOW ROLL NO MECH. RUN 1/2 h YES NO NO
16 OVERSPEED TRIP MECHANICAL PERFORMANCE NO NO NO
17 COMPLETE UNIT NO NO NO
18 No. ACTUATION DEVICES GEAR NO NO NO
19 MANUFACTURER SOUND LEVEL NO NO NO
20 MODEL AUX. EQUIPMENT NO NO NO
21 REMARKS RESIDUAL UNBALANCE CHECK NO NO NO
22
23
24 REMARKS
25 ENGINEERING REQUIREMENTS
26 SUPPLY ENGR. DATA FOR L.ATERAL/TORSIONAL ANALYSES
27 BY OTHERS DOCUMENTATION
28 CALCS AND/OR DATA FOR SEPARATION MARGIN PERFORMANCE CURVES YES
29 TRAIN TORSIONAL VIBRATION ANALYSIS PROGRESS REPORTS NO
30 TECHNICAL DATA MANUAL YES
31 WEIGHTS
32 PARTY HAVING UNIT RESPONSIBILITY TURBINE 1044 KG
33 ROTOR RUNNING CLEARANCES ROTOR 161 KG
34 INSPECTION REQUIREMENTS TURBINE UPPER HALF CASING 170 KG
35 USE INSPECTORS CHECKLIST NO MAX MAINTENANCE (TUHC) 170 KG
36 100% UT INSPECTION AFTER ROUGH MACHINING (ROTATING) NO T&T VALVE N/A KG
37 CASTING SURFACE INSPECTION NO BASEPLATE N/A KG
38 MISC. N/A KG
39 CASTING WELD REPAIR APPROVAL (REQUIRED) NO TOTAL SHIPPING WEIGHT 1180 KG
40 WELD INSPECTION NO REMARKS
41 SPECIAL NDT INSPECTION NO
42
43 MAG. DYE RADIO- ULTRA- OBSER- WIT-
44 COMPONENT PART. PENET. GRAPHIC SONIC VED NESS
45 T&T VALVE NO NO NO NO NO NO
46 STM CHEST NO NO NO NO NO NO
47 CASING NO NO NO NO NO NO
48 STEAM PIPING NO NO NO NO NO NO
49 ROTOR WHEEL NO NO NO YES NO NO
50 ROTOR SHAFT NO NO NO NO NO NO
51

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 CHAPTER ONE
GENERAL INFORMATION

INTRODUCTION

This technical manual supplies information for the installation, operation, and maintenance
for your Elliott equipment. To avoid operational and maintenance difficulties, special
attention should be given to the precautionary instructions emphasized throughout the
manual.

Table of Contents – includes Customer Order Information, Equipment Data and

Limitations, Warranty and Safety.

Chapter 1 - General Information – provides a description of the equipment and procedures

for unpacking, handling and storage.

Chapter 2 - Installation – discusses basic foundation requirements along with alignment

procedures, piping recommendations, and other installation details.

Chapter 3 - Operation – provides equipment guidelines for start-up and shutdown

procedures including recommended safety precautions to observe during operation.

Chapter 4 - Maintenance – supplies a recommended routine maintenance schedule along

with disassembly, assembly, and adjustment procedures.

Chapter 5 - Lubrication – describes the lubrication system, the oil requirements and gives
consideration to the care of the lubricating oil.

Chapter 6 - Control System – furnishes information required for operating, adjusting, and
maintaining the control system.

Chapter 7 - Troubleshooting – provides probable causes of problems and necessary

corrective actions.

Chapter 8 - Accessories – contains instructions and/or data and drawings applicable to

various accessory components provided with the equipment.

Chapter 9 - Service/Parts/Sales – provides the Spare Parts List, information on how to

order parts and where to obtain service assistance and training for operators and
maintenance personnel.

Chapter 10 - Technical Drawings – contains specific drawings for your equipment. The
drawing numbers may have a suffix number or group number identifying the applicable
assembly on the drawing. Be sure to use the suffix listed when making reference to a
drawing.

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Chapter 1
General Information

GENERAL DESCRIPTION

Elliott CYR, DYR, and BYRH turbines are single stage steam turbines controlled by single
steam admission valves. They are used for numerous drive applications under various
steam conditions. CYR and DYR Turbines are similar in design and construction and
differ only in size. DYRM and DYRN Turbines are identical to the DYR Turbine except for
the location and size of the turbine exhaust connection. The BYRH, BYRHH, CYRH and
DYRH are of heavier construction with more/different shaft seals to withstand higher
exhaust steam pressures and temperatures. In general, these turbines consist of the
following components: (Refer to Figure 1-1 and 1-2.)

Turbine Casing
The horizontally split turbine casing surrounds the rotating element of the turbine and
supports the stationary steam path parts. The steam end casing consists of the high
pressure steam ring and nozzle chambers. The exhaust end casing contains the steam
exhaust connection. The steam end casing and exhaust end casings support the casing
cover.

Packing Cases and Carbon Rings

The turbines are furnished with two horizontally split packing cases. One packing case is
bolted through a vertical flange to the steam end turbine casing and casing cover. The
other packing case is similarly attached to the exhaust end turbine casing and casing
cover. The packing cases house the carbon rings which seal the casing and rotor shaft.
These rings minimize steam leakage along the shaft when the turbine operates non-
condensing. Turbines operating condensing employ carbon rings, along with a sealing
steam arrangement, to prevent air leakage into the casing. The BYRHH turbine uses a
labyrinth seal in combination with the carbon rings and an intermediate leak-off port which
must be connected to a 75 to 125 psig (5.2 to 8.6 bar) header.

Sentinel Valve
This warning device, located on the top of the turbine casing, indicates excessive turbine
casing pressure. In the event the casing pressure exceeds a predetermined setting above
the normal operating pressure, the valve releases a small amount of visible steam to the
atmosphere, causing a hissing sound. The sentinel valve does NOT serve as a relief
valve. Full flow relief valves, or other protective devices used to relieve the turbine of
excessive casing pressure, MUST be installed by the customer. (See “Atmospheric Relief
Valve”, Chapter 2.)

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100qc.chap01.7/7/2008

SENTINEL VALVE
ROTOR
DISK ASSEMBLY

CASING COVER

ROTOR
LOCATING BEARING
OVERSPEED
TRIP ASSEMBLY
COUPLING
STEAM END (T GOVERNOR DRIVE)
EXHAUST END
SEALING GLAND SEALING GLAND

CARBON RING CARBON

ASSEMBLY T GOVERNOR
RING ASSEMBLY
SHAFT SLEEVE GOVERNOR
SEAL OIL RINGS OIL RINGS
LINKAGE

ROTOR
SHAFT

EXHAUST END
JOURNAL BEARING STEAM END
BEARING
HOUSING
SHAFT SLEEVE
SEAL

STEAM CHEST
724-527-2811

GOVERNOR VALVE
EXHAUST END STEAM END

General Information
BEARING PEDESTAL JOURNAL BEARING
STEAM END
CASING
REVERSING
1-3

EXHAUST
BLADE ASSEMBLY NOZZLE RING
END CASING
STEAM

Chapter 1
C ELLIOTT TURBOMACHINERY CO., INC.,(YR) END SUPPORT
© ELLIOTT CO., INC. (YR)
724-527-2811
1-4

General Information
Chapter 1
SENTINEL VALVE
CASING COVER
STEAM END
RIBS ON PACKING CASE
BYRHH ONLY ROTOR
LOCATING BEARING
EXHAUST END
PACKING CASE
OVERSPEED
LABYRINTH SEAL TRIP ASSEMBLY
(BYRHH ONLY) SPACERS
SLINGER COUPLING
SPACERS (T GOVERNOR DRIVE)
CARBON
SLINGER RING ASSEMBLY
CARBON RING SHAFT
ASSEMBLY SLEEVE SEAL
SHAFT SLEEVE T GOVERNOR
SEAL OIL OIL
RINGS RINGS
GOVERNOR
LINKAGE
ROTOR
SHAFT

SHAFT SLEEVE
SEAL

EXHAUST END
JOURNAL BEARING

ROTOR DISK
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100qc.caph01.7/7/2008

ASSEMBLY
STEAM CHEST

STEAM END
GOVERNOR VALVE
BEARING STEAM END
HOUSING JOURNAL BEARING
STEAM END
CASING
REVERSING STEAM
EXHAUST BLADE ASSEMBLY NOZZLE END SUPPORT
EXHAUST END END CASING RING
BEARING PEDESTAL

C © ELLIOTT
ELLIOTT CO., INC. (YR) CO., INC.,(YR)
TURBOMACHINERY
 Chapter 1
General Information

Nozzle Ring and Reversing Blade Assembly

The nozzle ring is bolted to the inside of the steam end turbine casing. The nozzles,
located in the nozzle ring, direct the steam against the first rotating row of buckets. The
reversing blade assembly is positioned between the two rotating rows of buckets and is
bolted to the nozzle ring. The reversing blades reverse the steam flow as it exits the
buckets on the first rotating row and directs the steam into the buckets on the second
rotating row.

Bearing Housings and Supports

The steam end bearing housing is bolted and doweled to the steam end casing. A
support, attached to the bottom of the steam end bearing housing, sustains the weight of
the steam end of the turbine and allows for thermal growth of the casing. The bearing
housing contains a journal bearing, rotor locating bearing, two oil rings (if required), the
overspeed trip assembly, governor drive arrangement and a shaft sleeve seal. The seal
prevents oil leakage from the bearing housing and restricts the entry of dust, dirt and
moisture.

The exhaust end of the turbine is supported by the exhaust end bearing pedestal, which is
attached to the turbine casing at the center line. The bearing pedestal houses a journal
bearing, two oil rings (if required) and two shaft sleeve seals.

Governor System
The turbines employ several types of governors to control turbine speed. The governor
positions the governor valve, by way of the governor linkage. The governor valve varies
the steam flow through the turbine, thereby matching the driven machine power and
speed.

Journal Bearings
Two journal bearings radially position and support the rotor. One is located in the steam
end bearing housing, the other in the exhaust end bearing pedestal. The bearings are
babbitt lined, horizontally split, precision machined steel sleeves. If tilt-pad journal
bearings are used, refer to YR Supplement 04-30-02, found in Chapter 8.

Rotor Locating Bearing

The rotor locating bearing is mounted on the rotor shaft and positioned in the steam end
bearing housing. The locating bearing positions the rotor axially within the turbine casing.
Some units utilize a double acting thrust bearing in place of the rotor locating bearing.

Overspeed Trip System

The emergency overspeed trip system operates independently from the governor system.
The trip system is designed to shut the turbine down at trip speed.

Rotor
Rotors used in YR Turbines are typically of the “built up” design whereby the disks are
keyed and shrunk on the rotor shaft. Two styles of disks are used on rotor assemblies:
two separate straight sided disks, each having a row of buckets (Detail A, Figure 4-5), or
one profile disk containing both rows of buckets (Detail B, Figure 4-5). A shaft sleeve seal,
rotor locating bearing (or thrust collar), overspeed trip mechanism and the governor drive
arrangement are mounted on the steam end of the rotor shaft. The drive coupling and two
shaft sleeve seals are mounted on the exhaust end. Shrink rings are mounted outboard
and between the disks on rotors equipped with straight disk assemblies. All rotor
assemblies are dynamically balanced to provide smooth operation.

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Chapter 1
General Information

Steam Chest
The steam chest is bolted to the steam end of the turbine casing. Steam flowing through
the steam inlet passes through a strainer in the steam chest, past the trip valve, then past
the governor valve and seat to the steam ring in the casing. In larger governor valves, part
of the flow passes through the outer seat and back through the hollow valve body
providing reduced valve forces.

FACTORY TESTS

The turbines are completely assembled and steam tested before shipment. During
testing, the speed governor, overspeed trip mechanism, trip valve and governor valve are
adjusted, and the overall mechanical operation is determined to be satisfactory.

SHIPMENT

The assembled turbine is mounted on a skid and covered with an open framework of light
crating. The purpose of the crating is to indicate the outside limits of the turbine, and to
provide a means of visually identifying the contents of the crate. The crating should not be
regarded as protection against damage resulting from rough handling. Internal surfaces
and exterior unpainted machined surfaces of the turbine are coated with a rust
preventative compound.

Turbines that are exported are boxed in containers having extra shoring and bracing. The
tops of the containers are waterproofed to provide additional protection against weather
damage.

UNPACKING

Remove the crating and check all items against the packing list. Ensure that parts are not
missing or damaged. Handle all parts carefully. If inspection shows that the turbine has
been damaged during shipment, contact the carrier and file a damage claim immediately.
If any parts are missing from the shipment, contact the nearest Elliott Company Office.

HANDLING

-WARNING-
DO NOT ATTEMPT TO LIFT THE TURBINE BY THE
EYEBOLT LOCATED ON THE TURBINE CASING
COVER. THIS EYEBOLT IS FOR LIFTING ONLY THE
CASING COVER. USING THIS EYEBOLT TO LIFT THE
ENTIRE WEIGHT OF THE TURBINE PRESENTS A
SERIOUS SAFETY HAZARD.

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 Chapter 1
General Information

The turbine can be lifted safely by the use of slings under both ends of the turbine casing
as shown in Figure 1-3. When lifting the turbine, machined surfaces must be adequately
protected and the turbine kept level. In general, the lifting and handling of the turbine, and
any associated equipment, must be planned around the facilities available at the
installation site. The exact equipment handling procedures should be the responsibility of
those charged with the handling task. The estimated weight of the turbine is provided on
the outline drawing that is located in Chapter 10, Technical Drawings.

© ELLIOTT CO., INC. (YR)

FIGURE 1-3
LIFTING THE TURBINE

STORAGE

Rust preventative compound is applied to the turbine before shipment. This provides
protection for up to 3 months outdoor storage or six months indoor storage. The turbine
should be stored indoors whenever possible. The storage area should provide a clean,
dry environment, free from temperature extremes. The turbine should be maintained in an
approximate level position while in storage. The expected protection of the rust
preventative does not take into consideration extreme conditions resulting from outdoor
storage. Storing the turbine outdoors often subjects it to frequent temperature changes,
excessive amounts of moisture and, in some instances, salt laden air. All of these
conditions reduce the effectiveness of the rust preventative and should be avoided.

When a turbine is taken out of service for an extended period, it should be prepared for
storage. The following steps will safeguard against rust and corrosion:

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Chapter 1
General Information

Refer to “Turbine Disassembly and Assembly” procedures, Chapter 4.

1. Isolate the turbine from the steam supply and exhaust source. Tag all isolating
valves.

2. Remove the bearing caps and coat the rotor shaft journals, bearing liners (bearings, if
tilt-pad journal bearings are utilized) and rotor locating bearing (or double acting thrust
bearing) with a suitable rust preventative.

3. Replace the bearing caps. Leave the bolts finger tight, and tag the bearing caps to
indicate that the bolts are loose.

4. Remove the top half packing cases and carbon ring assemblies. Coat the packing
case internals and carbon ring sealing areas on the rotor shaft with rust preventative
compound.

5. Remove the top half turbine casing and coat the rotor assembly and casing internals
with rust preventative.

6. Replace the top half casing carbon ring assemblies and top half packing cases. Tag
the casing cover and packing cases to warn that joints must be made up before
placing the turbine in operation.

7. Coat the external rotor shaft areas with rust preventative.

8. If the turbine is equipped with a Woodward Hydraulic Governor, fill the governor with
turbine oil.

9. Coat governor linkage and pins with rust preventative.

10. Inspect the turbine periodically and reapply rust preventative as necessary.

Prior to returning the turbine to service (refer to “Disassembly and Assembly” procedures,
Chapter 4):

1. Clean all rust preventative compound from the turbine with a suitable solvent and lint
free rags.

2. Inspect the turbine for possible damage incurred during handling and storage.

3. Carefully clean lightly corroded surfaces with fine emery cloth. Replace any heavily
corroded parts.

4. Make up all flange joints.

5. Refer to “Initial Start-Up”, Chapter 3.

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General Information

RECOMMENDED SPARE PARTS

Part lists are included with many of the illustrations throughout this manual. The Spare
Parts List, located in Chapter 9, designates recommended spare parts that should be kept
in stock. Stocking these parts will enable turbine maintenance and/or emergency repairs
that could otherwise cause lengthy shutdowns. Ordering, storing, and returning spare
parts is discussed in Chapter 9 also.

FIELD SERVICES

Field service representatives are available to oversee the installation and start-up, or any
phase of maintenance, on Elliott equipment. Also, field service engineers are available to
conduct performance analysis and other related equipment evaluations. For the location
of the nearest Elliott Company office, refer to the “Sales and Service Locations” located in
Chapter 9.

FACTORY REPAIR

Facilities are available for major repair and rebuilding of Elliott turbines at our factory or
our authorized repair shops around the world. Contact the nearest Elliott Company office
for details.

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 CHAPTER TWO
INSTALLATION

INTRODUCTION

Proper installation of the machinery will contribute to long trouble-free operating life with
minimum maintenance. To aid in making a proper installation, this chapter describes a
detailed procedure that has proven successful for installing numerous turbines and
associated equipment. The following chapter contains the installation methods
recommended by Elliott Company. Other procedures do exist that can provide a
satisfactory installation; however, prior to using any of these alternate procedures, it is
recommended that the purchaser carefully investigate both the procedure and the ability of
workers to produce a permanent and satisfactory installation.

Elliott Service Representatives are experienced in installation procedures and can assist
in providing a good installation. The installation procedures contained in this chapter are
as specific as possible but cannot possibly cover all variations in field conditions.
Therefore, the Elliott Service Representative may sometimes deviate slightly from the
published procedures. This is done to give a better installation by using procedures to fit
specific field and service conditions. Regardless of the procedure used, first class
materials and quality workmanship should be employed.

The procedure recommended by Elliott involves the following items:

1. Foundation

2. Chock Blocks

3. Grouting

4. Setting the equipment on foundation

5. Shaft alignment

6. Coupling Installation

7. Piping Recommendations

Included in this chapter is a detailed procedure for making “cold alignment” as well as
methods for making machine “hot alignment” checks.

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While many aspects of an installation are the responsibility of the purchaser or his
engineer, some suggestions are offered that may contribute to suitable installation. One
such example is whether to install the machine outdoors under only a roof, or in a
completely enclosed building. While this class of equipment can generally be installed
outdoors, local conditions may suggest alternate arrangements. Freezing or low ambient
temperatures around machinery can create difficulties during start-ups and shutdowns; for
example, lubricating oil must be warm before starting equipment. Water and steam
equipment must be drained completely or heated during shutdown.

Alternately, in tropical areas, direct sun on one side of the foundation might cause
expansions that, when coupled with other factors in the system, could create unacceptable
alignment.

In addition to operating considerations, maintenance and equipment inspections will be

required - sometimes scheduled and occasionally unscheduled. Regardless of which,
weather conditions may not always cooperate. Rain, snow, wind and low or high
temperatures generally extend maintenance and inspection when workers are exposed
directly to these elements. In addition, quality of workmanship may be lowered to a point
where work accomplished is futile.

For inspection and maintenance, a permanent overhead crane or hoist is recommended.

Casing top halves and rotors have close clearances that must be protected; therefore,
moves must be slow and positive. This is seldom achievable with crawler or wheel-
mounted cranes.

Installation of the machinery may be on either steel soleplates or a self-supporting

fabricated steel baseplate. The functional purpose of these intermediate supports is to
provide a permanent mounting plate for the machine feet that can be shimmed. When the
foundation support is not continuous or is mounted directly on columns, a self-supporting
fabricated steel baseplate must be designed that will minimize deflections between contact
supports.

Soleplates usually provide support for only one machine or smaller equipment strings. In
most cases, a baseplate is made to support larger equipment strings. Some baseplates
are also designed to contain or support lubrication and seal system piping and
instrumentation in addition to the machinery. Baseplates with the lubrication system built
in may require less space and have lower installation cost, but are generally more difficult
to maintain.

Installations of a self-supporting baseplate on a reinforced concrete foundation should

follow the guidelines presented with only the sections indicated on the outline drawing left
unsupported. When the installation of a self-supporting baseplate is on structural steel or
columns, care must be exercised to ensure that the mounting surfaces are machined level
(from end-to-end and side-to-side there should be less than 0°, 6' slope) and flat (each
pad must be flat within .003" [.076mm]). Full contact between the mounting surfaces is
required without the use of step shimming. With this installation arrangement, grouting is
not used to fill in gaps, but other procedures presented in this chapter should be followed.
See Figure 2-1.

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 Chapter 2
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EQUIPMENT BASEPLATE

FOUNDATION BOLT

BASEPLATE PAD

SHIMS

STRUCTURE PAD

PLANT SUPPORTING STRUCTURE

FIGURE 2-1
TYPICAL BASEPLATE MOUNTING ARRANGEMENT ON STRUCTURAL STEEL

FOUNDATION

The principle function of the foundation is to provide a permanently rigid, non-warping

support for the machinery. In meeting these requirements, the foundation should:
• Hold machines in proper alignment under all operating conditions.
• Support the machine’s weight and load, and distribute it uniformly and evenly to the
soil or main support structure.
• Maintain established equipment locations.
• Minimize transmission of vibration to or from the machines.

While the responsibility for a successful foundation rests with the purchaser, the following
suggestions are offered for assistance and consideration:

1. The outline drawing provides equipment mounting surface areas, anchor bolt
locations, main piping connections, and other information necessary in designing a
foundation.

2. A foundation of reinforced concrete should be of ample size and proportion for

adequate support of the machinery, as well as piping forces such as inlet and
discharge piping.

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3. Provision should be made in the foundation design for accessibility to all parts of the
machine or its auxiliaries during operation, inspection and maintenance.

4. The foundation should rest entirely on natural rock or entirely on solid earth. A
foundation resting partly on one or partly on another may warp due to settling of part
of the foundation support. Distortion may also occur due to unequal pressures
created by differences in ground water level.

5. Foundations supported on pilings should have a rigid continuous cap over the pilings
on which the foundation rests.

6. Temperature surrounding the foundation should be uniform. Temperature differences

between the top slab and mat, for instance, can create substantial bending stresses
in columns. Care must be taken to reduce thermal distortion from radiation or uneven
heating and cooling. Direct sunlight on outdoor tropical installations is to be avoided.
Steam lines passing close to the foundation should also be avoided; but when
unavoidable, the lines should be insulated and the foundation shielded.

7. Foundation should be isolated from all other structures and arranged so that outside
vibrations are not transmitted to it. Where foundations must be supported by floor
beams, a vibration dampening material should be interposed between the beams and
the foundation.

8. Design of foundation structure should avoid resonant frequencies of operating speed,

40% to 50% of operating speed, rotor critical speeds, and two times operating
speeds.

9. It is recommended that concrete foundations be allowed to cure for approximately 28

days before loading. This will allow for development of strength and reduction in
shrinkage rate. Curing procedure should be in accordance with American Concrete
Institute recommendations.

10. Recommended size of foundation anchor bolts and projection above foundation is
shown on the outline drawing. Suggested installation of the anchor bolt is as shown
in Figure 2-2. Use of a pipe sleeve around anchor bolt allows for some shifting of the
anchor bolt if found necessary during installation of equipment. It allows for
increased stretch length of anchor bolts.

11. When establishing the top elevation for the foundation, allow approximately 0.5 inch
(12 mm) for removal of top crust of concrete by chipping. Reinforcing rods, ties, or
steel members should be sufficiently below the surface to permit chipping away of
approximately 1.00 inch (25 mm) of concrete without making contact. A minimum
space of 1.00 inch (25 mm) should be provided between foundation and chock block
to provide adequate room for insertion of grout. The maximum distance between the
foundation and soleplate or baseplate should not exceed 4.00 inches (100 mm).

Figure 2-3 is a cross-sectional view showing the location of a soleplate with chock blocks,
chock block grout and final grout. Figure 2-4 is similar but shows the location of a
baseplate with chock blocks, chock block grout and final grout.

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BASEPLATE BOXBEAM CHIPPED HALF OF

ROUGH FOUNDATION

0.50 IN. (12 mm) + 1.5 D FINAL GROUT

4.00 IN. (100 mm) MAX. (DO NOT POUR UNTIL FINAL
BETWEEN BOTTOM OF ALIGNMENT ADJUSTMENTS
BASEPLATE AND FOUNDATION HAVE BEEN MADE)

1.00 IN. (25 mm) MIN.

BETWEEN CHOCK BLOCK AND
9 x D MIN.
TOP OF ROUGH FOUNDATION
2 x D MIN.
D
CHOCK BLOCK 2 x D RADIUS

PIPE SLEEVE
5 x D MIN.
CONCRETE
FOUNDATION

7 x D MIN. REINFORCING ROD

(PLACE SUFFICIENTLY
BELOW FOUNDATION SURFACE
ANCHOR BOLT TO PERMIT NECESSARY CHIPPING)

FIGURE 2-2
SUGGESTED ANCHOR BOLT ARRANGEMENT

FOUNDATION BOLT
EQUIPMENT SOLEPLATE
PIPE SLEEVE

SHIMS

CHOCK BLOCK HOLD DOWN

SCREW
ROUGH
FOUNDATION
SURFACE

CHOCK BLOCK GROUT

LEVELING SCREWS

FIGURE 2-3
TYPICAL SOLEPLATE MOUNTING ARRANGEMENT

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Foundation Preparation
When the foundation is constructed of reinforced concrete, it is not practical to pour the
concrete block with the necessary precision to permit setting the machinery directly onto
the block. Therefore, the soleplate or baseplate is set with a void between it and the
foundation. After the soleplate or baseplate is positioned, machinery placed and cold
alignment check made, the soleplate or baseplate is cemented or grouted to the
foundation. This procedure essentially creates one continuous support for the machinery.

FOUNDATION BOLT

BASEPLATE PAD

PIPE SLEEVE
SHIMS

HOLD DOWN
CHOCK BLOCK SCREW

ROUGH
FOUNDATION
SURFACE

CHOCK BLOCK GROUT

LEVELING SCREWS

FIGURE 2-4
TYPICAL BASEPLATE MOUNTING ARRANGEMENT

In order to obtain good bonding surfaces for the grout, all defective concrete, laitance, dirt,
oil, wax, grease and loose material must be removed from the mating surfaces. This can
best be accomplished by chipping, bush hammering or by other means until sound, clean
surfaces are obtained. Removal of approximately 0.5 inch (12 mm) of the top concrete
surface should provide a strong, laitance-free surface for bonding and anchoring of the
grout.

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CHOCK BLOCKS

In this manual, the term “chock block” is used to describe steel or grout blocks that serve
to level and support the soleplate or baseplate prior to full grouting. The size of a steel
chock block may vary, but the two sizes shown in Figure 2-5 will generally satisfy most all
conditions. When steel chock blocks are furnished by Elliott Company, the blocks will
conform to the information provided in Figure 2-5 or, when desired, this figure can be used
to make chock blocks. To provide for ease of installation and leveling, four jack screws
are furnished in the chock block. A screw anchor in the center of the block is used to
anchor the chock block securely until grouting in of the blocks.

Chock Block

1. Material carbon steel plate

2. Machine both top and bottom flat

3. Break all corners and chamfer all holes

1.0 in.
25 mm 0.5 in.
13 mm

4.00 in.
8.00 in. OR 12.00 in. 101 mm
203 mm OR 305 mm

0.75 in.
19 mm

4 - SET SCREWS
1/2" - 13 x 1-1/2" LONG
OVAL POINT OR EQUIVALENT

MACHINE SCREW
1/4" - 20 x 3" LONG
FLAT HEAD OR EQUIVALENT
SCREW ANCHOR SHIELD TO
MATCH MACHINE SCREW

FIGURE 2-5
TYPICAL CHOCK BLOCK

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Chapter 2
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Epoxy grout chock blocks can also be used in place of steel chock blocks. When using
epoxy grout chock blocks, position small forms at each anchor bolt just as suggested for
steel chock blocks. The top surface of each form should be level and at essentially the
same elevation as all other chock block forms. Forms should be anchored, coated with
wax and sealed around the bottom. When pouring grout, forms should be completely
filled. This will minimize the need for shimming between the chock and baseplate or
soleplate.

Use of chock blocks allows the installation workmen to easily make a change in elevation
at a soleplate or baseplate support pad. The chock blocks also distribute the machinery
weight and hold down nut force so that deflections of the soleplate or baseplate due to
these forces are minimized. With chock blocks, the soleplate or baseplate can be easily
shifted horizontally without disturbing established elevations.

For maximum effectiveness, two chock blocks should be positioned at each foundation
anchor bolt as shown in Figure 2-6. Machines mounted on baseplates generally have the
foundation anchor bolts spread out and close to only one edge; therefore, placement of
chock blocks can usually be accomplished as shown in Figure 2-6.

For machines mounted on soleplates, the number of foundation anchor bolts increases
while available surface area decreases, therefore making effective placement of chock
blocks more difficult.

ANCHOR BOLT
CHOCK BLOCK

BASEPLATE OR
APPROXIMATELY 4.00" (100 mm) SOLEPLATE

FIGURE 2-6
PREFERRED LOCATION OF CHOCK BLOCKS

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Figure 2-7 shows a preferred arrangement when space is available, while Figure 2-8
illustrates an alternate arrangement that may be used. The arrangement used should
provide maximum support and minimize deflection or warping to the soleplate or baseplate
during installation work.

36.00 in. (900 mm)

12.00 in
(300 mm)

CHOCK BLOCKS

FIGURE 2-7
PREFERRED LOCATION OF CHOCK BLOCKS

20.00 in (500 mm)

9.00 in
(320 mm)

TWO CHOCK BLOCKS

FIGURE 2-8
ALTERNATE LOCATION OF CHOCK BLOCKS

Figure 2-9 illustrates a typical arrangement with chock blocks positioned on either side of
the foundation anchor bolt. As described earlier, the foundation surface must be prepared
by chipping or other means prior to setting the chock blocks. The chock block surfaces,
where a bond with the grout is desired, must also be cleaned prior to setting. Surfaces
must be free of oil, dirt and oxidation.

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If the chock blocks have been coated with a catalyzed epoxy primer, the surface coating
should not be removed, but surfaces should be cleaned with solvent to remove any oil or
dirt prior to setting.

Foundation anchor bolt Obtain this dimension

Temporary plug from the certified
Seal outline drawing
Chock block

Leveling screws

Chock block Chipped foundation

grout surface

Form Seal
1.00 in (25mm) min.

Screw anchor

Hold down screw

Reinforcement rods

FIGURE 2-9
TYPICAL CHOCK BLOCK ARRANGEMENT

The chock block surfaces should be sandblasted if coated with rust or some other surface
coating. Sandblasting is best, but a disk grinder or other mechanical method can be used.
If chock blocks will be immediately grouted after setting, no further surface treatment is
required. A clean, sandblasted surface will provide a good bonding surface.

If grouting in one of the chock blocks will be delayed after cleaning, the cleaned surfaces
should be coated with an epoxy primer or surface coating recommended by the grout
supplier.

To set a chock block, determine the chock block anchor screw locations on the foundation
and drill 0.5-inch (12 mm) diameter by 1.00-inch (25 mm) deep holes (if screw anchor
shield is other than that shown, appropriate drilling should be used) in the concrete.
Position the chock block and engage the screw anchor as shown in Figure 2-9. Level the
individual blocks using the four set screws provided. All blocks must be level and
approximately at the same elevation. It is desirable to maintain all chock block elevations
within a few thousandths of an inch or a few hundredths of a millimeter. This makes final
installation and shimming of the equipment much easier. On installations where overall
length of the equipment is short, elevation of the chock blocks can best be set by use of a
straight edge and precision level. On installations where the overall length of the
equipment is large, use of a precision tilting level may be advantageous.

Regardless of the method used, shimming should be used between the chock blocks and
soleplate or baseplate to correct any elevation variations required.

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NOTE
Before making a check of chock block level and elevation,
be sure anchor screw is tight and all four leveling screws
are making contact with the foundation.

GROUTING

The procedure to be followed for grouting in of chock blocks, soleplates or baseplates is

the same except for quantity of grout placed. Elliott recommends that the grout used be a
good quality epoxy grout system from a reliable manufacturer of heavy machinery grouts.
Epoxy grouts consist of an epoxy resin, hardener and graded silica aggregate. The resin
and hardener serve as the adhesive while the aggregate serves as a filler to reduce cost,
improve thermal expansion compatibility, and absorb heat released by curing. With proper
application, an epoxy grout should provide a permanent, reliable installation. Use of sand-
cement grout or sand-cement grout with various additives may also provide an adequate
installation; however both are generally lower in strength, have more tendencies to shrink
unevenly, and are generally more susceptible to chemical attack and deterioration by oils.

The prime purpose of grouting is to:

• Fill all voids between the foundation and the soleplate or baseplate.
• Provide a permanent bond between the foundation and the soleplate or baseplate.
• To assist the foundation anchor bolts in preventing lateral movement.
• Provide a solid, level base to which the machine can be anchored by the
foundation anchor bolts to prevent vertical movement.
• Make the soleplate or baseplate more or less an integral part of the concrete
foundation.

As anchor bolts are designed for hold down purposes, it is desirable to provide for some
stretching of the anchor bolt between the bottom of the sleeve and the bottom of the nut.
Therefore, it is recommended that the sleeve be filled with a pliable material such as
silicone rubber, prior to final grouting.

Use of epoxy grouts requires some installation procedures that differ from those used for
sand-cement grouts. The procedure that follows provides a general guide for use with
epoxy grout; but for more specific details, consult the grout supplier’s bulletins or labels.
This is particularly important in regard to safety precautions.

-WARNING-
MOST EPOXY GROUT IS FLAMMABLE, TOXIC,
POISONOUS, AND CORROSIVE. THEREFORE,
MATERIAL SHOULD BE KEPT AWAY FROM OPEN
FLAME, HIGH HEAT SOURCES OR SPARKS. IT
SHOULD BE MIXED IN A WELL-VENTILATED AREA.
WORKMEN SHOULD WEAR EYE PROTECTION AT ALL
TIMES DURING MIXING OF GROUT AND HARDENER,
AND ALSO WHEN APPLYING MIXED GROUT.
GLOVES AND PROTECTIVE CLOTHING SHOULD BE
WORN AT ALL TIMES.

When grouting in baseplates, thermal expansion rates between sand-cement grout and
steel or an aggregate filled epoxy grout and steel generally can become significant.

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Therefore expansion joints should be installed when stretches greater than approximately
three feet are encountered. After the foundation has been dressed, the surface of the
expansion joint should be sealed with silicone rubber.

Timing and proper mixing are the secrets to successful grouting. Before mixing the
components together, everything else should be ready - surfaces cleaned and dry, forms
completed and sealed, pushing tools, rags, cleaning solvents available and adequate
manpower.

Because of epoxy grout’s higher compressive and tensile strengths and its readiness to
bond to metals, the top of the grout should be brought up along the side of the soleplate or
baseplate to give some protection against lateral movement.

Grout forms should be built of materials of adequate strength and should be securely
anchored and shored to withstand the pressure of the grout under working conditions.

For epoxy grout, the forms must be waxed to keep them from becoming bonded to the
grout. For chock block grouting, the anchor bolt sleeve should be sealed and the form
height sufficient to provide a grout height approximately half way up the chock block.
Because the epoxy grout will flow through even the smallest holes, the forms must be fit
together as tightly as possible. Putty can be used as caulking for small cracks or holes.
To permit easy cleanup, wax or cover all surfaces where grout may splash.

For outdoor installation, the foundation should be protected from rain since it is important
that the foundation be clean and dry at the time of grouting. Normal grouting temperature
should be between 40° and 90°F (4° and 32°C). Due to the accelerated rate of curing at
high temperatures, shade the foundation from summer sunlight for at least 24 hours
before and 48 hours after grouting. In the hot summer weather, place the grout during the
afternoon so the initial cure will occur during the cooler evening hours. In cold weather,
the grout materials should be stored in a warm place. Low temperatures make the grout
stiff and hard to handle. For best results, ingredients should have an actual temperature
of 70°F (21°C) or higher. (Refer to instructions for the particular grout mix being used for
allowable working time at various ambient temperatures.)

Flow grade epoxy grouts can generally be handled with the same methods and tools that
are used with flow grade sand-cement grouts. Mixing can be done in small mortar mixers.
Use of a purchased grout with all the ingredients accurately measured into convenient
batches reduces the chance of error. The actual placing of the material can be
accomplished by several means. Some contractors prefer to force the materials into place
while others, through years of experience, prefer to place the materials by other methods.
The material is very viscous; however, it will flow and seek its own level given time and an
ambient temperature within a given range. Generally, it is best to start at one end of the
baseplate and work toward the other end, forcing the air out to eliminate voids as the
material moves along. Plywood strips, sheet metal strips, wires and rods can be used to
flow the grout completely under the soleplate or baseplate.
NOTE
Check the forms frequently for leaks. Leaks do not self-
seal. If not stopped, leaks will cause voids.

Forms should be left in place until the grout is hard enough throughout that it cannot flow.
This usually occurs overnight but can be longer in cold weather.

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SETTING THE EQUIPMENT ON FOUNDATION

Once the chock block grout has cured sufficiently to withstand static load, installation of
the equipment on the foundation may proceed.

If the soleplates or baseplates have been coated with a catalyzed primer, the surface
coating should not be removed. Remove oil and dirt with solvent. If the surfaces that will
come in contact with the grout are coated with some other material or rust, the surfaces
should be sandblasted. While sandblasting is best, a disk grinder or some other
mechanical method may be used. The cleaned surface should be coated with epoxy
primer or surface coating recommended by the grout supplier.

Prior to placing the soleplate or baseplate on the chock blocks, clean chock block contact
surfaces and install approximately 0.125 inch (3.0 mm) thick shim pack having an
assortment of shim thicknesses on each chock block. Shim pack should be full size,
clean, smooth and rust free. This will provide a means of lowering any portion of the
machine or baseplate that requires adjustment during leveling.

Set the baseplate or soleplates on the shimmed chock blocks and tighten down all the
foundation bolts. Check for level and make necessary adjustments by adding or removing
shims. Normally, it is best to start at the middle and work toward the ends. All soleplate
or baseplate leveling should be done using the machined support foot surfaces.

Before mounting the equipment on the soleplates or baseplate, place a 0.125 inch (3.0
mm) thick stainless steel shim pack having an assortment of shim thicknesses on each
machine support. A stainless steel shim pack is generally preferred. Full size shims are
preferred when setting machinery or when making elevation changes during alignment.

NOTE
Shims and contact surfaces should be kept smooth, free of
burrs, and clean to prevent erroneous alignment readings.

Check that coupling hubs have been mounted on their respective shaft ends before setting
machinery on soleplate or baseplate. If not, refer to “Coupling Installation” procedure in
this chapter and the coupling manufacturer’s literature.

After machinery has been placed on soleplates or baseplate, install and tighten hold down
bolts. Check for a “soft foot” by loosening each hold down bolt in turn while measuring,
with a dial indicator, movement between machine foot and soleplate or baseplate. If
movement on loosening a nut exceeds approximately 0.002 inch (0.05 mm) at any foot,
shim changes to eliminate the “soft foot” should be made before proceeding.

With soleplates or baseplate set and leveled, machinery mounted and rough aligned,
remove all temporary shipping braces.

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NOTE
The journal bearings on the turbine have been fitted with
plastic inserts for protection during shipment. These
plastic inserts must be removed before the rotor is turned.
If the machine is to be reshipped, the plastic inserts must
be reinstalled for transit to final jobsite.

Then clean the bearings and bearing housings. All clearances should then be checked.
(Refer to clearance table and drawings.) Thoroughly oil all bearings and reassemble
bearing housings. (Refer to appropriate sections in Chapter 4.) The machinery is now
ready to be “cold aligned”. The “cold alignment” method to use is dependent on the
distance between the coupling hubs. For greatest accuracy, the method suggested
should be used whenever possible. Initial cold alignment should be obtained prior to
grouting in soleplates or baseplate. In order to provide maximum flexibility and minimum
confusion, the cold alignment should be completed with all piping disconnected from the
machinery. Axial coupling separation indicated on outline drawing must be maintained
during cold alignment.

COUPLING INSTALLATION

A flexible coupling is used between the turbine and the driven equipment. This type of
coupling can be manufactured for use with either straight or tapered shaft ends. Individual
preferences or certain operating conditions may dictate using different types of couplings.
Therefore, it is advisable to refer to the manufacturer’s instructions for specific details
pertaining to the coupling.

Installing a Straight Bore Coupling

1. Clean and de-burr the coupling hub and shaft end.

2. Place the coupling sleeve (if applicable) on the equipment shaft with the bolting
flange positioned toward the shaft end.

3. Check the key fit in the coupling hub and the shaft keyways. The key must have a
side clearance of .001 inch to .003 inch (0.03 mm to 0.07 mm) between the key and
coupling keyway. The fit between the key and shaft keyway must be .000 inch to
.002 inch (0.0 mm to 0.05 mm) interference. The key must be fitted to provide .005
inch to .013 inch (0.13 mm to 0.33 mm) top clearance in the coupling keyway.

4. After the key has been fitted to provide the proper clearances, insert it in the shaft
keyway.

5. Apply a light coat of suitable anti-galling lubricant on the mounting surface of the
shaft.

6. Heat the coupling hub in oil or in an oven to approximately 300°F (150°C). The
coupling should not be heated with an open flame or be allowed to exceed 600°F
(315°C).

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 Chapter 2
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-WARNING-
HEAT-RESISTANT GLOVES SHOULD BE WORN WHEN
HANDLING THE HEATED COUPLING.

BOLTING FLANGE
SLEEVE

KEYWAY LOCKNUT

THREADED
SHAFT END

HUB

TAPERED BORE
BOLTING FLANGE

HUB

KEYWAY

SLEEVE
STRAIGHT BORE

FIGURE 2-10
FLEXIBLE COUPLINGS/TAPERED AND STRAIGHT BORE

7. Place the coupling hub on the shaft and position it so that the hub face is flush with
the shaft end.

CAUTION
Do not drive the coupling on or off the shaft with a
hammer. The force of the hammer will result in
internal equipment damage.

Installing a Tapered Bore Coupling

1. Clean and de-burr the coupling hub and shaft end.

2. Apply a light coating of Prussian blue to the rotor shaft.

3. Place the coupling hub on the shaft.

4. Remove the coupling and check the contact with the shaft.

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Chapter 2
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CAUTION
Hand lapping the coupling hub on the rotor shaft may
form a ridge that will affect the coupling contact when
pulled up. Correct the contact by lightly stoning any
ridges, burrs or high spots.

5. Check the key fit in the coupling hub and the shaft keyways. The key must have a
side clearance of .001 inch to .003 inch (0.03 mm to 0.07 mm) between the key and
coupling keyway. The fit between the key and shaft keyway must be .000 inch to
.002 inch (0.0 mm to 0.05 mm) interference. The key must be fitted to provide .005
inch to .013 inch (0.13 mm to 0.33 mm) top clearance in the coupling keyway.

6. After the key has been fitted to provide the proper clearances and the coupling
contact is determined to be satisfactory, insert the key in the shaft keyway.

7. Place the coupling sleeve (if applicable) on the shaft. Position the bolting flange
toward the shaft end.

8. Fit the coupling hub on the shaft (at room temperature).

9. Take a reference dimension from the hub to a fixed part on the machine case or a
shaft shoulder. Make certain the shaft is seated against either of the thrust bearings.

10. Put a small amount of thread lubricant on the drive nut.

11. Tighten the shaft locknut to obtain an interference fit between the coupling and shaft.
See the Turbine Outline drawing in Chapter 10 for specifications on coupling pull up.

12. Recheck referenced dimension (step 9) and record for future use.

13. Lock drive nut.

CAUTION
Do not drive the coupling on or off the shaft with a
hammer. The force of the hammer will result in
internal equipment damage.

SHAFT ALIGNMENT

The turbine and the driven equipment are normally connected by flexible couplings.
Flexible couplings are used because changes in temperature and loadings during normal
operation, start-up or shutdown can cause one shaft end to move relative to its companion
shaft end. For high-speed, high-performance applications such as between compressors
and turbines, the coupling is usually the gear, disk or diaphragm type.

All flexible couplings have limits within operation without failure or undue wear. Even
when operating within the design limits, these couplings generate some resistance to
flexing. The force usually increases as the misalignment increases, thereby increasing or
decreasing bearing load fluctuations as the shaft rotates. Furthermore, operating with

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 Chapter 2
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collinear shafts at normal operating conditions minimizes tooth-sliding velocity or

diaphragm flexure while providing the maximum reserve for movement in any direction
should it be required.

Experience indicates that excessive vibration of compressors and their drivers is often
caused by improper shaft alignment. Frequently, high or unusual bearing and seal wear
can be traced to improper shaft alignment. In extreme cases, poor alignment can
precipitate a coupling, bearing or shaft failure. For smooth operation and long trouble-free
runs, good shaft alignment procedures are essential and cannot be over-emphasized.

An understanding of good shaft alignment techniques must begin with a few basic
definitions.

“Cold or ambient alignment” is the procedure that involves positioning the frames or
casings of compressors and other rotating machines while at standstill and ambient
conditions. The “cold shaft alignment” is normally accomplished using dial indicators,
feeler gauges, micrometers or a combination of these instruments. This positioning
should allow for thermal growth and material deflections that will occur between ambient
conditions and stabilized operating temperatures. The incremental movement used to
establish the cold shaft alignment may be actual measurements made during start-up or
shutdown, growths estimated by the machinery manufacturer, or estimates made by the
installer.

To calculate thermal expansion or contraction, multiply original length (generally distance

from machine shaft centerline to top of baseplate or soleplate) times expansion coefficient
(0.0000067 for steel) times temperature change in degrees Fahrenheit. (Expansion
coefficient is 0.000012 for steel and temperature change in degrees Celsius.)

Δ L (change in length) = L (length) x 0.0000067 x Δ T (change in temp. °F)

Δ L (change in length) = L (length) x 0.000012 x Δ T (change in temp. °C)

NOTE: Δ L and L in same units.

Normally, the vertical movement is minimized by use of a bolted joint where the support
foot attaches to the casing. Therefore, the average temperature of the support foot may
be considerably lower than the average of adjacent casing temperature to foot
temperature. A good “hot shaft alignment” will either verify or suggest alternate growth
figures to use.

“Hot shaft alignment” also known as operating shaft alignment or service alignment is a
procedure for monitoring the change in shaft alignment from cold or ambient conditions to
normal operating conditions. Knowing the “cold shaft alignment” and measuring the
change provides a method for determining if the shaft alignment becomes collinear at
normal operating conditions. This method is indirect, but if properly done, provides the
most reliable and acceptable method available.

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Chapter 2
Installation

A. COLLINEAR ALIGNMENT

B. ANGULAR MISALIGNMENT

C. PARALLEL MISALIGNMENT
© ELLIOTT CO., INC (YR)

FIGURE 2-11
TYPES OF SHAFT MISALIGNMENT

A. Collinear alignment - In Figure 2-11 part A; the two machine shaft ends are
considered to be “collinear aligned” when the two shaft ends rotate about the same
straight line (no misalignment). All machinery shafts have some deflection;
therefore, this reference is limited to the center of rotation of one shaft end relative
to the opposite shaft end. Each coupling must be analyzed individually.

B. Angular or Face misalignment - In Figure 2-11 part B; indicates the amount of

angular misalignment at a shaft end. Normally, angular displacement is measured
in mils of offset per inch (in mm of offset per meter) of coupling diameter or axial
separation.

C. Parallel misalignment - In Figure 2-11 part C; indicates the amount of parallel

misalignment between the centerlines of two adjacent shaft ends. Figure 2-11 part
C, shows two shafts with only parallel offset.

“Axial separation”. When the coupling connecting two shaft ends is a gear type, an axial
separation of plus or minus .0625 inch (1.60 mm) tolerance is usually acceptable. When
the coupling connecting the two shaft ends is a disk or diaphragm type, an axial
separation as shown in Figure 2-11 of less than plus or minus .015 inch (0.40 mm)
tolerance is usually required. Check coupling drawing and coupling instructions for
precise limits.

When aligning disk or diaphragm type couplings, adhere to the dimension information
shown on the coupling drawings. Measurements should be taken with the equipment in
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 Chapter 2
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normal thrust position (turbine rotor toward exhaust). Usually, the critical dimension is a
coupling flange face dimension as shown in Figure 2-13. For further information on axial
separation, refer to coupling vendor drawing and installation procedure.

AXIAL SEPARATION

cL cL

FIGURE 2-12
AXIAL SEPARATION

GUARDS

DIAPHRAGMS

CENTER TUBE

COUPLING FLANGE FACE TO

FLANGE FACE

FIGURE 2-13
AXIAL SEPARATION - DIAPHRAGM COUPLING

There are two similar procedures available for measuring parallel offset and angular
displacement. The most accurate measurements are obtained when one of the following
recommended methods is used.

The “Rim and Face Method” is the preferred procedure when the distance between the
two adjacent shaft ends is less than one-half the coupling diameter (this assumes face
readings are taken near outside diameter). This procedure is also known as the “Hub and
Face Method” or “Two Indicator Method”.

The “Reverse Indicator Method” is the preferred procedure when the distance between the
adjacent shaft ends is greater than one-half the coupling diameter.

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Shaft Alignment Map Instructions

Preparation and use of a “Shaft Alignment Map” for each installation is recommended. A
typical shaft alignment map is shown in Figure 2-14. Use of a shaft alignment map
provides a convenient form on which to record indicator readings and calculate equipment
moves. Maintaining this information for comparison during maintenance inspections or for
reference, should problems develop, can provide valuable diagnostic information. A blank
form for your use is provided in Figure 2-17.

In addition to providing machine identification information, date and shaft alignment

method used, the shaft alignment map provides a plan (top) and vertical (side) elevation of
the machine shafts, complete with all the important reference points identified. The
horizontal or abscissa coordinate should be scaled using some convenient scale such as
1.00 or 2.00 inches per division (25 or 50 millimeters per division). All support feet and
coupling faces should be located. When more than two machines are involved, a larger
map or graph may be advantageous. The vertical or ordinate coordinate should be an
expanded scale such as 1 mil (0.02 millimeters) per division in order to clearly identify
misalignment. Mark North compass direction in plan view and corresponding compass
directions in indicator reading circles so no confusion develops during measurements.

When making shaft alignment corrections, it is usually advantageous to hold one machine
in a fixed position and align other machine or machines to the fixed machine. Some
guidelines to determine the best machine to hold stationary are as follows:

1. If the equipment consists of turbine driven compressor, it is generally preferred to

level turbine and move compressor into desired cold alignment.

2. If a gear is present, level and square the gear to the foundation or baseplate and
move the other machinery into alignment with the gear.

3. If the equipment string consists of three or more pieces of equipment, level the
machine nearest the center, square it to the foundation or baseplate, and move the
other machinery into alignment with the selected machine.

The solid dark heavy lines on the shaft alignment map represent the desired hot shaft
alignment; i.e., collinear alignment. Plot historical or calculated thermal expansion or
contraction change for each support location on the shaft alignment map. Connect points
plotted for each machine with a dashed line.

Use dashed line for desired “cold alignment setting”. Read off differences between the
two dashed lines in vertical plane and record desired readings in circles so marked. Plan
or horizontal alignment usually remains unchanged from ambient (cold) of bottom reading.
If system has a gear, the gear case is usually doweled or keyed under the pinion and
allowed to expand toward bull gear shaft thus requiring alignment allowances in plan view
at bull gear or low speed shaft end.
NOTE
(For All Rim Measurements)
Actual measurement is ½ TIR (Total Indicator Reading);
therefore, value of measurement shown on indicator
reading circle should be twice the distance indicated on
plot.

Offset value is plus (+) if projected centerline of machine

that indicator is attached to is above coupling mark of the
machine that indicator is riding on.
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 SHAFT ALIGNMENT MAP
USER ABC Company SERVICE Propane Refrigeration EQUIP. NO. C508xxx / C5037xx DATE 10 / 95
COUPLING TYPE MP 153 LUBE Grease AMBIENT TEMP. 60 F NAME
NOTES: ALIGNMENT METHOD Reverse Indicator ALIGNMENT BAR SAG Negligible MILS/MM
1) Show North in Plan view of sketch.
2) Mark compass direction in circles.
LEFT 0 RIGHT LEFT 0 RIGHT
3) If offset value is plus, projected center
line of machine that the indicator was COMP TURB DESIRED COLD READING
attached to will be above the coupling -12.5
W TO E
-12.5 +10
W TO E
+10
-14 0 C/T ACT
.
mark of the opposite machine.
TURB COMP Vo = Bot - Top = -7
4) If offset value is minus, projected center 2
line of machine that the indicator was -25 +20 -4 -10
attached to will be below the coupling 0 0 Ho = Right - Left = +3
mark of the opposite machine. 2
COMP TURB
-10 -4 +7 +9
W TO E W TO E
ACTUAL COLD READING
TURB COMP
-14 +16

STEAM END FOOT EXHAUST FOOT DISCHARGE FOOT SUCTION FOOT

PLAN
DESIRED OPERATING LINE
MOVE 6 MIL WEST W
MOVE 22 MIL WEST N
SEPG5 E
38M4
STEAM TURBINE COUPLING
cL cL cL COMPRESSOR cL

DESIRED OPERATING LINE

VERTICAL
MOVE 3 MIL UP MOVE 17 MIL UP

48 " 14" 14" 18" 57"

Installation
Chapter 2
PICK A CONVENIENT SCALE SCALE 2 inches PER DIVISION SUGGEST 1" OR 2" PER DIVISION
724-527-2811
2-21

FIGURE 2-14
SHAFT ALIGNMENT MAP – EXAMPLE
Chapter 2
Installation

Sometimes the work descriptions, such as those used on an alignment map, can be
confusing. Figure 2-15 is a pictorial view of Note 3 on alignment map. It reads:

“If offset value is plus, projected centerline of machine that the indicator was attached to
will be above the coupling mark of the opposite machine.”

FIGURE 2-15
PICTORIAL OF NOTE 3 ON ALIGNMENT MAP

Figure 2-16 is a pictorial view of Note 4 on alignment map. It reads:

“If offset value is minus, projected centerline of machine that the indicator was attached
to will be below the coupling mark of the opposite machine.”

FIGURE 2-16
PICTORIAL OF NOTE 4 ON ALIGNMENT MAP

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 SHAFT ALIGNMENT MAP
USER SERVICE EQUIP. NO. DATE
COUPLING TYPE LUBE AMBIENT TEMP. NAME
NOTES: ALIGNMENT METHOD ALIGNMENT BAR SAG MILS/MM
1) Show North in Plan view of sketch.
2) Mark compass direction in circles.
LEFT RIGHT LEFT RIGHT
3) If offset value is plus, projected center Bot - Top
line of machine that the indicator was
Vo = =
attached to will be above the coupling 2
TO TO
mark of the opposite machine. Right - Left
Ho = =
4) If offset value is minus, projected center 2
line of machine that the indicator was
attached to will be below the coupling
mark of the opposite machine.

TO TO

PLAN DESIRED OPERATING LINE

LEFT

RIGHT
VERTICAL

Installation
Chapter 2
724-527-2811

PICK A CONVENIENT SCALE SCALE PERDIVISION SUGGEST 1" OR 2" PER DIVISION
FIGURE 2-17
2-23

BLANK ALIGNMENT MAP

Chapter 2
Installation

Rim and Face Method of Alignment

1. Use Rim and Face Method when distance between the two adjacent shaft ends is
less than one-half the coupling diameter.

2. Lubricate bearings before rotating shafts.

3. Mark both coupling hubs at four locations 90° apart so that their position is evident at
all times during alignment work.

4. All piping strain must be removed from machine. For initial alignment work during
installation, all piping should be left unconnected from machinery. After cold
alignment has been secured, arrange dial indicators between shaft ends, or between
foundation and machine case such that any movement of machine can be detected.
Connect one flange at a time and observe indicator readings continuously. Should
movement exceed 2 mils (0.05 mm), piping strain is considered excessive. Reason
for strain should be investigated and condition corrected before proceeding with
alignment.

5. Shift rotors to running position and determine that coupling spacer distance is as
specified on coupling drawing.

6. Mount dial indicator so indicator button rides near center of rotation. Rotate shaft
against which button rests to measure axial wobble. If unable to maintain axial
wobble to less than 0.001 inch (.025 mm) on either shaft, use of two face indicators
180° apart or multiple measurements is recommended.

NOTE
Axial shaft movement during face reading measurements
can cause false readings. Two dial indicators mounted
180° apart should be used when axial float cannot be
easily controlled. When using this setup, set dial indicators
at 0° and 180° position and zero indicators. Dial indicator
at 0° should be tagged prime dial indicator. At each
interval, subtract second dial indicator’s reading from prime
dial indicator reading. Divide this result by two and record
result in prime’s location. Be sure to retain proper plus or
minus signs.

7. Measure angular misalignment with inside micrometer, feeler gauges or dial indicator,
as shown in Figure 2-18. This is best accomplished by marking measurement point
at 0° and recording readings or change in readings between 0° point and points at
90°, 180°, 270° and 360°.

On return to 0° position, indicator should return to zero or repeat measurement. Take

several sets of readings to be sure no mistake has been made or something has
moved that shouldn’t have. When taking measurements, rotate both shafts equal
amounts to cancel out eccentricity and surface imperfections.

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 Chapter 2
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DIAL INDICATOR WITH HOLE

ATTACHMENT

0
INSIDE MEASUREMENT
MICROMETER POINT

270 90

FEELERS
GAUGE BLOCK OR BAR 180

FIGURE 2-18
MEASURING ANGULAR MISALIGNMENT

8. Readings observed in step 7, above, should be recorded on alignment map. As face

readings provide the slope of shaft on which dial indicator is mounted relative to
coupling face of the opposite machine (See Figure 2-19), use an indicator recording
circle for an axial location equal to the “face reading measurement diameter” away
from the hub on which the indicator button is riding.

ANGULAR DISPLACEMENT

ANGULAR DISPLACEMENT DISTANCE EQUAL TO

MEASUREMENT DIAMETER

FIGURE 2-19
ANGULAR DISPLACEMENT

9. To measure Parallel Offset, attach the dial indicator to bracket mounted on machine
that will be moved. Set the indicator button to contact periphery of opposite coupling
hub at top approximately 0.25 inch (6 mm) from edge (as shown in Figure 2-20). Set
the indicator to zero at top, rotate both shafts together, and record dial readings on
alignment map for 90°, 180°, 270°. On return to top position, the indicator should
return to zero. Repeat this procedure several times to be sure no mistake has been
made or something moved. These four readings will be TIR (Total Indicator
Readings), and actual parallel offset is one-half of indicator (TIR) readings.

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o

o o

DIAL INDICATOR

FEELER GAUGE
© ELLIOTT CO., INC (YR)

FIGURE 2-20
MEASURING PARALLEL OFFSET

10. Readings observed in Step 9 should be recorded on alignment map in indicator

recording circle corresponding to same axial location as dial indicator measuring
location (fixed machines coupling).

11. Vertical offset (Vo) and horizontal offset (Ho) for projected centerline of machine to be
moved at fixed machine’s coupling face can be determined by using alignment map
Note 3 or 4.

12. Slope of machine’s shaft to be moved relative to fixed machine is determined by (a)
drawing a line through the point determined in Step 11 and parallel to fixed machine’s
centerline, (b) applying alignment map Note 3 of 4 to face readings at the axial
location previously determined in Step 8, above.

13. In each view, draw a straight line through points located in Step 11 and 12 with line
extended to intersect both supports of machine to be moved. Read off distance
between line just completed and desired cold shaft position (dashed line) at each
support for component to be moved. This measurement represents movement
necessary to obtain correct cold alignment.

14. Make adjustments indicated in Step 13.

15. Repeat Steps 7 through 14 to verify adjustments made in Step 14 correct.

16. Unless otherwise noted, a final hot alignment should provide for an angular
displacement between machine coupling hub centerline and coupling spacer
centerline of approximately 0.25 mil per inch (0.25 mm per m) at the coupling gear
teeth or flex elements. This angular displacement is not a limit, but a suggested
alignment goal. (Refer to coupling literature for more information on maximum
allowable misalignment.)
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 Chapter 2
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Reverse Indicator Method of Shaft Alignment

1. Use the reverse indicator method of shaft alignment when distance between two
adjacent shaft ends is greater than one half the coupling diameter.

NOTE
For alignment purposes, the effective distance between
shaft ends can be increased by spanning the shaft end to
obtain a dial indicator location inboard of actual shaft ends.
Key factor is to spread two indicators as far apart as
practical with negligible bracket sag. (As spread
increases, so do possibilities for bracket sag.)

The reverse indicator method of shaft alignment eliminates the need for taking face
readings.

2. The reverse indicator method involves taking readings from one shaft to the rim
surface on the hub of the adjoining shaft and vice versa as shown in Figure 2-21.

READ HERE

SHAFT “A”

SHAFT “B”
FIRST SET OF READINGS

READ HERE

SHAFT “A”

SHAFT “B”
SECOND SET OF READINGS

© ELLIOTT CO., INC (YR)

FIGURE 2-21
REVERSE INDICATOR READINGS

3. Lubricate bearings before rotating shaft.

4. Mark both the coupling hubs at four locations 90° apart so that their position can
easily be seen at all times during the alignment work.

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5. All piping strain must be removed from machine. For initial alignment work during
installation, all piping should be left unconnected from machinery. After cold
alignment has been secured, arrange dial indicators between shaft ends or between
foundation and machine case such that any movement of machine can be detected.
Connect one flange at a time and observe indicator readings continuously. Should
movement exceed 2 mils (0.05 mm), piping strain is considered excessive. Reason
for strain should be investigated and condition corrected before proceeding with
alignment.

6. When spanning the coupling gap with an indicator rig or bracket, zero sag is
impractical to achieve; therefore, the actual amount of sag should be determined and
recorded on the alignment map. The bracket should be sturdily constructed to
minimize shifting and sag during use.

NOTE
For purposes of this explanation, the fixed machine is
called shaft “A”. The shaft of machine to be aligned to
shaft “A” will be called shaft “B”. Therefore, shaft “B”
belongs to machine that will be moved.

7. Attach the indicator bracket to shaft “A”.

8. Attach the dial indicator to the bracket so that the button will rest on the outer rim of
coupling hub “B”. The indicator button should contact in about 0.25 inch (6 mm) from
the hub face.

9. Position dial indicator at top dead center, in line with 0° marking on coupling “B” and
zero indicator.

10. Rotate both shafts together and record dial readings on alignment map at 90°, 180°
and 270° positions. On return to top position, the indicator should return to zero.
Repeat this step several times to be sure no mistake has been made or something
moved.

11. The accuracy of the readings may be verified by algebraically adding the side
readings and comparing this sum to bottom reading. The readings should be equal
to or within 1 mil (.25 mm).

12. Remove the bracket from shaft “A” and install on shaft “B”. Using the same
procedure, obtain indicator readings from shaft “B” to the rim of coupling hub “A”.

13. Using the two equations shown on the suggested shaft alignment map, calculate the
vertical offset (Vo) and the horizontal or plan view offset (Ho). Plot these results in
the proper view and in the axial location where indicator readings were taken. Note 3
or 4 on the alignment map can assist in determining the shaft location above or below
other shaft. When making this determination, it is sometimes helpful to locate
centerline of shaft end “B” first, that is shaft end of machine to be moved, and then
the projected centerline of shaft end “B” at shaft end “A”. In this explanation, shaft
end “A” is fixed, and therefore, shaft “B” must be located relative to shaft “A”.

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 Chapter 2
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NOTE
Correct the bottom reading for sag in the bracket by
algebraically adding to bottom indicator reading. No
correction is needed on the side readings since it is
negative on both sides and will cancel out.

14. In each view, draw a straight line through points located in Step 13, extending the line
to intersect both supports of machine “B”. Read off distance between line just
completed and desired cold shaft position (dashed line) at each support for machine
“B”. This measurement represents movement necessary to obtain correct cold
alignment.

15. Make adjustments indicated in Step 14.

16. Repeat Steps 7 through 14 to verify adjustments made in Step 15 were correct.

17. Unless otherwise noted, a final hot alignment should provide for an angular
displacement between machine coupling hub centerlines and coupling spacer
centerline of approximately 0.25 mil per inch (0.25 mm/m) at the coupling gear teeth
or flex elements. This angular displacement is not a limit, but a suggested alignment
goal. (Refer to coupling literature for more information on maximum allowable
misalignment.)

After cold alignment has been made, the soleplates or baseplates must then be grouted;
refer to previous section titled “Grouting”. After final grouting is completed, cold alignment
should be checked and adjusted, if necessary.

Hot Alignment Check

A hot alignment check should be made after the equipment string has operated with full
load for several hours and stable operating temperatures have been reached. This check
will indicate any final adjustments necessary to achieve collinear alignment of the turbine
and driven equipment under operating conditions.

The purpose of the hot alignment procedure is to measure the movement of one shaft end
relative to the opposite shaft end. As the shaft rotates, it is not practical to measure the
actual position of one shaft end relative to its companion with dial indicators or similar
instruments, as was the case during the cold alignment procedure. Therefore, most Hot
Alignment procedures make the assumption that the machine casing and bearing housing
expand uniformly in a radial direction from the shaft center of rotation and maintain this
relationship to the shaft center regardless of the casing temperature. This basic
assumption appears to be valid as compressors and turbines are nearly symmetrical about
the shaft; therefore, distortions are minimized. Using this principle, one of the following
methods should be used to make a hot alignment check.

The “mechanical hot alignment” method uses accurate measurements between fixed
reference points on the foundation or base and the machinery bearing housings to indicate
shaft movement between ambient and normal operating conditions. This method
assumes that the fixed reference points do not move between cold alignment conditions
and machinery operation. In general, this is a good assumption provided one side or area
of the foundation is not exposed to direct sun when the other is not. Unprotected hot
steam and process lines passing in close proximity to the foundation can also contribute to
uncertainty in incremental movements.

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This method eliminates the requirement for alignment brackets or bars by using
permanent reference points (called benchmarks) that are affixed directly to the foundation
and to the bearing housing as shown in Figure 2-22. All four reference points should lie in
a plane perpendicular to the centerline of the machine shaft. Similarly mounted reference
points should be established at each bearing housing in the train.

Suggested benchmarks for this technique are 0.5 inch (12.7 mm) diameter precision balls.
Because these benchmarks become an integral part of the installation and the accuracy of
alignment records over the long term are dependent upon these references, it is
recommended that the balls be made of stainless steel to prevent corrosion and mounted
solidly to avoid inadvertent movement. It is also recommended that the benchmarks be
protected with covers when not in use.

ROTOR SHAFT

BEARING HOUSING

A COLD B COLD

A' HOT B' HOT

BENCHMARKS

FOUNDATION

FIGURE 2-22
TYPICAL DISPLACEMENT OF BENCHMARKS ON FOUNDATION AND BEARING
HOUSING

NOTE
Acculign, Inc markets a tool kit designed specifically for the
purpose of conducting hot alignment checks by this
method.

Following cold alignment of the equipment string, reference dimensions A and B and
angles θ and ∅ are determined at each bearing housing and recorded. Lubrication
system should be operating and oil supply temperature near design to minimize effect of
bearing housing growth.

After the machine is brought to normal stabilized operating conditions, dimensions A' and
B' are measured at each position. With these two sets of data, the vertical and horizontal
movement of each bearing housing of the machines in the train can be determined relative
to the foundation.

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See Figure 2-23. Using common grid paper (5 x 5 grid is usually a convenient size), lay
out reference vectors A and B at angles θ and ∅, having these vectors cross at one of the
grid intersections. The intersection of these vectors represents the centerline of the
machine shaft in the cold position. Now refer to the cold and hot measurements
previously made (A, A', B, and B') and determine the movement of the bearing housing
along vectors A and B by taking the differences between cold and hot measurements ( Δ A
and Δ B) for each location. Lay out the movements along vectors A and B using any
convenient scale, say 0.25 inch equals 0.001 inch (2 mm equals 0.01 mm), to establish
points a and b.

VECTOR B H
VECTOR A
FINAL SHAFT
POSITION
90
a

b V
A
90
B
INITIAL SHAFT POSITION

FIGURE 2-23
GRAPHICAL DETERMINATION OF SHAFT IN HOT POSITION RELATIVE
TO COLD POSITION

Draw lines through a and b perpendicular to vectors A and B. These lines represent arcs
of radii A' and B' drawn from the foundation benchmarks. The intersection of these lines
defines the position of the machine shaft centerline in the hot position relative to the cold
position. To determine the movement in vertical and horizontal directions, it is necessary
only to scale off the dimensions referred to as Δ H and Δ V, using the same scale as used
in plotting Δ A and Δ B.

A similar plot for the data secured at each bearing housing can be compared to the
alignment map information for validity of the original estimates. Where differences exist,
corrections should be made to the original estimates used on alignment map and the
machinery realigned.

With the permanent benchmark installed and the desired cold alignment reference
dimensions recorded, this information can also be used for resetting machines quickly or
for maintenance checks.

Another hot alignment check is the “reverse hot alignment” method that uses the same
basic principles as the reverse indicator method of shaft alignment. Rather than mounting
brackets off the coupling, the brackets are mounted permanently off the bearing housing
or casing.

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Regardless of the measurement method used, several things should be kept in mind when
making a setup:

1. The probes and indicating blocks should be positioned to measure both the horizontal
and vertical movement at the coupling of each machine. Generally, vertical
movement is the most important; therefore, placement of brackets or bars should
favor making the most accurate readings in this direction (mount along horizontal
centerline).

2. The brackets or bars can either be located inside or outside the coupling guard.

3. Brackets or bars should be constructed and protected to minimize deflections due to

thermal gradients and local forces such as windage or high velocity lube oil (for
brackets mounted in side coupling guard).

4. Regardless of where brackets or bars are mounted, it must be on a thermally stable

part of the machine.

5. Regardless of where brackets or bars are mounted, it is recommended that a guard

be provided to protect them.

Normally, some variations can be expected in the hot alignment data observed for various
operating conditions. The central point about which most of the observations gather will
normally indicate the desired operating alignment.

Recording of the change in alignment data between ambient conditions and the central
operating condition (desired operating alignment) on the alignment map will provide
confirmation of the original data or suggest modifications to original data. The conclusion
drawn from this analysis should be recorded for future use during maintenance
turnarounds.

Once the alignment bars have been properly installed and referenced to the cold
alignment readings, the bars can also be used for aligning the machines.

In addition to these methods, there are also other methods available for making a hot
alignment check, such as optical alignment, non-contact proximity probes mounted on
water-cooled pedestals, etc. A hot alignment check with optical equipment measures the
movement of reference points (generally tooling balls mounted on the bearing housing) by
use of optics. When using this method for making a hot alignment check, great care
should be exercised as the line of sight between the measuring instrument and the
reference point can be bent by temperature gradients or air currents. Instrument stands
and their supports are also subject to vibration and distortions that can influence accuracy
of data obtained. In general, it is recommended that measurements be double-checked
by making measurements from both sides of machines and comparing results. Any lack of
correlation should be resolved.

Use of non-contact proximity probes mounted on water-cooled pedestals with the probes
looking at the shaft, couplings, bearing housing or casing can also be used. When using
one of these methods, great care should be exercised to design pedestals and mounting
such that temperature distortions are minimized.

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Realign as Necessary
Regardless of the method used for making hot alignment check, it must be evaluated for
accuracy of information measured. Temperature variations and air currents can cause
significant changes in support temperatures between cold alignment conditions and
operating conditions. Expansions, contractions and heat flow are therefore seldom linear.
This can and does contribute to introducing errors if care is not exercised in analyzing
results.

NOTE
Before making alignment changes based on hot alignment
data, evaluate the setup to be sure data is valid and
logical.

When the hot alignment check confirms that the machines have been properly aligned, the
machines should be doweled as indicated on the outline drawing.

TURBINE PIPING RECOMMENDATIONS

No part of the turbine installation is more important for successful operation than well-
designed and properly installed piping. There are two definite objectives for good piping:

1. To prevent the heated piping from imposing strains on the turbine casing and, thus,
affecting the alignment.

2. To connect and drain the turbine inlet and exhaust piping so that dry steam is
furnished to the turbine and that water accumulation in these lines is prevented.

A main steam isolation valve is recommended in the steam piping, preferably at a

convenient accessible location in the turbine room, between the steam header and the
turbine inlet, to allow working on the turbine without shutting down the boiler.

The turbine casing must be protected from piping weight and piping expansion strains.
The weight of piping should be carried by suitable supports. Expansion joints with limit
rods or piping bends should be used adjacent to the turbine flanges. Connections
between the piping flanges and turbine flanges are made without forcing the pipeline in
any direction in order to make a satisfactory joint. Connections may be considered
satisfactory if the connecting pipe lines, when heated to operating temperature, do not
shift out of line with the turbine flanges when the bolting is withdrawn. (Refer to NEMA
standards for maximum forces and moments allowable.) Before piping is connected to
turbine, mount at least two indicators from one coupling hub to the other coupling hub –
one to measure any vertical movement, the other to measure any horizontal movement.
Then connect piping to turbine. If movement shown on any indicator exceeds 0.002" (0.05
mm) loosen piping and refabricate, realign or adjust anchors as required.

All steam piping between the turbine and boiler or steam header must be adequately
“blown down” to remove welding beads, scale, dirt, etc. During blow down, the piping
should be disconnected and directed away from the turbine. Blow down should be at
maximum design turbine throttle flow to obtain design steam temperature and velocity.
The piping should be blown down several times until a polished metal plate held in the
stream indicates the absence of foreign material.

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If supplied, the trip and throttle valve always contain a permanent screen to guard against
the ingestion of large loose particles. In addition, many valves will also have a temporary
screen installed around the permanent one. The temporary screen should be removed
after approximately one month of operation and should never be left in longer than six
months.

NOTE
Strainers do not take the place of a properly setup and
conducted blow down.

STEAM LINE BLOW DOWN (Reference SM 23; latest edition)

All new steam piping between turbine and boiler or existing header must be adequately
blown to remove welding beads, scale, dirt, broken backing rings, weld rod, etc. This
includes all steam lines that can import steam into the turbine, including but not limited to:

- Main Steam
- Gland Sealing Steam

Proper setup and implementation of a sound blow down procedure are normally the
responsibility of the installation contractor. Elliott responsibility is normally only as a
witness and to verify that placement targets are acceptable before connecting to the
turbine.

Since the steam lines to the turbine cannot be connected for blow down, temporary blow
down piping will be required. Piping must be adequately secured prior to blow down.
Piping also must be rated for steam conditions at the time of the test and discharged into
an area that is properly secured and marked off.

In broad terms, blowing down the steam lines is a process that uses a cycle of heating and
cooling to break free any loose particles. Pressure is built up in the boiler and a valve is
opened to release this pressure though the steam lines. By the time the pressure is built
up again in the boiler, the piping has usually cooled. This forms the heating and cooling
cycle. The number of cycles will depend on the attention that was given to cleanliness
during erection, the design of the plant piping system, and the design of the blow down
system used.

Verification of the blow down is made by installing polished targets in the temporary blow
down piping. The targets are usually mild steel bar with a ground finish; however, key
stock material can be used. Each target can be used four times by turning the target in
ninety-degree increments.

The temporary blow down piping setup and size are very important. The force on a
particle is proportional to the mass velocity head of the fluid; therefore, the mass velocity
head developed during the blowing cycle must be at least equal to that developed during
full load operation. The temporary piping should not have a greater flow area than the
permanent piping so that satisfactory velocities can be maintained.

It is not possible to ascertain how many steam blows will be required to properly clean the
system since too many variables are involved. Experience has shown that up to fifty total
blows may be required for the main steam line and ten to twenty for the secondary lines.
Normally the blow down cycle will require one to three hours. The actual steam flow
through the pipe should be about fifteen to twenty minutes in duration and the piping
should allowed to cool for at least two hours if insulated and one hour if not insulated.

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Polished targets are to be installed after approximately ten blows on the main steam line.
At this point the targets should indicate the approximate relative condition of the system.
After two successive blows with no pitting observed on the targets, the blown down can be
considered completed. Retain these targets for reference. Discoloration of the targets is
normal. After successful completion of the blow down procedure, the temporary piping is
to be removed. Reinstall any piping removed for the blow down. Test the system for
leaks and piping strain.

Taking proper care to ensure an effective blow down procedure has been carried out will
ensure a successful start-up of the turbine.

TURBINE STEAM SUPPLY

Steam should at all times be free from moisture. A receiver type separator with ample
drains should be provided ahead of the stop valve to prevent slugs of water from entering
the turbine. When a separator is not provided, a blowoff valve or continuous drain should
be connected to the lowest point of the steam inlet piping.

A strainer should be installed in the steam supply piping for protection against large
particles of scale, welding beads, etc. A strainer does not guard against abrasive matter,
boiler compound or acid or alkaline substances that may be carried over in the steam.
These substances will corrode, erode, or form deposits on the steam parts, reducing
efficiency and power. It is imperative that feed water treatment and boiler operation be
carefully controlled to ensure a supply of clean steam at all times.

TURBINE ATMOSPHERIC RELIEF VALVES

An atmospheric relief valve must be installed between the turbine exhaust flange and the
first exhaust line steam isolation valve (See Figure 2-24) or check valve. The purpose of
this relief valve is to protect the turbine casing from excessive exhaust pressure or failure
of exhaust valve. The relief valve must be of ample size to pass the maximum quantity of
steam flowing through the turbine without allowing the turbine casing pressure to exceed
the maximum designed pressure shown on the turbine nameplate. It is the user’s
responsibility to install the relief valve in the piping. Failure to install relief valve may
violate local or national codes and must be approved by an officer of the company.

-WARNING-
THE TURBINE SHOULD NOT BE OPERATED UNLESS
THE ATMOSPHERIC RELIEF VALVE OR OTHER
PROTECTIVE DEVICE HAS BEEN INSTALLED AHEAD
OF ANY ISOLATION VALVE AND IS IN OPERATING
CONDITION.

Condensing Turbines
The atmospheric relief valve should be sized so that it is capable of passing all of the
steam that may reach the exhaust with the pressure rising to a value not greater than 10
pounds per square inch gauge. The relief valve should be installed between the turbine
exhaust flange and any shutoff valve. (Usually on the condenser shell for direct
connected condenser.)

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Non-condensing Turbines
A relief valve should be installed between the turbine exhaust connection and the first
steam isolation valve. The valve should be designed for full relief of the maximum steam
flow through the turbine with a pressure and flow rating as shown on the turbine outline
drawing located in Chapter 10 of this manual.

The sentinel valve, located on the turbine casing cover, does not serve as a relief valve.
The sentinel valve will not pass sufficient steam to relieve the turbine casing of excessive
exhaust pressure. The relief valve should be set to open at the sentinel valve setting to
give a visual or audible indication when the relief valve is starting to lift and be fully open
with an additional 10 psig or 10%, whichever is greater.

If a high back pressure trip is furnished, the relief valve pressure should be raised 5 psig
(.345 bar) and the high steam pressure trip should be set at the “start to open” pressure.
LOOP IN STEAM PIPE
ABSORBS EXPANSION
AND RELIEVES TURBINE
OF STRESSES
Y STEA M
DR
SLOPE TOWARD
HEADER
STEAM
HEADER

DRAIN
EXHAUST STEAM ISOLATION DRAIN
VALVE
INLET STEAM
ISOLATION
VALVE

ATMOSPHERIC
RELIEF VALVE
BYPASS VALVE

SPRING SUPPORT
RELIEVES CASING
OF STRESSES
SPRING SUPPORT DRAIN
RELIEVES CASING
OF STRESSES

© ELLIOTT CO., INC (YR)

Figure 2-24 Suggested Steam Piping Arrangement

MISCELLANEOUS PIPING CONNECTIONS

Considerable attention should be given to the installation of miscellaneous piping. Poorly

planned and installed piping may obscure drain line functions and lead to error when
opening or closing drain lines during operation. In addition, poorly installed piping will
detract from the appearance of the installation. All drain and leakoff lines should be
installed in a neat and orderly manner. They should be grouped and brought to an open
collector box and, from there, piped to a common sump or sewer.

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All valves should be conveniently grouped as close as possible to the collector box and all
lines should be tagged for identification. Drain lines connected through valves must have
the valves tightly closed during operation. On condensing units, these valves must not be
opened unless the turbine casing is no longer under vacuum. Leakoffs, connected without
valves must be clean and piped to an open drain.

(Refer to certified outline and connection drawings for the specific sizes of all connections
and for their exact locations.) The pipe size must be the same as or larger than
connecting sizes. All connections are brought outside the jacket when the turbine is
insulated and jacketed.

NOTE
All drains and leakoffs should be run as separate lines to
an open collector box.

NOTE
All drains and leakoffs must have sufficient flexibility to
allow for thermal growth of the turbine without excess
strains.

The following identifies the most common miscellaneous piping connections that may be
furnished and explains their individual functions (Refer to figure 2-25). (Refer to the
certified outline and purchaser’s connection drawing to verify the connection required.)

1. Casing Drain (M): Connect through a suitable valve to an open drain. Open
before starting the turbine; close when water no longer emerges from the drain.
Open when the turbine is shut down and the exhaust valve is closed. On
condensing turbines, do not open this valve while the turbine is under vacuum.

2. Steam Chest Drains [M4, M5, and M1 (BYRH, HH only)]: Connect through high
pressure piping and suitable valves to an open drain. Open before starting the
turbine to drain water from the steam chest. Close when water ceases to flow from
the drain lines. Open when the turbine is shut down. On condensing turbines, do
not open this valve while the turbine is under vacuum.

3. Shaft Packing Case Leakoff (L3): Connect to an open drain without a valve.
Connect to a vacuum source when applicable.

4. Trip Valve Stem Leakoff (L4): Connect to an open drain without a valve.

5. Governor Valve Stem Leakoff (L5): Connect to an open drain without a valve.

6. Cooling Water Connections to Bearing Housings (N5, N6, N9 and N10): These
connections are located on the side of the turbine bearing housings. See Figure 2-
25. Connect to a cooling water supply that does not exceed 90°F (32°C). Pipe the
cooling water through a stop cock and hand valve into N5, out of N6, into N9, out of
N10 through a one-foot head loop to an open drain. Adjust the stop cock to supply
water at a rate of 2 gpm (7.5 lpm.) when the hand valve is fully open. See Figure
2-26 for piping arrangement of water cooled bearing housings and caps. These
connections are not used on pressure lubricated turbines.

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NOTE
Cooling water pressure must not exceed 100 psig (6.89
bar).

7. Shaft Packing Case Steam Piping (T1): Furnished only when the turbine is
operated condensing. Connect through a valve to a pressurized, saturated steam
supply. Admit steam to packing cases until a slight amount of steam leaks out of
L3. A typical arrangement is shown in Figure 2-27.

8. Nozzle ring gauge connection (S1): A shut-off valve and gauge arrangement may
be installed in this connection. The gauge can be used for indicating the inlet
steam pressure drop across the steam chest.

9. Intermediate leakoff (L3-1) for BYRHH only: Connect to a 75 to 125 psig (5.1 to
8.6 bar) header. The leakoff line should have a gauge located near each packing
case. A valve should be used to isolate the packing cases from the header.

N-8
N-7
N-6 N-11
N-12
N-5
L-4

N-10
N-9

M-5 S-1
M-4 L-5 M-1
L-3 T-1 M

* L3 LEAK OFF FROM SHAFT SEALING GLANDS N7 COOLING WATER TO STEAM END BEARING CAP
* L4 TRIP VALVE STEM LEAK-OFF N8 COOLING WATER FROM STEAM END BEARING CAP
* L5 GOVERNOR VALVE STEM LEAK-OFF N9 COOLING WATER TO EXHAUST END BEARING PEDEST AL
** M TURBINE CASING DRAIN N10 COOLING WATER FROM EXHAUST END BEARING PEDEST AL
**M1 HIGH PRESSURE STEAM RING DRAIN (BYRH, HH Only) N11 COOLING WATER TO EXHAUST END BEARING CAP
** M4 STEAM CHEST DRAIN (BELOW SEAT) N12 COOLING WATER FROM EXHAUST END BEARING CAP
** M5 STEAM CHEST DRAIN (ABOVE SEAT) S1 NOZZLE RING GAUGE CONNECTION
N5 COOLING WATER TO STEAM END BEARING HOUSING T1 SEALING STEAM TO SHAFT PACKING CASE
N6 COOLING WATER FROM STEAM END BEARING HOUSING
* ROUTE TO OPE N DRA IN NO VALVE.
** ROUTE TO OPEN DRA IN W ITH VALVE.

© ELLIOTT CO., INC (YR)

Figure 2-25
Miscellaneous Piping Connections

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1ft.(30cm)
HEADLOOP
N10 N6

CONTROL VALVE

N9 N5
STOP
COCK
COOLING
OPEN
DRAIN WATER

© ELLIOTT CO., INC (YR)

Figure 2-26
Suggested Piping Arrangement for Water Cooled Bearing Housings

1ft.(30cm) 1ft.(30cm)
HEADLOOP HEADLOOP

N12 N11 N7 N8

N10 N6
CONTROL VALVES

N9 N5

STOP COCK

OPEN
OPEN
COOLING DRAIN
DRAIN
WATER

© ELLIOTT CO., INC (YR)

Figure 2-27
Suggested Piping Arrangement for Water Cooled Bearing Housings and Caps

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EXHAUST END STEAM END

SEALING GLAND SEALING GLAND

TO DRAIN L3 TO DRAIN L3

T1

RELIEF VALVE
20 psig (1.35bar)
PRESSURE GAUGE
SHUT-OFF
VALVE

SHUT-OFF
VALVE

SEALING STEAM
© ELLIOTT CO., INC (YR)

Figure 2-28
Suggested Sealing Steam Piping Arrangement for Condensing Turbines

VACUUM BREAKER FOR CONDENSING TURBINES

It is recommended that provisions be made in the exhaust piping or on the condenser for
breaking the vacuum. The vacuum breaker may consist of a hand-operated valve to be
opened when shutting down the turbine. Breaking the vacuum serves two purposes:

1. It increases the deceleration rate of the rotor.

2. It prevents the in leakage of cold air into the turbine casing along the shaft when
gland sealing steam is turned off.

CONNECTING TURBINE TO CONDENSER

A condenser connected directly to the turbine exhaust flange, when not suspended from
the flange or spring-supported, must have an expansion joint to provide the necessary
flexibility for expansion unless otherwise approved by Elliott Company. When the
condenser is spring-supported or hung from the turbine exhaust flange, no expansion joint
need be used, provided the maximum condenser weight under any condition is within the
allowable weight that the exhaust end is designed to support. In the latter case, the
condenser load on the exhaust flange must be central. Provisions must be made in the
supports for lateral expansion. All other piping connections to the condenser must be
provided with suitable expansion joints.

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To avoid air leaks and maintain the highest attainable vacuum, see that all joints are tight
and that the shaft packing is receiving sufficient sealing steam. Suitable paint applied
along the joints and around the bolts of the exhaust connection will assist in keeping them
airtight.

TURBINE INSULATION

Insulating a turbine greatly reduces heat loss and sound pressure levels, isolates hot
turbine parts from personnel, and protects the turbine from the environment. Insulate the
high-temperature areas of the turbine surface indicated on the outline drawing. For
condensing turbines, these parts are the steam end casing, intermediate casing (when
used), trip and throttle valve, and steam chest. For non-condensing turbines, insulate the
exhaust end casing also.

Turbine Jacketing
Elliott supplies a sheet metal, jacket-type insulation that sheathes the turbine casing. This
removable jacketing, which provides access to turbine parts for servicing, separately
houses the high-temperature turbine sections. Available in carbon steel or optional
stainless steel, the sheet metal jacketing squares the turbine’s shape for a neater
appearance. Jacketing for the upper turbine casing consists of a metal shell and a layer
of high-temperature fibrous insulation that is fixed to its underside. The lower turbine
casing is fitted with a metal shell that is stuffed with loose insulation. Jacketing is made to
each turbine's specifications and can be obtained through Elliott field service offices.

NOTE
Elliott recommends jacketing for all outdoor installations to
protect high-temperature turbine parts from precipitation.

FIGURE 2-29
TURBINE RECOMMENDED INSULATION METAL JACKETING

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NOTES

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 CHAPTER THREE
OPERATION

INTRODUCTION

Turbine applications differ widely; therefore, operating procedures must be tailored to each
particular installation. Instructions in this chapter provide a recommended procedure for
the initial start-up and serve as a guide for establishing routine operating procedures.

Operating personnel must review this technical manual to become familiar with
the safety precautions and operating procedures for YR Turbines. Particular
attention should be directed to the WARNINGS, CAUTIONS, and NOTES in
this chapter.

For location of parts described in the following text, refer to the Steam Chest Assembly
and Typical YR Turbine Assembly figures in Chapter 4.

STEAM SUPPLY

Steam should be free from moisture and preferably superheated. A receiver type
separator with ample drains should be provided upstream of the shut-off valve to prevent
water from entering the turbine. When a separator is not provided, a continuous drain
must be connected to the lowest point of the steam inlet piping.

CAUTION
If continuous drainers are on the steam piping or
turbine drains, check frequently to verify that proper
operation is maintained. Failure to drain water from
steam lines or turbine casing may result in erosion,
thrust failures, and/or poor performance.

The steam strainer protects the turbine from large particles of scale, welding beads, etc.
This strainer does not protect against abrasive matter, boiler compound, acids or alkaline
substances, all of which may be carried over in the steam. These substances may
corrode, erode or form deposits on the internal turbine parts, thus reducing efficiency and
power. Feed water treatment and boiler operation must be carefully controlled to verify a
supply of clean steam for long-term satisfactory operation.

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SAFETY PRECAUTIONS

1. Do not operate the turbine if inspection shows that the rotor shaft journals and/or
shaft packing case areas are corroded.

2. Before starting, verify the rotor rotates freely by hand and that it is not rubbing any
stationary parts.

CAUTION
Do not rotate shaft until lubrication has been applied.
Rotating the shaft without lubrication may result in
damage to the rotor shaft and bearing liners.

If rubbing or vibration occurs during operation,

immediately shut down the turbine, investigate and
correct the cause.

3. Verify all piping (steam, water, air) and electrical connections are made before
operating the turbine.

4. Verify that all valves, controls, trip mechanisms and safety devices are in good
operating condition.

-WARNING-
UNDER NO CIRCUMSTANCES SHOULD THE TRIP
VALVE BE BLOCKED OR HELD OPEN TO CAUSE THE
TRIP SYSTEM TO BECOME INOPERATIVE.

OVERRIDING THE TRIP SYSTEM AND ALLOWING THE

TURBINE TO EXCEED THE RATED (NAMEPLATE) TRIP
SPEED MAY RESULT IN FATAL INJURY TO
PERSONNEL AND EXTENSIVE TURBINE DAMAGE.

IN THE EVENT THE TRIP SYSTEM MALFUNCTIONS:

IMMEDIATELY SHUT THE TURBINE DOWN BY
CLOSING THE INLET STEAM SHUT-OFF VALVE.

5. Before initial start-up, after major maintenance and after an extended shutdown, do
not leave the turbine unattended at any time until proper operation with load has been
demonstrated.

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PREPARING THE TURBINE FOR INITIAL START-UP

NOTE
Complete installation work before attempting to operate
turbine. (Refer to Chapter 2.)

1. Disconnect the coupling between the turbine and driven machine. Turbines driving
through reduction gears can remain coupled to the gear and operated together.

2. Disconnect the steam inlet piping at the turbine and blow out the line with the supply
steam to remove any foreign material from the pipe. Use targets for determination of
cleanliness. (Refer to NEMA SM23 section 8.4 for additional details.)

3. Verify the steam strainer is clean and properly installed in the steam chest inlet
flange. Connect the pipe to the turbine as a permanent joint. Adjust piping hangers
to eliminate any unacceptable strain on the turbine in cold and hot conditions. Piping
strains must be calculated in agreement with current NEMA SM23 standards.

4. If operating a condensing turbine, clean rust preventative compound from internal

turbine surfaces.

CAUTION
Rust preventative compound will foul surface
condenser tubes if not removed before operating the
turbine.

NOTE
As an alternative to manually cleaning the turbine internals
to remove rust preventative compound, the turbine may be
run for several hours while exhausting to atmosphere.

5. Remove bolting from the steam end bearing cap and the exhaust end bearing cap.
Lift the caps approximately 1 inch (25 mm) and pry out the top bearing liners to
release the oil rings (if supplied). Remove the bearing caps and roll out the bottom
bearing liners by lifting up on the rotor and rotating the bearing liners toward the
positioning lugs. Clean and inspect the bearing liners. Keep the steam and exhaust
end bearing liners separate.

CAUTION
Attempting to remove the bearing caps without prying
out the top bearing liners can distort the oil rings.
Distorted oil rings will not rotate and fail to provide
adequate lubrication, resulting in bearing failures.

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NOTE
Turbines with Class 3 (or higher) rotors are pressure
lubricated and may not have oil rings supplied. (Refer to
the Turbine Operating Data page located in the front of this
manual to determine the rotor class.)

6. Clean the rotor shaft journals, locating bearing, and the bearing housings with clean,
lint free rags. If turbine is equipped with Kingsbury type thrust bearings, remove
thrust bearings and clean; reassemble per Supplement 03-91, located in Chapter 8
Accessories.

7. Lift the weight off the rotor and roll the bottom bearing liners into place. Make certain
the positioning lugs on the liners are correctly seated in the bearing housing locating
grooves.

CAUTION
Verify that the steam end and exhaust end bearing
liners are not interchanged.

8. Place the top bearing liners on the shaft journals. If the turbine is ring oiled, position
oil rings in the slots of the top liners. Flood the rotor locating bearing, shaft journals,
and bearing liners with oil. (Refer to Chapter 5 for proper oil levels and lubrication
requirements.)

9. Replace the bearing caps. Verify that the positioning lugs on the top liners engage
the grooves in the bearing caps. Apply a very thin coat of sealant to the split line.
Insert the dowel pins and tighten all bolts.

10. If supplied, review the driven machine instruction manual for pre-start inspection
procedures.

11. Inspect the governor linkage. For specific details on preparing the governor for start-
up, refer to Chapter 6, and the governor manuals located in Chapter 8 Accessories.

12. Verify that all lube oil piping has been installed and the lubrication system has been
flushed.

CAUTION
If the turbine is pressure lubricated, verify orifice plugs
are installed at the bearing housings. If orifice plugs
are not installed, oil leakage will occur.

13. Verify free movement and clearances of the trip system. Manually activate the
overspeed trip pin to verify the overspeed trip system is functional.

14. Fabricate a clamp or other blocking device to secure the coupling sleeve (if supplied)
to the hub while operating the uncoupled turbine.

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NOTE
Use a balanced adapter to secure balanced gear type
coupling hubs during uncoupled operation.

15. Verify that the exhaust relief valve is installed correctly and operates at the correct
pressure.

-WARNING-
THE TURBINE SHOULD NOT BE OPERATED UNLESS
THE ATMOSPHERIC RELIEF VALVE OR OTHER
PROTECTIVE DEVICE HAS BEEN INSTALLED
BETWEEN THE TURBINE EXHAUST CONNECTION
AND FIRST EXHAUST ISOLATION VALVE (OR
CONDENSER, IF THE TURBINE IS A CONDENSING
TURBINE).

THE ATMOSPHERIC RELIEF VALVE OR OTHER

PROTECTIVE DEVICE MUST BE DESIGNED FOR FULL
RELIEF OF THE MAXIMUM STEAM FLOW THROUGH
THE TURBINE WITHOUT EXCESSIVE EXHAUST
PRESSURE.

FAILURE TO INSTALL THIS TYPE OF DEVICE MAY

RESULT IN SEVERE EQUIPMENT DAMAGE AND/OR
SEVERE INJURY OR DEATH TO PERSONNEL.

16. Fill oil lubricators (if ring oiled) or oil reservoir (if pressure lubricated) with proper oil.
(Refer to Chapter 5 for details.)

17. Inspect and test all controls, alarms, trips and relief valves. Calibrate and install all
instrumentation.

18. Roll the shaft by hand through several revolutions, checking for possible binding or
rubbing. Any sign of binding or rubbing should be thoroughly investigated before
attempting to start the unit.

19. If automatic controllers or regulators are supplied, do not enable during initial start-up;
use only after the general operation of the equipment has been determined
satisfactory.

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INITIAL START-UP

1. Open drain valves to drain water from the steam inlet piping, turbine casing, steam
chest, and the exhaust piping.

2. Verify that the lube oil temperature is greater than 70°F (20°C).

3. If turbine is ring oiled, check that oil lubricators are filled. If turbine is pressure
lubricated, prime the oil pump(s) and verify that the oil reservoir is filled to the correct
level. Start the auxiliary oil pump (if supplied) and circulate the lubricating oil. Check
the oil piping for leaks and that oil is being delivered to the bearings.

4. Adjust the governor speed setting to minimum speed. (Refer to “Governor Operation”
in Chapter 6.)

5. Completely open the overload hand valves (if supplied). For further details review the
section on overload hand valves in this chapter.

6. Verify that the trip valve is closed and open the turbine exhaust isolation valve.

7. Verify proper oil pressure is present (pressure lubricated with auxiliary oil pump only).

8. Latch the trip valve resetting lever.

9. Commission the eductor/ejector (if supplied).

NOTE
When ejectors/eductors are used on packing case leakoff
lines, the customer can turn on at their discretion.
However, care must be taken to prevent steam from
blowing out of packing cases along the turbine shaft, which
may contaminate oil in bearing housings.

10. Close the intermediate leakoff valve (BYRHH and optional on BYRH turbines) and
maintain closed position until leakoff pressure builds to line pressure.

11. For condensing turbines, close all drain valves and commission main condenser
according to manufacturer’s instructions.

12. Slowly open the main steam isolation valve until the turbine reaches approximately
500 rpm.

CAUTION
Steam should not be admitted to the turbine casing by
partially opening the main steam isolation valve while
the rotor is stationary. This condition will cause
uneven heating of the turbine rotor and casing, which
may result in a distorted casing, bowed rotor shaft or
other related problems.

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13. For condensing turbines, adjust the sealing steam supply valve to permit a slight
amount of steam to be discharged from the packing case leakoff drain lines. A
pressure of 3 to 5 psig (0.20 to 0.35 bar) is usually sufficient sealing steam pressure.
However, care must be taken to prevent steam from blowing out of the packing cases
and along the turbine shaft.

CAUTION
If sealing steam is allowed to leak into the bearing
housings, the lubricating oil may become
contaminated and form sludge and foam. To prevent
this condition, adjust the sealing steam accordingly.

14. Immediately verify operation of the trip valve by striking the trip lever. Close the main
steam isolation valve as the turbine speed decreases.

15. Latch the resetting lever and slowly open the main steam isolation valve to bring the
turbine back to 500 rpm. If the turbine is ring oiled, remove the inspection plugs from
the bearing caps and check to be sure the oil rings are rotating. Verify proper oil
pressure is present (pressure lubricated only). Monitor the speed carefully during the
low speed operation.

CAUTION
Do not leave the turbine unattended at any time during
the initial start-up.

16. Introduce cooling water to bearing housing cooling chambers or oil cooler (if supplied)
to prevent overheating. (Refer to Chapter 5 [Table 5-3], for recommended bearing
operating temperatures.)

17. Listen for any unusual noises, rubbing, or other signs of distress in the turbine. Do
not operate if any of these conditions are present. Monitor the turbine for signs of
overheating and excessive vibration. (Refer to the Troubleshooting Guide in Chapter
7 for possible causes and corrective actions for abnormal conditions which might
occur.)

18. When the turbine is thoroughly warmed up and low speed operation is determined to
be satisfactory, close the overload hand valves (if supplied).

19. For non-condensing turbines, close all drain valves provided no signs of condensate
are visible at all drain lines.

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20. Proceed with wearing in of the carbon rings (if supplied). (Refer to Turbine Operating
Data Sheet located in the front of this manual, for steam seals supplied with this unit.)

a. Gradually increase turbine speed to 1000 rpm and hold for 10-15 minutes.
b. Reduce turbine speed to 500 rpm and hold for 5-10 minutes, allowing shaft to
cool.
c. Increase turbine speed by 1000 rpm and hold for 10-15 minutes.
d. Reduce turbine speed by 500 rpm and hold for 5-10 minutes, allowing shaft to
cool.
e. Continue increasing turbine speed by 1000 rpm and decreasing by 500 rpm until
rated operating speed as shown on the turbine nameplate is achieved.

NOTE
The stepped start up procedure (wearing in of the carbon
rings) must be done for the first 2 or 3 turbine starts, or
after installation of new carbon rings. Failure to do so may
result in improper wearing in of carbon rings and cause
excessive packing case steam leakage.

21. After the turbine is operating, closely observe oil pressures and temperatures. For
condensing turbines, adjust sealing steam to maintain 3 to 5 psig (0.20 to 0.35 bar).

22. Verify the overspeed trip by temporarily overriding the governor to actuate the
overspeed trip mechanism. (Refer to Control System, Chapter 6, for specific details
on overspeeding the turbine.)

CAUTION
Do not operate the turbine more than 2% above the
rated trip speed listed on the turbine nameplate. If the
overspeed trip does not operate within 2% of the
designated speed, shut the turbine down and make
necessary adjustments as described in Chapter 4,
Overspeed Trip System.

Three consecutive, non-trending trip speeds within the required range (refer to
Turbine Data sheet located in the front of this manual) must be recorded to verify safe
trip system operation. After a turbine trip and the speed decreases by 15-20% of
rated speed, the resetting lever may be relatched and the turbine brought back up in
speed.

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 Chapter 3
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-WARNING-
DURING TESTING OF THE MECHANICAL OVERSPEED
TRIP, THE FOLLOWING GUIDELINES MUST BE
ADHERED TO:

A. LIMIT PERSONNEL TO THE MINIMUM NUMBER

REQUIRED TO CONDUCT THE OVERSPEED
TESTS.

B. THE MAIN STEAM ISOLATION VALVE TO THE

TURBINE MUST NOT BE FULLY OPENED. IT
SHOULD ONLY BE OPENED AS FAR AS
NECESSARY TO REACH THE TRIP SPEED.

C. DURING THE TEST, TRAINED PERSONNEL MUST

OPERATE THE MAIN STEAM ISOLATION VALVE
TO THE TURBINE.

D. TWO SOURCES OF SPEED INDICATION ARE

PREFERRED. BOTH SHOULD BE OF KNOWN
ACCURACY AND CURRENT CALIBRATION.

23. Continue operating the turbine for approximately one hour, while carefully monitoring
bearing temperatures, turbine speed, vibrations levels, and listening for any unusual
noises.

24. Shut down the turbine upon satisfactory completion of the initial run. (Refer to
“Turbine Shut Down” at the end of this chapter.)

25. Couple the turbine to the driven equipment. If the turbine is used with a speed
reduction gearbox or other special equipment, follow all instructions pertaining to
those particular items.

ROUTINE START-UP

1. Verify proper oil pressure is present (pressure lubricated only).

2. Open drain valves to drain water from the steam inlet piping, turbine casing, steam
chest, and the exhaust piping.

3. Verify that the lube oil temperature is greater than 70°F (20°C).

4. If turbine is ring oiled, check that oil lubricators are filled. If turbine is pressure
lubricated, prime the oil pump(s) and verify that the oil reservoir is filled to the correct
level. Start the auxiliary oil pump (if supplied) and circulate the lubricating oil.

5. Completely open the overload hand valves (if supplied). For further details, review
the section on overload hand valves in this chapter.

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6. Verify that the trip valve is closed and open the turbine exhaust isolation valve.

7. Latch the trip valve resetting lever.

8. Verify proper oil pressure is present (pressure lubricated with auxiliary oil pump only).

9. Commission the eductor/ejector (if supplied).

NOTE
When ejectors/eductors are used on packing case leakoff
lines, the customer can turn on at their discretion.
However, care must be taken to prevent steam from
blowing out of packing cases along the turbine shaft, which
may contaminate oil in bearing housings.

10. Close the intermediate leakoff valve (BYRHH and optional on BYRH turbines) and
maintain closed position until leakoff pressure builds to line pressure.

11. For condensing turbines, close all drain valves and commission main condenser
according to manufacturer’s instructions.

12. Slowly open the main steam isolation valve until the turbine reaches approximately
500 rpm.

CAUTION
Steam should not be admitted to the turbine casing by
partially opening the main steam isolation valve while
the rotor is stationary. This condition will cause
uneven heating of the turbine rotor and casing which
may result in a distorted casing, bowed rotor shaft or
other related problems.

13. For condensing turbines, adjust the sealing steam supply valve to permit a slight
amount of steam to be discharged from the packing case leak off drain lines. A
pressure of 3 to 5 psig (0.20 to 0.35 bar) is usually sufficient sealing steam pressure.
However, care must be taken to prevent steam from blowing out of the packing cases
and along the turbine shaft.

CAUTION
If sealing steam is allowed to leak into the bearing
housings, the lubricating oil may become
contaminated and form sludge and foam. To prevent
this condition, adjust the sealing steam accordingly.

14. Immediately verify operation of the trip valve by striking the trip lever. Close the main
steam isolation valve as the turbine speed decreases.

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 Chapter 3
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15. Latch the resetting lever and slowly open the main steam isolation valve to bring the
turbine back to 500 rpm. If the turbine is ring oiled, remove the inspection plugs from
the bearing caps and check that the oil rings are rotating. If the turbine is pressure
lubricated, verify proper oil pressure is present.

16. Introduce cooling water to bearing housing cooling chambers or oil cooler (if supplied)
to prevent overheating. (Refer to Chapter 5 [Table 5-3] for recommended bearing
operating temperatures.)

17. Listen for any unusual noises, rubbing, or other signs of distress in the turbine. Do
not operate if any of these conditions are present. Monitor the turbine for signs of
overheating and excessive vibration. (Refer to the Troubleshooting Guide in Chapter
7 for possible causes and corrective actions for abnormal conditions which might
occur.)

18. For non-condensing turbines, close all drain valves, provided no signs of condensate
are visible at all drain lines.

19. Adjust governor to attain desired speed as load is applied to the turbine. (Refer to
“Control System”, Chapter 6). Close overload hand valves as required by turbine
operation. (Refer to the “Unit Outline” in Chapter 10, Technical Drawings, for
overload hand valve settings.)

20. After the turbine is operating, closely observe oil pressures and temperatures. For
condensing turbines, adjust sealing steam to maintain 3 to 5 psig (0.20 to 0.35 bar).

OVERLOAD HAND VALVES (Optional)

Overload hand valves are used sometimes to control the steam flow through an extra bank
of nozzles. These valves can serve three functions:

a. When closed, the valves will provide more efficient turbine operation at reduced load
with normal steam conditions by reducing the nozzle area and also reducing the
steam flow.

b. In some applications, overload hand valves are used to develop the required power
by opening the valves when steam conditions are less than normal (such as
encountered during boiler start-up).

c. Sometimes overload hand valves are used to develop increased power for meeting
overload requirements with normal steam conditions.

(Refer to the “Turbine Outline” in Chapter 10, Technical Drawings, for overload hand valve
positioning versus turbine power, speed and operating steam conditions.) For the best
efficiency and speed control, open only the overload hand valves required for the actual
steam conditions present and power required.

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TABLE 3-1
OVERLOAD HAND VALVES

Turbine Frame Size Number of Turns

AYR 7

BYR, BYRIH 9

CYR, CYRH 12

DYR, DYRH, DYRM, DYRN 12

DYR, DYRH, DYRM, DYRN
14
with 8" inlet
BYRH, BYRHH 12

NOTE
Overload hand valve must be positioned either completely
open or completely closed. Turning the stem
counterclockwise approximately 1½ turns will open the
pilot valve. (Refer to Table 3-1 for the correct number of
turns required to completely open the main valve disk.)
Open all overload hand valves during start-ups to verify
even heating of casing and prevention of valves binding in
the casing. The overload hand valves can be completely
closed if not needed when governor control is reached.

CAUTION
Operation of the overload hand valve, in anything
other than completely open or completely closed
position, can cause valve failure and possible internal
damage to the turbine.

For further information on Auto-Overload hand valves (if supplied), refer to Supplement
02-86-R1, in Chapter 8.

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TURBINE SHUTDOWN

CAUTION
Before shutting down turbine, verify that the governor
system and trip system are in proper working order. If
the operational integrity is uncertain, shut off the main
steam isolation valve to stop the turbine.

1. Reduce the turbine speed to a minimum.

2. Shut down the turbine by striking the top of the trip lever by hand.

3. Observe the action of the trip valve and linkage.

4. Close the main steam isolation valve.

NOTE
Isolation valves, located in the turbine inlet steam piping,
must be closed after the trip valve has closed. Do not use
the trip valve as a long-term shut-off valve.

5. If non-condensing turbine, close the exhaust valve and open turbine casing drains.

6. If condensing turbine, shut down the condensing equipment, open the turbine casing
drains and close the sealing steam shut-off valve.

CAUTION
Do not apply sealing steam to the packing cases while
the turbine rotor is idle. This condition will cause
uneven heating of the turbine rotor and casing which
may result in a distorted casing, bowed rotor shaft or
other related problems.

7. Allow the rotor to come to a complete stop and cool down for approximately 2 hours
before turning off the cooling water or stopping auxiliary oil pump, if supplied.

8. If the turbine is to be taken out of service for an extended period, follow the storage
instructions in Chapter 1.

OPERATION OF EMERGENCY AND STANDBY TURBINES

Emergency and standby turbines do not require a warm-up period before applying the load
and may be rapidly placed into service. However, it is important that turbines used for
emergency and standby services have drain lines open and isolating valves closed when
the turbine is idle. Turbines not used for extended periods should be inspected and
operated occasionally to verify good working condition.

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Where impractical to operate the turbine, the rotor should be turned over by hand to
introduce oil to the journal bearings (oil ring lubricated turbines). If an auxiliary oil pump is
furnished (pressure lubricated turbines), oil can be supplied to the bearings by operating
the pump. To prevent corrosion, introduce dry, heated air into the casing during shutdown
periods.

CAUTION
Steam should not be admitted to the turbine casing by
partially opening the main steam isolation valve while
the rotor is stationary. This condition will cause
uneven heating of the turbine rotor and casing, and
may result in a distorted casing, bowed rotor shaft or
other related problems.

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 CHAPTER FOUR
MAINTENANCE
INTRODUCTION
Turbines, like most quality machinery, require periodic maintenance and service. This
chapter supplies turbine disassembly, assembly and adjustment procedures.
Maintenance personnel should be familiar with these to ensure effective repairs and
proper adjustments to components requiring service. Maintenance personnel should
thoroughly understand, and at all times observe, all safety precautions related to turbine
maintenance. It is of primary importance to ensure the turbine is isolated from all utilities
to prevent the possibility of applying power or steam to the turbine when performing
internal maintenance.

-WARNING-
CLOSE, LOCK AND TAG ALL ISOLATING VALVES
AND OPEN ALL DRAINS TO DEPRESSURIZE THE
TURBINE CASING AND STEAM CHEST BEFORE
PERFORMING ANY INTERNAL TURBINE
MAINTENANCE. ALSO, TAKE NECESSARY
PRECAUTIONS TO PREVENT POSSIBLE TURBINE
ROTATION DUE TO REVERSE FLOW THROUGH THE
DRIVEN MACHINERY.

Non-destructive type testing is recommended for determining operational reliability of parts

during turbine inspections. If major parts replacement (such as turbine shaft, disks,
blading etc.) becomes necessary, it is advisable that an Elliott Company representative
supervise the repair work or that it be done in an Elliott approved repair shop.
NOTE
Throughout this chapter, figure numbers are referenced in
the paragraph heading. Within the paragraph, reference to
the component item number is in parentheses (). These
component items can be found on the figure. Figure
number and component number are also called out on the
Spare Parts List found in Chapter 9.

SCHEDULED MAINTENANCE

Scheduled maintenance inspections are necessary for safe and efficient turbine operation.
Inspection intervals cannot be specified in this manual because maintenance scheduling is
dependent upon factors best known by those directly involved with the turbine and its
particular application. Table 4-1 serves as a general guideline for establishing a
scheduled preventative maintenance program.

The actual frequency of required maintenance inspections can only be determined after
carefully considering turbine performance records, maintenance history, corrosion/erosion
rates, tests, observations and anticipated service demands. The established inspection
schedule will usually be consistent with the availability of the turbine, necessary manpower
and an adequate supply of repair parts. At the same time, scheduled inspections must be
frequent enough to avoid unsafe operating conditions.

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Maintenance
It is also necessary to test and adjust all safety devices on a definite schedule to ensure
their operational reliability. These devices are designed to prevent injury to personnel
and/or major equipment damage. If these devices are not operated at frequent intervals,
they may not work when needed.
TABLE 4-1
SCHEDULED MAINTENANCE GUIDELINES
APPROX. MAINTENANCE DESCRIPTION REFERENCE
FREQUENCY
1. Check all oil levels and add oil as necessary.
2. Check bearing and lubricating oil temperatures. 2. Chapter 5
3. Check turbine speed.
Daily 4. Check smoothness of operation; investigate sudden
4. Chapter 4
changes in operating conditions or unusual noises.
5. If daily shutdowns are made: test the trip valve by
striking the hand trip lever.
1. Exercise trip valve to prevent sticking due to deposits
or corrosion. If on a continuous operation schedule;
Weekly exercise the trip valve by striking the hand trip lever.
Reset the lever when the turbine speed decreases to
approximately 80% of rated speed.
1. Sample lubricating oil and renew as necessary. 1. Chapter 5
2. Check governor linkage for excessive play. Replace
2. Chapter 4
Monthly any worn parts.
3. Check the overspeed trip by overspeeding the turbine
3. Chapter 6
(if the driven machine permits).
1. Check all clearances and adjustments. 1. Chapter 4
2. Remove and clean steam strainer. If strainer is
2. Chapter 4
exceptionally dirty, clean every six months.
3. Inspect governor valve seat. Hand lap the valve if
signs of uneven wear exist. Replace the governor 3. Chapter 4
valve stem packing.
4. Clean and inspect trip valve. Replace worn out parts
4. Chapter 4
and hand lap if necessary.
5. Disassemble, clean and inspect overspeed trip and
linkage. Inspect trip pin and check for ease of 5. Chapter 4
operation.
Annually 6. Check journal bearings and rotor locating bearing for
6. Chapter 4
wear and replace if necessary.
7. Inspect and clean bearing housing oil reservoirs and
7. Chapter 4
cooling chambers.
8. Lift turbine casing cover and inspect rotor shaft, disks,
8. Chapter 4
blades and shrouding.
9. Inspect carbon rings and replace as necessary. 9. Chapter 4
10. Remove rotor assembly from casing and inspect
10. Chapter 4
reversing blades and nozzle ring.
11. Check operation of sentinel valve. 11. Chapter 1
12. Adjust and check overspeed trip when turbine is put
12. Chapter 4
back in operation.

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 Chapter 4
Maintenance

TURBINE CASING AND MISCELLANEOUS JOINTS – Refer to Figure 4-1

The turbine steam joints are carefully made up and factory tested under pressure to
ensure steam tightness. Two types of sealing compounds are used: one is a paste, which
is spread on the joints, the other is a plastic string type sealant. These products,
“Copaltite” (paste) and “Temp-Tite” (plastic string), produce a superior joint seal and are
available from Elliott Company.

NOTE
Plastic string sealant, “Temp-Tite”, can be purchased in
the desired diameter and is available on sealed spools.
The paste sealant, “Copaltite”, is available in quart
containers. See the Spare Parts List for part numbers.

A combination of paste and plastic sealing compound is used to seal the vertical joints
between the packing cases and turbine casing. The plastic sealant (³⁄16 inch, 5 mm wide)
and paste compound is used to fill the sealing grooves on the vertical flange faces of the
packing cases. A combination of plastic sealant (¹⁄16 inch, 1.6 mm wide) and paste
compound is used to seal the following steam joints:

1. Steam chest body (1, Figure 4-13) to the turbine casing.

2. Governor valve cover (22, 31, Figure 4-13) to the steam chest body (1, Figure 4-13).

3. Trip valve cover (3, Figure 4-13) to the steam chest body (1, Figure 4-13).

4. Nozzle ring to turbine casing.

5. The horizontal and vertical turbine casing joints.

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Because of the high exhaust pressures and resultant temperatures under which the DYR,
DYRH, CYRH, BYRH and BYRHH turbines operate, particular precautions are taken to
seal the steam joint of the horizontal cover flange. A combination of a paste type sealing
compound and “strings” of a plastic sealer is used. The seal face at the horizontal flange
cover or case is grooved to receive a ³⁄16" diameter string of plastic compound then coated
over with the paste sealer.

Screw threads subjected to high temperatures often gall during disassembly. It is

recommended that anti-galling compound be applied to the threads of all studs, bolts,
socket head cap screws, and other threads subjected to high temperatures. The joints
between the bearing caps and bearing housings may be made up with a thin coat of oil
resistant sealant.

Anti-galling compound and sealants should be among the normal maintenance items
stocked, and may be purchased from Elliott Company. The sealants have a shelf life of
approximately 1 year when stored in a cool place. If Elliott Company materials are not
stocked, high-grade materials of suitable pressure and temperature rating may be used.

USE ONLY PASTE COMPOUND

ON HORIZONTAL SEALING
GLAND FLANGES. EXHAUST END

CUT OFF PLASTIC SEALANT

SHARPLY AT JOINT

PLACE A LINE OF PLAST IC SEALING

USE PASTE COMPOUND ON VERTICAL COMPOUND (1/16 in.,1.6 mm WIDE)
SEALING GLAND FLANGES; FILL STEAM END IN A LAYER OF PASTE COMPOUND
GROOVES ON FLANGE FACES WITH (APPROXIMATELY 1/2 in.,13 mm WIDE
PLASTIC SEALANT (3/16 in.,5 mm WIDE).
PASTE
SEALER

FIGURE 4-1
HORIZONTAL JOINT DETAIL

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PACKING CASE (SHAFT SEALING GLAND) AND CARBON RING SERVICE

The steam end and exhaust end packing cases (10, Figure 4-12) house the carbon ring
assemblies (Figure 4-2). Each carbon ring assembly consists of three carbon segments
and an anti-rotation stop which are held together by a retainer spring (Figure 4-3). Axial
positioning of the carbon rings is maintained by machined grooves in the packing cases.

Intermediate Leak-Off
Connection
Labyrinth
Carbon Ring Seal
Assembly Carbon Ring
Assembly

CYR/DYR BYRHH
CYRH/DYRH BYRH

Leak-Off Leak-Off
Connection Connection

Sealing Steam
Connection
 ELLIOTT CO., INC (YR)

FIGURE 4-2
PACKING CASE ARRANGEMENT

MATCH
MARKS
CARBON RING
SEGMENT
RETAINER

..
SPRING

MATCH
MARKS

....

ANTI-ROTATION STOP
 ELLIOTT CO., INC (YR)

FIGURE 4-3
CARBON RING SEAL ASSEMBLIES

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The BYRHH turbine packing case contains a labyrinth seal in combination with four
carbon rings. The labyrinth seal is located inboard of the carbon rings and consists of four
segments held together by two garter springs. The labyrinth seal is held in position by a
rabbit fit in the turbine casing and an anti-rotation pin located in the top half packing case
that fits into a notch in the labyrinth seal.

Packing Case Disassembly – Refer to Figure 4-12

1. Disconnect piping from top half packing cases (BYRHH Turbine).

2. Remove cap screws (7 & 8) from the horizontal and vertical flanges on the top half
packing cases (10).

3. Break the horizontal and vertical joints by prying the top half packing cases away
from the bottom halves.

4. Carefully remove the top half packing cases by lifting straight up until they clear the
carbon ring assemblies (9).

NOTE
If excessive sealant was used or large amounts of boiler
carry over is present, the carbon rings may become “glued”
to the packing case. Should this happen, it is necessary to
chip the carbon segments from the packing case.

Carbon Ring Removal:

1. Unhook the retaining spring surrounding the carbon ring.

2. Remove the anti-rotation stop by sliding it off the retaining spring.

3. Remove the carbon ring segments by rotating them around the rotor shaft.

4. Pull the retaining spring from the packing case.

NOTE
Do not mix carbon ring segments. Mark each ring so it can
be returned to its original location.

5. Clean the packing cases (taking care to clean axial faces of each carbon ring slot),
rotor shaft and all sealing surfaces on the packing case flanges. Blow out the
packing cases with air.

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Replacement:

1. Place the carbon ring retaining springs under and part way around the rotor shaft.

2. Roll the carbon ring segments around the shaft and into the packing case grooves.
Align the match marks on the carbon ring segments to ensure proper assembly.

3. Slide the anti-rotation stops onto the retainer springs and position the stops in
notched carbon ring segments.

4. Hook the ends of each retaining spring together and rotate the carbon rings so the
anti-rotation stops are seated in the anti-rotation notches in the bottom half packing
cases.

Clearances
The inside diameters of new carbon rings are selected to match to the calculated design
turbine exhaust temperature (Refer to Table 4-2, 4-2-1). The inside diameters of used
carbon rings may be slightly larger than new rings. Measuring the carbon rings is difficult,
however, an inside micrometer or snap gauge may be used with a fair degree of accuracy.

The cold clearances may be determined by measuring the inside diameter of the
assembled rings and the diameter of the rotor shaft at sealing areas. The difference
between the measurements is the cold diametral clearance.

An alternate method employing a dial indicator may be used. With the carbon rings
assembled and on the shaft, mount a dial indicator firmly to any part of the casing. With
the dial indicator button reading the top of the carbon ring, zero the dial indicator.
Carefully lift the carbon ring vertically and record the dial reading.

Adjustments
The carbon rings are not adjustable. Replacement is recommended if excessive steam
leaks from the packing cases. Packing case cleanliness is of the utmost importance in
achieving proper carbon ring seating. If an air supply is available, blow out the packing
cases before replacing the carbon rings. For best results, install new carbon rings in
complete sets.

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Labyrinth Seal (BYRHH Turbine Only)

Removal:

1. Unhook the retaining springs surrounding the labyrinth seal, which consists of four
segments.

2. Remove the upper segment by sliding it away from the turbine casing and lifting it off
when out from under the casing. Note location of anti-rotation slot in seal.

3. Remove the lower half segments by rolling around to the top of the shaft then remove
as the first segments.

NOTE
Do not mix the labyrinth segments. Mark the segments so
they can be returned to the original position.

4. Clean the packing case grooves and rotor shaft (taking care to clean axial faces of
grooves). Clean rabbit fit in turbine casing. Check the intermediate leakoff for
blockage or corrosion. Blow out packing case with air.

Replacement:

5. Insert both labyrinth springs into the lower half packing case, under and halfway
around rotor shaft.

6. Insert and roll the lower half labyrinth segments into place. Ensure the segments are
installed properly.

7. Insert the upper half labyrinth segment, positioning the anti-rotation pin slot in the
vertical direction.

8. Align the springs and connect each end of the retaining spring.

Clearances
The cold clearance may be determined by measuring the inside diameter of the
assembled seal and the diameter of the shaft at the sealing area. The difference between
the measurements is the cold diametral clearance.

The design diametral clearance of Class 1 or 2 rotors is .0155" to .018" (0.39 to 0.46 mm),
of a Class 3 rotor is .0135" to .016" (0.34 to 0.41 mm), and of Class 4 or higher rotor is
.0145" to .017" (0.37 to 0.43 mm).

Adjustments
Labyrinth seals are not adjustable. Seals experiencing a high leakage rate or with
clearance of .010" (0.25 mm) greater than design should be replaced.

NOTE
Monitoring and tending of the intermediate leakoff
pressure, by use of a good quality gauge at packing case
leak off, may assist in detecting labyrinth seal wear.
Increased wear will usually result in increased leak off line
pressure.

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TABLE 4-2
MINIMUM/MAXIMUM CARBON RING DIMENSIONS
FOR OPERATING EXHAUST TEMPERATURES to 750°F (400°C)
CYR, CYRH, DYR, DYRH, DYRN, & DYRM TURBINES

OPERATING EXHAUST TEMP. CARBON RING INSIDE DIAMETER

*Class 3 & Higher
*Class 1 & 2 Rotors
Rotors
LIMITS INCHES mm INCHES mm
Min. 2.935 74.55 2.937 74.60
UNDER 300°F (150°C)
Max. 2.936 74.57 2.938 74.63
Min. 2.937 74.60 2.939 74.65
301° TO 400°F (151° TO 204°C)
Max. 2.938 74.63 2.940 74.68
Min. 2.939 74.65 2.941 74.70
401° TO 500°F (205° TO 260°C)
Max. 2.940 74.68 2.942 74.73
Min. 2.941 74.70 2.943 74.75
501° TO 600°F (261° TO 315°C)
Max. 2.942 74.73 2.944 74.78
Min. 2.943 74.75 2.945 74.80
601° TO 700°F (316° TO 370°C)
Max. 2.944 74.78 2.946 74.83
Min. 2.945 74.80 2.947 74.85
701° TO 750°F (371° TO 400°C)
Max. 2.946 74.83 2.948 74.88

TABLE 4-2-1
MINIMUM/MAXIMUM CARBON RING DIMENSIONS
FOR OPERATING EXHAUST TEMPERATURES to 750°F (400°C)
BYRH AND BYRHH TURBINES
OPERATING
EXHAUST CARBON RING INSIDE DIAMETER
TEMP.
*Class 1 & 2 *Class 3B &
*Class 3 Rotors
Rotors Higher
LIMITS INCHES mm INCHES mm INCHES mm
UNDER Min. 2.937 74.60 2.941 74.70 3.256 82.70
400°F (204°C) Max. 2.938 74.63 2.942 74.73 3.257 82.73
401° TO 500°F Min. 2.939 74.65 2.943 74.75 3.258 82.75
(205° TO 260°C) Max. 2.940 74.68 2.944 74.79 3.259 82.78
501° TO 600°F Min. 2.941 74.70 2.945 74.80 3.260 82.80
(261° TO 315°C) Max. 2.942 74.73 2.946 74.83 3.261 82.83
601° TO 700°F Min. 2.943 74.75 2.947 74.85 3.262 82.86
(316° TO 370°C) Max. 2.944 74.78 2.948 74.88 3.263 82.88
701° TO 750°F Min. 2.945 74.80 2.949 74.90 3.264 82.91
(371° TO 400°C) Max. 2.946 74.83 2.950 74.93 3.265 82.93

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Packing Case Assembly

1. Clean packing case flange surfaces and mating turbine casing surfaces.

2. Blow out the packing cases with air.

3. Fill the grooves provided in the packing case vertical flange faces with plastic sealing
compound (³⁄16 inch, 5 mm wide). Cut the sealant to prevent it from extending beyond
the horizontal flange.

4. Apply a thin coat of paste sealing compound to the horizontal flanges and inside bolt
circles of the vertical flange faces (Refer to Figure 4-1).

NOTE
Excessive paste sealant on packing case flanges may
result in sealant entering the packing cases and adhering
to carbon rings. This may prevent the carbon rings from
seating properly. Keep paste sealant approximately ³⁄16
inch (5 mm) away from inside edges of flanges to prevent it
from squeezing into carbon ring chambers.

NOTE
On a BYRHH Turbine, be sure the anti-rotation slot of the
labyrinth seal is vertically positioned in the center of the
rotor shaft.

5. Place top half packing cases in position and replace cap screws (7 & 8, Figure 4-12).

NOTE
Turn cap screws (7) on vertical flange until snug. Tighten
cap screws (8) on horizontal flange, and then tighten cap
screws (7) on vertical flange.

TURBINE CASING – Refer to Figure 4-12

The turbine casing cover (3) must be lifted to inspect or remove the rotor assembly, nozzle
ring (33) or reversing blade assembly (37).

Disassembly

1. If desired, remove top half packing cases as outlined in “Packing Case Disassembly”,
otherwise unbolt the horizontal packing case bolts.

NOTE
The packing case upper halves may remain bolted to the
casing cover.

2. Remove bolts (4) and dowels (5) from the horizontal casing flange.

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3. Carefully lift the casing cover by the eyebolt (60) until it clears the rotor disks (44 &
45).

4. Remove the cover to a safe location. Take care to protect the machined surfaces of
the cover.

Assembly

1. Clean all mating sealing surfaces between the bottom half turbine casing, casing
cover and packing cases. Remove old plastic sealing string from grooves of turbine
cover flanges of BYRH and BYRHH turbines.

2. Apply sealing compounds to the sealing surfaces as shown in Figure 4-1.

NOTE
Do not place plastic string sealant near turbine casing
boltholes. A poor seal may result if sealant enters these
holes. Place new plastic sealing string in grooves of
BYRH, BYRHH, DYR, DYRH, and CYRH turbine covers.

3. Lower the casing cover onto the bottom half casing.

4. Seat the dowel pins (5).

5. Tighten bolts (4) at horizontal casing flange, starting with the bolts located closest to
the packing cases.

6. Replace packing cases (10) as described in “Packing Case Assembly”.

BEARING LINERS – Refer to Figure 4-12

If tilt-pad journal bearings are required, refer to YR Supplement 04-30-02 found in the
Accessories chapter of this manual.

Locating tabs on each bearing liner (15 & 16) engage grooves in the horizontal split of the
steam bearing housing (21 & 53) and exhaust pedestal (12 & 54). This arrangement
retains the liners in the proper position. Units with number 1 or 2 rotors are supplied with
oil rings to provide lubrication during operation or startup/shutdown on pressure lubricated
turbines.

Disassembly

1. Remove any wiring, piping, etc., that would interfere with removing the bearing caps.

2. Remove the dowels (14) and bolts (13) from the bearing cap joints.

3. Break the joints by prying the bearing caps away from the bearing housings.

4. Raise the caps approximately 1 inch (25 mm) and pry the top liners (16) (at the
locating tabs) from the bearing caps with a screwdriver. This will release the oil rings
(49) (if supplied) from the caps.

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CAUTION
Attempting to remove the bearing caps, without prying
out the top bearing liners, can distort the oil rings.
Distorted oil rings will not rotate to provide lubrication,
thereby resulting in bearing failures.

5. Remove bearing caps and the top journal bearing liners.

6. Lift the rotor slightly and remove the bottom bearing liners by rolling them away from
the locating tabs. The rotor shaft will rest on the shaft sleeve seals (47) when the
bottom liners are removed.

Clearances
Bearing liners used with rotors designated Class 1 and 2 provide a cold diametral
clearance of .0075 inch (0.19 mm) to .010 inch (0.25 mm). Diametral journal bearing
clearances are .0055 to .008 inch (0.14 to 0.20 mm) when turbine is equipped with a Class
3 or higher. (Refer to Cold Clearance Diagrams, Figure 4-14, 4-15.)

To Check The Bearing Liner Clearances:

Dimensional Method
This is the most accurate method of measuring diametral bearing clearances.

1. Using a micrometer with an accuracy of 0.0001" (0.0025 mm), measure the shaft
journal at several places (axial and radial). Record and average these readings.

2. With the rotor removed, install the upper and lower half bearing liners in the bearing
housing. Torque the bearing housing bolts. (Refer to Table 4-3.)

3. With an inside micrometer (range of 2 to 3 inches [50.8 mm to 76.2 mm]), measure

the bearing liner bore in several places (axial and radial). Record and average these
readings.

4. Subtract the value obtained in Step 3 from the value in Step 1. This is your cold
diametral clearance.

Plastigage Method – Refer to Figure 4-12

1. With the top liners (16) removed, place a piece of plastigage axially on the shaft
journals.

2. Place the top bearing liners (16) over the shaft journals.

3. Place the oil rings (49) (if supplied) in the slotted guides in the top bearing liners,
taking care so as not to disturb plastigage.

4. Replace the bearing caps. Be sure the top bearing liner locating tabs engage the
grooves in the bearing caps.

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5. Insert dowels (14) and tighten bolts (13). Torque the bearing housing bolts.
(Refer to Table 4-3.)

6. Remove the bolts (13) and dowels (14). Lift the bearing caps approximately 1 inch
(25 mm) and pry the top liners (16) from the caps with a screwdriver.

7. Remove bearing caps and top liners and compare the plastigage thickness to the
sleeve scale provided on the plastigage sleeve. Determine the clearance between
the shaft journals and top bearing liners.

Lift Check Method – Refer to Figure 4-12

1. Place the top bearing liners (16) over the shaft journals.

2. Place the oil rings (49) (if supplied) in the slotted guides in the top bearing liners,
taking care so as not to disturb plastigage.

3. Replace the bearing caps. Be sure the top bearing liner locating tabs engage the
grooves in the bearing caps.

4. Insert dowels (14) and tighten bolts (13). Torque the bearing housing bolts. (Refer to
Table 4-3.)

5. Remove a pipe plug (28) located on top of the bearing cap.

6. Using a dial indicator of 0.0005" (0.0127 mm) accuracy, place the indicator stem
against the shaft and zero the indicator.

7. Carefully lift the shaft until it contacts the top of the bearing. The dial indicator
reading is the diametral clearance. Repeat Step 7 several times to verify correct
readings.

Adjustments
Bearing liners are not adjustable. They should not be filed, scraped, shimmed, fitted or
altered in any way. Worn bearing liners can lead to vibration and other operational
problems. Replace worn bearing liners if the clearances exceed the maximum shown in
the Cold Clearance Diagram by .003 in. (.076 mm). Bearing liners should also be
replaced if inspection shows signs of scoring, wiping, cracking, flaking or loose bonding
between the babbitt and the steel backing.

Assembly – Refer to Figure 4-12

1. Clean the flanges on the bearing caps and housings.

2. Drain and clean bearing housing reservoirs and refill with clean oil.
(Refer to Table 5-1.)

3. Lift the weight of the rotor and roll the bottom bearing liners (15) (bearings; if tilt pad)
around the shaft journals and into the bearing housings. Be sure the liner locating
tabs are firmly seated in the bearing housing locating grooves.

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4. Place the top bearing liners (16) (bearings; if tilt pad) over the shaft journals.

NOTE
With Class 3 or higher rotors, the upper half liner bearing is
a Dam type. Check to see that rotation is into the Dam.

5. Place the oil rings (49), if supplied, in the slotted guides in the top half bearing liners.

6. A thin coat of oil resistant sealant may be applied to the bearing cap flanges, if
desired.

7. Replace the bearing caps. Be sure that the top bearing liner locating tabs engage the
corresponding locating grooves in the bearing caps.

CAUTION
Bearing caps must seat firmly on the bearing
housings. Do not force the caps down by tightening
the bolts. Forcing the caps down will damage the
bearing liners.

8. When the locating tabs are properly seated, replace the dowels (14).

9. Tighten all bolts (13).

WATER COOLED BEARINGS

Provisions for cooling the bearing oil are supplied as standard equipment on oil ring
lubricated turbines. The lubricating oil is cooled by water flow through chambers in the
bottom halves of the steam bearing housing and exhaust pedestal. If water-cooled caps
are supplied, water is directed from lower half bearing housing to the water chamber
located in the cap then to drain.
WATER COOLED CAP
(OPTIONAL)
LUBRICATOR

COOLING
WATER

COOLING DRAIN
TUBE PLUG
 ELLIOTT CO., INC (YR)
FIGURE 4-4
SCHEMATIC VIEW, WATER COOLED BEARING HOUSING

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CAUTION
If the turbine is idle during cold weather, the cooling
water chambers must be drained to prevent damage
from freezing water.

Disassembly – Refer to Figure 4-12

1. Disconnect cooling water piping from the cooling chamber flanges (27).

2. Remove machine bolts (20) from the cooling chamber flanges.

3. Remove the flanges (27), gaskets (19) and cooling tube assemblies (26) from the
bearing housings.

Adjustments

1. During operation, adjust the water flow through the chambers to approximately 2 gpm
(7.5 lpm). Cooling water pressure must not exceed 75 psig (5 bar).

2. Annually inspect the cooling water chambers. Clean as required. (Refer to Table 4-
1.)

Assembly – Refer to Figure 4-12

1. Install new gaskets (19 & 57).

2. Replace the flanges (27) on the cooling chambers.

3. Replace the cooling chamber flange bolts (20) and connect the cooling water piping.

ROTOR ASSEMBLY – Refer to Figure 4-12

The rotor assembly must be removed from the turbine casing before removing or replacing
the following:

1. Oil Rings (49) 5. Nozzle Ring (33)

2. Shaft Sleeve Seals (47) 6. Reversing Blade Assembly (37)
3. Trip Body (52) 7. Bearing Housings (12, 21, 53 & 54)
4. Rotor Locating Bearing (50) 8. Packing Cases (10)

Removal – Refer to Figure 4-12

1. Disconnect the coupling between the turbine and driven machine.

2. Remove the turbine casing cover (3), top half packing cases (10) and carbon rings (9)
as described in “Disassembly” section and “Carbon Ring Replacement” section.

3. Remove the journal bearing liners (15 & 16) (bearings; if tilt pad) as described in
“Disassembly” section.

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4. Disconnect the governor linkage and remove the governor as outlined in the Control
System-Governor, Chapter 6.

5. Place a sling either outside or between the rotor disks (44 & 45), and slowly lift the
rotor approximately 1 inch (25 mm).

DETAIL “A” DETAIL “B”

STRAIGHT PROFILE
DISC ASSEMBLY DISC ASSEMBLY
 ELLIOTT CO., INC (YR)

FIGURE 4-5
ROTOR DISK ARRANGEMENTS

6. Lift the oil rings (49) if supplied, from the bearing housings. Move the rings to the
side so that they are free of the cast bearing liner supports, and then lift the rotor
assembly out of the turbine casing.

CAUTION
Keep the rotor level when lifting to prevent binding it
in the casing or damaging machined surfaces.

CAUTION
Chock the rotor assembly with blocks to prevent it
from rolling when removed from the casing. Also
protect the rotor journals and carbon ring sealing
areas by wrapping them with clean rags or other
suitable covering.

Clearances
Refer to the Cold Clearance Diagram (Figure 4-14 & 4-15) for rotor dimensions.

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Adjustments
The parts of the rotor assembly are not adjustable. Work on the rotor must be done by an
Elliott authorized service shop.

Replacement – Refer to Figure 4-12

1. Lower the rotor assembly to within 1 inch (25 mm) of full replacement in the casing.
Carefully guide the rotor while lowering it into the casing to prevent the disks (44 &
45) from contacting the reversing blade assembly (37).

2. Position the oil rings (49), if supplied, so they fall into the openings between the
bearing liner supports located in the bottom of the bearing housings.

3. Position the anti-rotation tab on the rotor locating bearing (50) to engage the groove
in the steam bearing housing (21).

4. Slowly lower the rotor into the casing.

5. Check bearing housing alignment.

6. Replace the journal bearing liners (bearings; if tilt pad) and caps.

7. Replace the governor and connect the governor linkage (Refer to Control System -
Governor, Chapter 6).

8. Replace the carbon rings (9) top half packing cases (10) as outlined in “Carbon Ring
Replacement” section and turbine casing cover (3) as outlined in “Turbine Casing
Assembly” section.

EXHAUST PEDESTAL REPLACEMENT – Refer to Figure 4-12

The exhaust pedestal (12) is attached to the turbine casing by four socket head cap
screws (23) and two combining studs (17). The combining studs are threaded into the
bottom half turbine casing and pinned to the pedestal.

Two dowel pins (25), pressed into the exhaust end of the turbine casing, position and hold
the pedestal in correct horizontal and vertical parallel alignment with the steam bearing
housing (21). Spacers (24), located between the pedestal and turbine casing, are used to
adjust and maintain proper angular bearing alignment.

Disassembly – Refer to Figure 4-12

1. Remove the rotor assembly as outlined in “Rotor Removal” section.

2. Remove the hold-down bolts and dowel pins from the pedestal support feet.

3. Support the weight of the turbine exhaust end casing with a jack, wooden blocks, or
other adequate means.

4. Remove the tapered pins (18) from the combining studs (17).

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5. Loosen the four cap screws (23) three or four turns and pry the pedestal away from
the casing until the spacers (24) are free to move.

6. Remove the cap screws and spacers. Mark each spacer so it can be returned to the
location from which it was removed.

CAUTION
If spacers (24) are not returned to their original
locations, bearing misalignment may occur. This will
cause uneven bearing wear or possible failure.

7. Slide the pedestal off the combining studs and dowel pins (25).

Clearances
The bearing housing bores should be checked for roundness. The bore should be round
to within .002" (.05 mm).

Adjustments
The bearing case bore is not adjustable. If distortion exists, the bearing case must be
replaced.

Replacement – Refer to Figure 4-12

NOTE
Bearing anti-rotation locating grooves must be provided at
the horizontal split on replacement bearing pedestals.
These grooves may be made by hand filing. Hold the liner
so the tab is on the upstream end for clockwise rotation
(looking in direction of steam flow) and on the downstream
end for counterclockwise rotation. Upper half bearings
with a pressure dam relief must be positioned so rotation is
into the dam. If tilt pad journal bearings are utilized, the
anti-rotation hole will be pre-drilled.

1. Slide the pedestal onto the combining studs (17) and dowel pins (25).

2. Replace the spacers (24) and cap screws (23). Spacers must be returned to the
same locations from which they were removed.

3. Tighten the cap screws (23) and insert the taper pins (18) in the pedestal and
combining studs (17).

4. Replace the rotor assembly as outlined in “Rotor Replacement” section.

5. Replace the bottom half journal bearing liners (15) (bearings; if tilt pad). Check the
bearing alignment and adjust as necessary.

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STEAM BEARING HOUSING REPLACEMENT – Refer to Figure 4-12

The steam bearing housing (21) is attached to the turbine casing by four socket head cap
screws (23). Two dowel pins (25), pressed into the steam end of the turbine casing,
maintain the bearing housing in correct horizontal and vertical parallel alignment with the
exhaust pedestal (12). Spacers (24), located between the housing and turbine casing, are
used to correct any angular misalignment and also to adjust the axial position of the
turbine rotor in the casing.

Disassembly – Refer to Figure 4-12

1. Remove the rotor assembly as outlined in “Rotor Removal” section. Remove the
governor and related housings (Refer to Control System -Governor, Chapter 6).

2. Remove the hold-down bolts and dowel pins from the steam end bearing support
(29).

3. Place a jack, wooden blocks or other adequate support under the steam end of the
turbine casing and steam chest.

4. Remove the bolts (30) securing the support (29) to the bearing housing (21).

5. Loosen the socket head cap screws (23) and pry the bearing housing away from the
turbine casing until the spacers (24) are free to move.

6. Remove the cap screws and spacers. Mark the spacers so they can be returned to
their original locations.

CAUTION
If the spacers (24, Figure 4-12) are not replaced in their
original locations, bearing misalignment may result.
This can cause uneven bearing wear or possible
bearing failure. Nozzle ring to rotating blade clearance
may also be affected, resulting in poor performance or
mechanical failure.

7. Pull the bearing housing off the dowel pins (25).

Clearances
The bearing housing bores should be checked for circularity. The bore should be round to
within .002" (.05 mm).

Adjustments
The bearing case bore is not adjustable. If distortion exists, the bearing case must be
replaced.

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Replacement – Refer to Figure 4-12

NOTE
Bearing anti-rotation locating grooves must be provided at
the horizontal split on replacement bearing pedestals.
These grooves may be made by hand filing. Hold the liner
so the tab is on the upstream end for clockwise rotation
(looking in direction of steam flow) and on the downstream
end for counterclockwise rotation. Upper half bearings
with a pressure dam relief must be positioned so rotation is
into the dam. If tilt pad journal bearings are utilized, the
anti-rotation hole will be pre-drilled.

1. Push the bearing housing onto the dowel pins (25) that are pressed into the steam
end turbine casing.

2. Replace the cap screws (23) and spacers (24). Ensure that the spacers are returned
to the same location from which they were removed.

3. Bolt the support (29) to the bearing housing.

4. Replace the rotor assembly as outlined in “Rotor Replacement” section.

5. Replace the bottom half journal bearing liners (15) (bearings; if tilt pad), check the
bearing alignment and adjust as necessary.

EXHAUST PEDESTAL AND STEAM BEARING HOUSING ALIGNMENT – Refer to

Figure 4-12

To obtain the correct bearing and rotor shaft journal contact the bores of the exhaust
pedestal and the steam bearing housing must be in parallel and angular alignment. Dowel
pins (25), pressed into the turbine casing, position the pedestal and bearing housing in
horizontal and vertical parallel alignment. Spacers (24), located between the pedestal and
turbine casing and between the steam bearing housing and turbine casing, are used to
correct any angular misalignment and to position the turbine rotor axially in the turbine
casing.

To Check The Bearing Housing Alignment

1. Remove the rotor assembly from the turbine casing and clean the shaft journals.

2. Install bottom half journal bearing liners (15) (bearings; if tilt pad) in the bearing
pedestal and steam bearing housing. Be sure the liners are properly seated. Liners
should be clean and free of any oil.

3. Apply a very light coating of Prussian blue to both shaft journals.

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4. Lower the rotor assembly until the full weight of the rotor is supported by the journal
bearing liners (bearings; if tilt pad).

NOTE
Bolting down of the bearing caps will ensure bearings are
seated.

5. Rotate the rotor assembly slowly one turn in the direction of rotation.

NOTE
Ensure the rotor shaft is seated on the bottom of the
bearing liners and not moving sideways or upward while
being rotated.

6. Remove the rotor assembly from the turbine casing and check the bearing contact.

NOTE
The exhaust pedestal and steam bearing housing are
considered to be in alignment when bearing contact with
the shaft journals is no less than 85% along the bottom of
the bearing liners and when the contact along the sides of
the liners is parallel with the bearing bore and equal on
each side (See Figure 4-6).

CORRECT
BEARING
CONTACT

CONTACT INDICATES
VERTICAL ANGULAR
MISALIGNMENT

CONTACT INDICATES
HORIZONTAL ANGULAR
MISALIGNMENT

 ELLIOTT CO., INC (YR)

FIGURE 4-6
JOURNAL BEARING AND ROTOR SHAFT CONTACT

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To Correct Any Misalignment

1. Place shim stock, in increments of .002 inch (0.05 mm), behind the spacers (24) to
correct the misalignment.

2. Recheck the bearing contact and continue to add shims to achieve proper alignment.

3. After the correct bearing contact is obtained, the shims must be removed from each
spacer, and the thickness of the opposite spacer altered accordingly. (Surface
grinding is the preferred method.)

EXAMPLE
If it is necessary to add .004 inch (0.10 mm) shim
thickness to the two bottom spacers to achieve correct
alignment, .004 inch (0.10 mm) must be ground from the
two top spacers to maintain the alignment after the shims
are removed.

4. Recheck the bearing contact, after the ground spacers have been installed.

ROTOR LOCATING BEARING – Refer to Figure 4-12

(If double acting thrust bearing is supplied, see supplement 03-91 located in Chapter 8 -
Accessories.)

The rotor locating bearing (50) maintains the correct axial position of the rotor assembly to
the nozzle ring. The bearing is mounted on the rotor shaft with the shielded side of the
bearing toward the trip body. A beveled retainer ring (51) holds the bearing in place on
the rotor shaft. The outer bearing race fits into a groove in the steam bearing housing (21)
and is prevented from rotating by an anti-rotation tab, which is permanently attached to the
outer race. The anti-rotation tab fits into a slot at the horizontal split of the bearing
housing.

Clearances
To check the axial bearing clearance, an axial rotor float check must be made:

1. Mount a dial indicator perpendicular to a vertical shaft face (such as the coupling hub
or a rotor disk).

2. Shift the rotor as far as possible in both axial directions while observing the dial
indicator. The normal axial rotor float is from .010 inch (0.25 mm) to .018 inch (0.46
mm). In no case should the total indicator reading exceed .025 inch (0.64 mm).

NOTE
Excessive axial float may be the result of bearing case
wear. If wear is found in rotor locating bearing groove, the
bearing case must be replaced.

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Disassembly

1. With the rotor removed from the turbine casing, disassemble and remove the trip
body as described in “Trip Body Removal” section.

2. Remove the retainer ring (51) with ring expanding pliers.

3. Remove the locating bearing (50) with a bearing puller.

Adjustments
The rotor locating bearing is not adjustable. A rotor locating bearing must be replaced
when the axial rotor float reaches .025 inch (0.64 mm).

Assembly

1. Heat the bearing in an oil bath to 200F (94C). Install the bearing on the shaft by
using a sleeve-type bearing driver that contacts only the inner bearing race. Seat the
bearing solidly against the machined shoulder on the shaft (43).

NOTE
Do NOT use an open flame to heat ball bearings.

NOTE
Be sure the shielded side of the bearing is positioned
toward the trip body (52).

2. Replace the retainer ring (51). Seat the ring firmly in the groove on the rotor shaft,
with the beveled edge of the ring positioned toward the trip body.

3. Replace the trip body as outlined in “Trip Body Replacement” section.

4. Flush the locating bearing with oil before replacing the bearing cap.

NOZZLE RING AND REVERSING BLADE ASSEMBLY – Refer to Figure 4-12

The nozzle ring (33) directs the steam flow from the steam ring to the buckets of the first
rotor disk (44). Steam exits the buckets of the first disk and passes through the reversing
blade assembly (37) that directs it into the buckets on the second rotor disk (45). The
reversing blade assembly is positioned between the two rotor disks and is bolted to the
nozzle ring. Two styles of reversing blade assembly may be supplied. The standard
version uses a straight-sided holder to fit the bucket in position. It is positioned through
the use of spacers. The holder must be correctly installed for the proper rotation. The tip
seal version is used to increase stage efficiency by limiting radial steam leakage from the
buckets. It is mounted to the nozzle ring with bolts and spacers. Clearances must be
checked on reinstallation.

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ROTOR DISC
BUCKETS

NOZZLE
RING

TO
EXHAUST

NOZZLE

FROM
STEAM ROTATION
INLET

STATIONARY
REVERSING
BUCKETS
 ELLIOTT CO., INC (YR)

FIGURE 4-7
NOZZLE RING AND REVERSING BLADE ARRANGEMENT

Disassembly

1. Remove the rotor assembly as outlined in “Removal” section.

2. Remove the bolts (38), lockwashers (39), and spacers (40), and lift out the reversing
blade assembly (37). Mark each spacer (40) so that it may be returned to its original
location.

3. Remove the nozzle ring bolts (34 & 36), lockwashers (35) and nozzle ring (33) from
the casing.

Clearances
The clearance between the nozzle ring (33) and the shroud on the first rotor disk (44) must
be checked whenever the rotor assembly, nozzle ring or reversing blade assembly is
removed or replaced. This clearance is a minimum of .050 inch (1.27 mm) and a
maximum of .072 inch (1.83 mm). The clearance can be measured with a feeler gauge on
the left and right of the turbine. The clearance must be taken with the rotor in running or
downstream position. (Thrust toward driven machine.)

Adjustments
Inspect the nozzle ring and reversing blade assembly annually. Clean scale or boiler
compound deposits as necessary. Replace eroded parts as needed. The nozzle ring
clearance is adjustable by changing thickness of washers at steam bearing housing.

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Assembly

1. Clean the casing and nozzle ring sealing surfaces.

2. Apply a thin coat of paste type sealer and plastic string compound to the nozzle ring
sealing surface on the steam end turbine casing (Reference Figure 4-1).

3. Apply anti-galling compound to the threads of the nozzle ring bolts (34 & 36).

NOTE
When inspecting the nozzle ring and reversing blade
holder, the reuse of bolts is not recommended. New bolts
and lockwashers should be used. The bolts used are
specially treated to withstand the pressures and
temperatures of steam turbines.

4. Bolt the nozzle ring to the turbine casing. Be sure that lockwashers (35) are used
with all bolts.

5. Place lockwashers (39) on the reversing blade assembly bolts (38) and apply anti-
galling compound to the bolt threads. Put the bolts through the holes in the reversing
blade assembly and slip the spacers (40) over the bolts.

6. Position the reversing blade assembly (37) in the turbine casing and bolt it to the
nozzle ring (33).

NOTE
Be sure the reversing blade assembly is installed in the
same location from which it was removed so that it covers
all the nozzles and overlaps the end nozzles by a minimum
of five blades. The reversing blade trailing edges must
point in the same direction as the nozzles.

7. If a tip seal reversing blade assembly is used, check clearances per Fig. 4-16.
Adjustment can be done by loosening bolts and repositioning the holder.

8. Return the rotor assembly to the turbine casing.

SHAFT SLEEVE SEALS – Refer to Figure 4-12

Three seals (47) mounted on the rotor shaft, prevent oil leakage from the steam bearing
housing (21) and exhaust pedestal (12 & 54). The seals also restrict the entry of steam,
dust and dirt into bearing housings.

Disassembly

1. Remove the rotor assembly from the turbine casing as described in Chapter 4
“Removal” section.

2. Remove the drive coupling from the rotor shaft.

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3. Remove the trip body (52) and rotor locating bearing (50) from the rotor shaft.

4. Remove the two set screws (48) from each sleeve seal (47) and slide the sleeve off
the rotor shaft (43).
Replacement And Adjustment
1. Place sleeve seals (47) on the rotor shaft (43).

2. Replace the rotor locating bearing (50) and trip body as outlined in Chapter 4
“Assembly” section.

3. Install the drive coupling on the rotor shaft.

4. Return the rotor assembly to the turbine casing.

4. Position the shaft sleeve seals to provide the axial clearances shown in Figure 4-14,
4-15.

5. Tighten set screws (48) to lock the sleeves (47) in position on the shaft.

NOTE
The tops of the set screws must be below the outside
diameter of the sleeve seals. Care must also be taken to
avoid distorting shaft sleeve seals when tightening the set
screws. It may be helpful to spot the shaft with a drill to
get the proper depth.

7. Peen sleeve metal over set screws to lock set screw in place.

8. Replace the casing cover (3) and bearing caps.

Clearances

1. Disassembly is not required to check axial clearances. (H, L & M, Cold Clearance
Diagram.)

2. Remove bearing caps to check radial clearances (A, Cold Clearance Diagram) with
feeler gauges.

OVERSPEED TRIP SYSTEM – Refer to Figure 4-8

The overspeed trip pin assembly is contained in the trip body mounted on the turbine rotor
shaft. When the turbine speed increases above the rated operating speed, centrifugal
force exerted on the trip pin (1, Figure 4-8) increases. When the centrifugal force
overcomes the force of the trip pin spring (2), the weighted end of the pin protrudes from
the trip body. The pin strikes the plunger assembly (7), forcing it against the adjustable
jack screw (8) in the bottom of the hand trip lever. The lever pivots on a shoulder stud,
causing the top of the lever to move away from the resetting lever. This movement
disengages the latch from the resetting lever knife edge and allows the closing spring to
pull the trip valve closed. This stops the steam flow through the turbine.

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-WARNING-
UNDER NO CIRCUMSTANCES SHOULD THE TRIP
VALVE BE BLOCKED OR HELD OPEN TO RENDER
THE TRIP SYSTEM INOPERATIVE. OVERRIDING THE
TRIP SYSTEM, AND ALLOWING THE TURBINE TO
EXCEED THE RATED (NAMEPLATE) TRIP SPEED,
MAY RESULT IN FATAL INJURY TO PERSONNEL AND
EXTENSIVE TURBINE DAMAGE. ALWAYS CLOSE ALL
ISOLATING VALVES AND OPEN DRAINS TO
DEPRESSURIZE THE TURBINE CASING AND STEAM
CHEST BEFORE PERFORMING MAINTENANCE ON
THE OVERSPEED TRIP SYSTEM.

Class 3 and higher rotors will have a QV Trip mechanism; these are described in
supplement 01-77 in Chapter 8 - Accessories.

Disassembly, Standard YR Overspeed Trip Mechanism

NOTE
To check the trip pin for cracks, it is recommended that
either the zyglow or dye check method be used. The “U”
lock staples should also be examined for nicks or cracks.
The overspeed trip pin assembly can be checked by
monitoring the frequency of overspeed trips. Check the
assembly at least every 30 overspeed trips and at 2 year
intervals.

1. Remove the steam bearing housing cap as outlined in Chapter 4 – “Bearing Liners,
Disassembly” section.

2. Remove the “U” lock staple (3), surrounding the adjusting nut (4), by prying it out of
the trip body.

3. Remove the adjusting nut, trip spring (2) and washers (5), if provided.

NOTE
Record the number of turns required to remove the
adjusting nut (4) so it can be returned to its original setting
during assembly.

4. Rotate the rotor shaft 180° and remove the “U” lock staple surrounding the weighted
end of the trip pin (1).

5. Remove the trip pin from the trip body. (Remove the auxiliary weight [6], if furnished).

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Trip Body Removal – Refer to Figure 4-12

1. Remove the rotor assembly from the turbine casing.

2. Remove the set screw from the trip body (52).

3. Heat the trip body evenly with a torch. Apply heat as rapidly as possible, and then
pull the trip body from the rotor shaft.

CAUTION
Care must be exercised to prevent heating the rotor
locating bearing and the rotor shaft when heating the
trip body. Protect both by wrapping in insulated cloth.

Plunger Assembly Replacement – Refer to Figure 4-12

The plunger assembly (7) can be removed by lifting it out of the bearing housing while the
rotor assembly is out of the turbine casing. (Except turbines equipped with bearing
housings having a flanged governor fit such as PG, UG and O Governors.) Turbines
equipped with a flanged governor mount employ an “Umbrella” plunger. A retainer ring,
washer and spring arrangement must be removed from the bottom of the “Umbrella”
plunger before lifting it from the bearing housing. (See Chapter 6 for applicable details for
“Umbrella” Plunger removal.)

If necessary, worn plunger assemblies can be replaced without removing the rotor
assembly. To remove the plunger assembly:

1. Remove the steam bearing cap.

2. Remove the governor and adapter piece from the steam bearing housing.

3. Loosen the jam nut (10) and remove set screw (11) from the side of the bearing
housing.

4. Remove the set screw from the plunger assembly and separate the two halves of the
plunger to remove them from the bearing housing.

5. Assemble in reverse order.

NOTE
When replacing the plunger assembly in this manner, both
parts of the new plunger assembly must be installed.

Trip Body Replacement

1. Heat the trip body in hot oil or an oven. Do not exceed 500°F (260°C).

NOTE
It may be helpful to chill the turbine shaft end before
installing the trip body.

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2. Place the heated trip body on the rotor shaft and align the set screw hole in the trip
body with the dimple in the shaft.

3. Tighten the set screw to ensure proper positioning on the shaft, and then back the
set screw out of the body 1 or 2 turns.

4. Tighten the set screw when the trip body has cooled to ambient temperature.

5. Check the trip body runout. Runout should not exceed .003 inch (0.07 mm) on the
outboard end of the trip body.

6. Correct the trip body runout, if necessary, then peen metal over the set screw to
lock set screw.

7. Check that the plunger assembly (7) is properly positioned in the bearing housing,
and return the rotor to the turbine casing.

Assembly, Overspeed Trip Mechanism

1. If furnished, place the auxiliary weight (6) on the trip pin (1).

NOTE
The auxiliary weight is typically used for trip speeds from
2400 to 3100 rpm. Check the Turbine Operating Data
page of this book for design trip speed of this turbine.

2. Insert trip pin (1) into the trip body. Position the weighted end of the pin on the
opposite side of the trip body set screw.

3. Press the “U” lock staple (3) into the trip body to secure the weighted end of the
trip pin. Be sure the staple is fully seated in the circular groove in the trip body.
Install lock wire (18 gauge) and secure as shown in Figure 4-8.

4. Place the trip spring (2) in the trip body. (Install washers [5], if furnished.)

5. Return the adjusting nut (4) to its original setting, by tightening the nut the same
number of turns recorded during disassembly.

6. Press the “U” lock staple (3) into the trip body to lock the adjusting nut (4). Be sure
the staple is fully seated in the circular groove in the trip body.

7. Using a suitable blunt end tool, press on the nut end of the trip pin and verify the
trip pin slides in the circular groove in the trip body

-WARNING-
OVERSPEED TRIP SYSTEM MALFUNCTION CAN
RESULT IN INJURY TO PERSONNEL AND/OR
EXTENSIVE TURBINE DAMAGE. FOR THIS REASON,
THE TRIP SYSTEM MUST BE TESTED TO ENSURE ITS
OPERATIONAL RELIABILITY AFTER PERFORMING
MAINTENANCE OR MAKING ADJUSTMENT TO IT.

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KNIFE RESETTING
HAND TRIP LEVER LEVER
EDGE

12

CLOSING
SPRING(S)

LATCH

SHOULDER
STUD TRIP VALVE
ASSEMBLY

1.58mm 1/16"
11

10

7 STEAM
9 INLET

3
4
5
TRIP

2
1
ITEM NUMBER DESCRIPTION QUANTITY

6 4-8-1 TRIP PIN 1

2 TRIP SPRING 1
3 3 "U" LOCK STAPLE 2
4 ADJUSTING NUT 1
5 WASHER *
6 AUXILIARY WEIGHT 1*
7 PLUNGER ASSEMBLY 1
8 JACK SCREW 1
9 JAM NUT 1
10 JAM NUT 1
11 SET SCREW 1
12 INSPECTION PLUG 1
OVERSPEED
TRIP PIN ASSEMBLY * INDICATES PART NOT USED ON ALL TURBINES OR
VARIABLE QUANTITIES

 ELLIOTT CO., INC (YR)

FIGURE 4-8
OVERSPEED TRIP SYSTEM

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Adjusting The Trip Pin And Plunger Clearance – Refer to Figure 4-8

1. Remove the inspection plug (12) from the steam bearing housing cap.

2. Rotate the rotor shaft, by hand, until the adjusting nut (4) can be observed through
the inspection hole. This will position the weighted end of the trip pin (1) directly
above the plunger assembly (7).

3. Latch the resetting lever and loosen the jam nut (9) on the trip lever jack screw (8).

4. Push the plunger assembly (7) upward and into the bearing housing, until it is in solid
contact with the trip pin.

5. Adjust the jack screw to obtain ¹⁄16 inch (1.6 mm) clearance between the base of the
plunger (7) and the jack screw (8).

6. Tighten the jam nut (9) and recheck the clearance.

CAUTION
The jam nut (9) must be locked, at all times, to prevent
the jack screw from vibrating loose during operation.
A loose jack screw can render the trip system
inoperative.

Adjusting The Turbine Trip Speed

1. Remove the inspection plug (12) from the steam bearing housing cap.

2. Rotate the rotor shaft, by hand, until the adjusting nut (4) can be viewed through the
inspection hole.

3. Latch the resetting lever (8, Figure 4-13).

4. Place a non-ferrous drift pin on the adjusting nut and strike the drift pin sharply to
ensure that the trip pin (1), trip valve and trip linkage function properly.

5. Latch the resetting lever and start the turbine. Closely monitor the turbine speed
during operation.

6. Gradually overspeed the turbine by overcoming the governor (Refer to Control

System-Governor, Chapter 6).

CAUTION
Do not allow turbine to exceed 2% above the rated
(nameplate) trip speed.

7. If the overspeed trip does not function within 2% of the rated trip speed, manually trip
the turbine by striking the top of the hand trip lever. Then close the steam inlet shut-
off valve.

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8. When the rotor shaft stops rotating, turn the shaft, by hand, until the adjusting nut is
visible through the bearing cap inspection hole.

9. Partially pry the “U” lock staple away from the trip body until the adjusting nut is free
to turn.

10. Turn the adjusting nut to change the trip speed. Turning the nut counterclockwise will
decrease the trip speed. Turning the nut clockwise will increase the trip speed.

11. Push the “U” lock staple into the trip body, and check that the trip pin (1) moves
freely. (Be sure staple is firmly seated.)

12. Start the turbine and check the trip speed. Continue to make trip adjustments until
the turbine trips at the rated (nameplate) trip speed. Final trip speed must be verified
3 times to ensure consistent readings.

Disassembly, Trip Valve – Refer to Figure 4-13

-WARNING-
CLOSE ALL ISOLATED VALVES AND OPEN DRAINS
TO DEPRESSURIZE TURBINE CASING AND STEAM
CHEST BEFORE PERFORMING MAINTENANCE ON
THE TRIP VALVE, GOVERNOR VALVES OR
LINKAGES.

1. Place the trip valve in the tripped position and disconnect the closing spring (11 and
45) from the resetting lever (8).

NOTE
On some units, only one closing spring may be supplied.

2. Remove nut (12), spring seat (36), spring (37), bushing (39) and spring seat (38) from
the valve stem.

CAUTION
Firmly grasp spring (37) to prevent rapid
decompression while removing locknut (12).

3. Remove the cap screws (4) from the valve cover (3) and lift the trip valve assembly
(17) and cover from the steam chest body (1).

4. Turn the valve stem out of connection (42) and remove the valve assembly (17) from
the cover (3).

Guide Bushing Replacement

1. Disassemble the trip valve as described above in “Disassembly, Trip Valve” section.

2. Use a small grinder to remove upset metal.

3. Drive the bushings (13) out of the valve cover (3) with a non-ferrous drift pin.

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4. Clean and de-burr the valve cover.

5. Press new bushings into the valve cover and lock them in place by peening metal
over bushing.

6. Assemble the valve as outlined in the “Trip Valve” section.

Assembly, Trip Valve – Refer to Figure 4-13

1. Clean the sealing surfaces on the valve cover flange and the steam chest body.

2. Insert the trip valve assembly into the guide bushings (13) and through the valve
cover.

3. Turn the valve stem into and through connection (42).

4. Apply a combination of paste and ¹⁄16" (1.6 mm) diameter plastic string sealants to the
sealing surfaces of the steam chest flange.

5. Return the valve assembly and cover to the steam chest body and tighten the cap
screws (4).

6. Replace spring seat (38), bushing (39), spring (37), spring seat (36) and locknut (12).

7. Backseat the trip valve per Chapter 4 “Backseating the Trip Valve” section, and
connect the closing spring (11 & 45) to the resetting lever (8).

Backseating The Trip Valve – Refer to Figure 4-9

1. Disassemble and inspect the trip valve and linkage to ensure cleanliness of all parts.
Replace worn linkage pins, guide bushings, valve stem, knife edge, latch, etc.

2. Reassemble the trip valve and linkage per Chapter 4, “Assembly, Trip Valve” section.

3. Disconnect closing spring (11, 45) from resetting lever (8).

4. Remove locknut (12) from trip valve stem (17).

CAUTION
Firmly grasp spring (37) to prevent rapid
decompression while removing locknut (12).

5. Raise connection (42) to backseat the valve (17) against the lower guide bushing (13)
by prying against the bottom of connection (42) and the valve cover (3) with a long
screwdriver as shown in Figure 4-9.

CAUTION
Do not bend trip valve stem when prying with
screwdriver.

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Maintenance

6. Slightly release the pressure on the screwdriver and turn valve stem (17) in or out of
connection (42) to provide .12 inch (3 mm) overlap between the bottom of the
resetting lever (8) knife edge and the top of the hand trip lever (26) latch. Turning the
valve stem (17) clockwise (rotation viewed from top of trip valve) decreases the
overlap; counterclockwise increases the overlap.

NOTE
Turning the valve stem in small increments will have great
effect on the overlap adjustment. Care must be taken to
prevent over adjusting.

7. Replace and fully tighten locknut (12) until the upper spring seat (36) is firmly seated
against bushing (39). Prevent the valve stem from turning by placing a wrench on
the valve stem flats (17) located below the connection (42).

TURN VALVE STEM (17) IN OR OUT OF CONNECTION (42) SCREW

UNTIL THE BOTTOM OF RESETTING LEVER (8) KNIFE DRIVER
EDGE IS 0.12 in. (3 mm) BELOW TOP OF HAND TRIP
LEVER (26) LATCH WITH VALVE (17) BACKSEATED 12
AGAINST BUSHING (13). 36
26 39 37
KNIFE EDGE
42

8
LATCH

3
11, 45

13

17

STEAM
INLET

Note
This drawing not to be used for ordering
replacement parts (see Figure 4-13).
 ELLIOTT CO., INC (YR)

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 Chapter 4
Maintenance

FIGURE 4-9
BACKSEATING THE TRIP VALVE

8. Raise the resetting lever (8) until the valve (17) backseats against bushing (13) and
check that the bottom of the resetting lever (8) knife edge is still .12 inch (3 mm)
below the top of the hand trip lever (26) latch.

9. Latch the resetting lever and verify that spring (37) compresses.

CAUTION
If spring (37) does not compress, readjustment is
required.

10. Reconnect closing spring (11, 45) and check trip valve operation.

Trip System Linkage – Refer to Figure 4-13

1. Frequently inspect the trip system linkage for cleanliness and freedom of movement.

2. Replace pin (5), bushing (6), blocks (41) or shoulder stud (29) if the linkage develops
excessive play.

3. Lubricate the linkage pins and shoulder stud with a high temperature water resistant
silicone grease.

Trip System Clearances – Refer to Figure 4-13

1. With the resetting lever latched, maintain ¹⁄16 inch (1.6 mm) clearance between the
weighted end of the trip pin (1, Figure 4-8) and plunger assembly (7, Figure 4-8).

2. The diametral clearance between the valve cover bushings (13) and the trip valve
stem should be .008 to .010 inch (0.20 to 0.25 mm).

3. To ensure positive backseating, adjust the trip valve to provide .12 inch (3 mm)
overlap between the resetting lever knife edge (9) and the hand trip lever latch (27).

4. The resetting lever knife edge (9) and latch knife edge (27) must overlap
approximately ¹⁄8 inch (3 mm) when the resetting lever (8) is latched.

NOTE
Latch knife edge (27) can be rotated in 90° increments to
provide a new latching surface for the resetting lever knife
edge (9). The resetting lever knife edge (9) can be rotated
180° to provide a new mating surface for the latch knife
edge (27). Replace the knife edge and latch when
adjustment can no longer be made to compensate for worn
latching surfaces.

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Chapter 4
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GOVERNOR VALVE – Refer to Figure 4-13

-WARNING-
CLOSE ALL ISOLATING VALVES AND OPEN DRAINS
TO DEPRESSURIZE TURBINE CASING AND STEAM
CHEST BEFORE PERFORMING MAINTENANCE ON
THE GOVERNOR VALVE OR ITS LINKAGE.

The governor valve (15), located in the steam chest body (1), regulates the steam flow
through the turbine. The valve is positioned through mechanical linkage by the speed
governor.

Disassembly – Refer to Figure 4-13

1. Remove the linkage connecting the governor valve to the governor.

2. Remove bolts (47) from the valve cover (22, 31) and pull the cover and valve (15)
away from the steam chest body (1).

3. Remove the valve stem connection (32) and jam nut (33) from the valve stem (14)
and remove the stem from the cover assembly.

4. The valve seat (23) has a shrink fit in the steam chest. The governor valve seat is
secured by three pins that are pressed into the governor valve cover. Check to
ensure these pins are removed with the cover.

5. Chill the valve seat (23), by packing with dry ice (C02), and pull the seat from the
steam chest with a puller.

CAUTION
Do not use other cryogenic material such as liquid
nitrogen to shrink the valve seat.

Clearances – Refer to Figure 4-13

1. The governor valve must move freely at all times. A smooth sliding fit is necessary
between the valve stem (14) and the packing (19, 30), and between the stem and
guide bushings (18, 24).

2. The governor lever and linkage should also be smooth sliding fits. The governor
valve travel should be set in accordance with the value shown on the Turbine
Operating Data page.

Adjustments – Refer to Figure 4-13

1. With the governor valve and linkage fully assembled:

a. With governor servo in full open position, turn the valve stem (14) from the
connection (32) until the valve is fully seated.

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 Chapter 4
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b. Adjust the jam nut (33) so the distance between the jam nut and connection
(32) is equal to the valve travel dimension shown on the Turbine Operating
Data page.

c. Screw the valve stem into the connection until the jam nut contacts the face
of the connection.

d. Lock the jam nut by tightening it against the connection.

2. Replace the governor linkage pins and bushings if the linkage becomes loose fitting
or if excessive play is evident.

3. Inspect the governor valve stem (14) and guide bushings (18, 24) for wear and
replace as necessary.

4. Remove the packing follower (21) and replace the valve stem packing (19, 30) if
excessive steam leakage is evident. (See Details A & B, Figure 4-10.)

NOTE
Do not over tighten the packing follower (21). The
governor valve stem can bind in the valve cover and result
in erratic speed control.

5. Lubricate the governor linkage pins with high temperature, water resistant silicone
grease.

Assembly – Refer to Figure 4-13

1. Chill the valve seat (23) with dry ice (C02) and press it into the steam chest body (1).

CAUTION
Do not use other cryogenic material such as liquid
nitrogen to shrink the valve seat.

NOTE
During installation of the governor valve seat, position the
valve seat to ensure steam flow is directed between the
governor valve seat ribs and not directed at a rib section.

2. Weld blocks to the steam chest (180° apart) to secure the valve seat. Leave .010"
(.25 mm) clearance between the valve seat (23) and blocks (25).

NOTE
Do not weld blocks (25) to the governor valve seat (23).
This may distort seating surfaces.

If using the ring in place of the welded blocks, measure the depth of the valve seat
from the face of the steam chest cover. Measure the rabbit fit step height on the
steam chest cover. Subtract the rabbit height plus .015" (.38 mm) from the valve seat
depth and grind the face of the valve seat ring to obtain this thickness.

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100qc.chap04.5/15/2009

Maintenance
Chapter 4
GOVERNOR VALVE GOVERNOR
COVER VALVE COVER
PACKING
RINGS (8)
PACKING GLAND PACKING
GOVERNOR FOLLOWER
VALVE STEM GOVERNOR VALVE GLAND
STEM FOLLOWER

GUIDE GUIDE
PACKING RINGS (7) LANTERN
BUSHING BUSHING RING
LEAKOFF
CONNECTION

DETAIL “A” DETAIL “B”

Detail “A” shows Governor valve cover Detail “B” shows Governor valve cover
and packing arrangement usually used and packing arrangement for inlet steam
for inlet steam conditions below 250 psig conditions above 250 psig (17.2). The
(17.2 bar), the packing arrangement packing arrangement consists of 7
consists of 7 packing rings packing rings, a lantern ring, followed by
1 packing ring.
724-527-2811

 ELLIOTT CO., INC (YR)

4-38
 Chapter 4
Maintenance

3. Place the governor valve stem (14) in the valve cover (22, 31).

4. Replace connection (32) and jam nut (33) on the valve stem (14).

5. Clean the joint between the valve cover (22, 31) and the steam chest body (1). Apply
a combination of paste and plastic string sealing compounds on the sealing surfaces.

6. Replace the cover and tighten bolts (47).

7. Connect the governor valve linkage and adjust the valve travel.

OVERLOAD HAND VALVE – Refer to Figure 4-11

-WARNING-
CLOSE ALL ISOLATING VALVES AND OPEN DRAINS
TO DEPRESSURIZE TURBINE CASING AND STEAM
CHEST BEFORE PERFORMING MAINTENANCE ON
THE HAND VALVE ASSEMBLIES.

Disassembly

The hand valve assembly is bolted to the bottom half steam end turbine casing.

1. Remove cap screws (8) to remove hand valve from casing.

2. Use 2 of the cap screws removed in tapped holes (180° apart) as jack screws to back
the overload valve from the casing.

Adjustments

1. Keep the valve stem packing (4) tight by adjusting the packing follower (2).

2. Replace the packing when follower adjustment no longer prevents steam leakage
along the valve stem.

Assembly

1. Clean the casing and overload valve flange of all sealant.

2. Apply a thin coat of paste type sealing compound on the valve body flange.

3. Coat the cap screw threads (8) with an anti-galling compound.

4. Bolt the valve body to the turbine casing and tighten.

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Chapter 4
Maintenance

EXHAUST
CONNECTION
STATIONARY REVERSING
BLADE ASSEMBLY BUCKETS

SECOND ROW OF
ROTOR BUCKETS

FIRST ROW OF
ROTOR BLADES

NOZZLE
RING

STEAM
VALVE #2 VALVE #1 RING

8, 9 4 STEAM FROM
GOVERNOR VALVE
1
2
12

10, 11
3

ITEM NUMBER DESCRIPTION QUANTITY

4-11-1 HAND VALVE ASSEMBLY 1

2 FOLLOWER 1
3 STEM & DISC ASSEMBLY 1
4 PACKING 1 SET
7 SCREW 1
8 CAP SCREW 6
9 LOCKWASHER 6
10 CAP SCREW 4
11 LOCKWASHER 4
12 COVER 1

 ELLIOTT CO., INC (YR)

FIGURE 4-11
OVERLOAD HAND NOZZLE VALVE ASSEMBLY

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 Chapter 4
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PARTS LIST
(Refer to Figure 4-12)

FIGURE ITEM NO. DESCRIPTION QUANTITY

1 Casing, Steam End 1
2 Casing, Exhaust End 1
3 Casing Cover 1
4 Machine Bolt (Cover), CYR 26
Studs/Nuts CYRH 28
Machine Bolt (Cover), DYR 28
Studs/Nuts DYRH 32
Studs/Nuts (Cover), BYRH, BYRHH 18
5 Taper Dowel/Nut (Cover) 4
6 Machine Bolt (Casing), CYR 17
Machine Bolt (Casing), DYR 21
Machine Bolt (Casing), BYRH, BYRHH 20
7 Cap Screw, Packing Case (Vertical) 24
8 Cap Screw, Packing Case (Horizontal) 8
Cap Screw, Packing Case, BYRH, BYRHH (Horizontal) 10
9 CARBON RING ASSEMBLY, CYR, DYR, BYRHH 8
CARBON RING ASSEMBLY, BYRH 14
10 Packing Case 2
11 Set Screw 1
12 Exhaust pedestal And Cap 1
13 Machine Bolt (Bearing Caps) 10
14 Taper Dowel/Nut (Bearing Caps) 4
152 BEARING LINER, BOTTOM 2
161,2 BEARING LINER, TOP 2
17 Combining Stud (Exhaust pedestal) 2
18 Pin, Combining Stud 2
193 Gasket, Water Cooling Flange 2
20 Machine Bolt, (Water Cooling Flange) 12
21 Bearing Housing and Cap (Steam End) 1
224 Oiler 2
23 Cap Screw, Bearing Case & Pedestal to Casing 8
24 Spacer (Between Bearing Case & Pedestal to Casing) 8
25 Dowel, Bearing Case & Pedestal to Casing 4
263 Cooling Tube Assembly 2
273 Flange, Water Cooling 1
28 Pipe Plug, Oil Ring Inspection 6
29 Support, Steam End Bearing Case 1
30 Machine Bolt, Support 2
31 Lock washer 2
32 Nut, Support 2
33 Nozzle Ring 1
34 Nozzle Ring Cap Screw (Special Inner Radius), BYRH, BYRHH 14
Nozzle Ring Cap Screw (Special Inner Radius), CYR 18
Nozzle Ring Cap Screw (Special Inner Radius), DYR 24
35 Lockwasher, CYR, BYRH, BYRHH 36
Lockwasher, DYR 48
36 Cap Screw (Special Outer Radius), CYR, BYRH, BYRHH 22
Cap Screw (Special Outer Radius), DYR 24
37 REVERSING BLADE ASSEMBLY 1
38 Cap Screw, Reversing Blade 6
39 Lockwasher 6
40 Spacer, Reversing blade 6
41 Stud, Steam Chest To Casing 10

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Chapter 4
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PARTS LIST - Continued

(Refer to Figure 4-12)

FIGURE ITEM NO. DESCRIPTION QUANTITY

42 Nut, Steam Chest To Casing 10

43 Rotor Shaft 1
447 1st Disk Assembly 1
457 2nd Disk Assembly 1
46 Key, Disk 2
47 SLEEVE SEAL 3
48 Set Screw 6
496 OIL RINGS 4
50 ROTOR LOCATING BEARING 1
51 Retaining Ring 1
52 Trip Body 1
53 Bearing Housing W/Water Cooled Cap (*Steam End) 1
54 Bearing Pedestal W/Water Cooled Cap (Exhaust End) 1
555 ¾" Pipe Plug, Bearing Housing Drain (Not Shown) 2
565 Standpipe (Not Shown) 2
57 Gasket 2
58 Cover 2
59 Machine Bolt 26
60 Eye Bolt, Cover Lifting 1
61 SENTINEL VALVE 1
627 Shrink Ring, Steam End 1
637 Shrink Ring, Center (Not Shown) 1
647 Shrink Ring, Exhaust End (Not Shown) 1
65 Nameplate 1
66 LABYRINTH PACKING, BYRHH (Not Shown) 2
67 Drive Screws (Name Plate) 4

Notes
1
Top liners used with Class 1 & 2 rotors are not interchangeable with top liners
used with Class 3 rotors. (Rotor class designation is on the Turbine Operating
Data page found in the Equipment Data Section of this manual.)
2
Steam end liners may differ from exhaust end liners.
3
Not used on pressure lubricated turbines. Blank flange used
in place of Items 27.
4
Not used on pressure lubricated turbines.
5
Item 56 used in place of item 55 when pressure lubricated turbine is equipped
with Class 1 or 2 rotor. (Rotor class designation is on the Turbine Operating
Data page found in the Equipment Data Section of this manual.)
6
Not furnished with turbines equipped with Class 3 and higher rotors. (Rotor
class designation is on the Turbine Operating Data page found in the
Equipment Data Section of this manual.)
7
Single profile disk assembly used in place of these items.

Items listed in bold capital letters are found in the Spare Parts List, Chapter 9,
Sales/Service/Parts
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 Chapter 4
Maintenance

13
61 14
28 57, 58
60 8 28 28
28
59
4 3
5
54

59
58
12
14
28
28
57
13

28 28

53 65
67
43
10
16
7 47,48

21
62,63,64 12, 54
47,48
16 46 23
49
49
9
15
50 26
51 19
27
11 20
52
45
22
27 44
19 24
20
25 18
15

6
10 17
26 38, 39
37

24
2

1
21, 53 33
40
41, 42
30, 31, 32 34, 35, 36

23
29
See
Fig. 4-13

 ELLIOTT CO., INC (YR)

FIGURE 4-12
TYPICAL YR TURBINE

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Chapter 4
Maintenance

PARTS LIST
(Refer to Figure 4-13)

FIGURE ITEM NO. DESCRIPTION QUANTITY

1 Steam Chest Body 1

2 STEAM STRAINER 1
3 Trip Valve Cover 1
4 Cap Screw 8
5 PIN, RESETTING LEVER 1
6 BUSHING, RESETTING LEVER 1
7 Set Screw 1
8 Resetting Lever 1
9 KNIFE EDGE, Resetting Lever 1
10 Machine Screw 1
11 SPRING Closing 1
12 Lock Nut 1
13 BUSHING, Trip Valve 2
14 GOVERNOR VALVE STEM 1
15 GOVERNOR VALVE 1
16 PIN, Governor Valve Stem 1
172 TRIP VALVE ASSEMBLY
(Includes Trip Valve, Stem, and Pins) 1
18 Bushing, Governor Valve Cover 1
194 PACKING (High Pressure) 1 Set
204 Lantern Ring 1
21 FOLLOWER 1
224 Governor Valve Cover (High Pressure) 1
23 VALVE SEAT 1
24 BUSHING, VALVE SEAT (Not Shown) 1
25 Weld Block 2
26 Hand Trip Lever 1
27 KNIFE EDGE 1
28 SPRING, Hand Trip Lever 1
29 Shoulder Stud 1
303 PACKING (Low Pressure) 1 Set
313 Governor Valve Cover (Low Pressure) 1
323 CONNECTION (T Governor) 1
33 Jam Nut, Valve Stem 1
34 Stud, Inlet 8
35 Nut, Inlet 8
36 SPRING SEAT (Top) 1
37 SPRING, BACKSETTING 1
38 SPRING SEAT (Bottom) 1
39 Bushing 1
40 Washer 2
41 BLOCK 2
42 CONNECTION, BACKSETTING 1
43 Roll Pin, Knife Edge 1

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 Chapter 4
Maintenance

PARTS LIST - Continued

(Refer to Figure 4-13)

FIGURE ITEM NO. DESCRIPTION QUANTITY

44 Retainer Ring 1
454 SPRING, AUXILIARY CLOSING 1
46 Machine Bolt, Strainer 1
47 Machine Bolt, Governor Valve Cover 10
48 Rivet (6" Steam Chest Only) 2
491 SINGLE SEATED TRIP VALVE 1
50 CONNECTION PIN 1

(49)

STEAM
INLET

DETAIL 4-13A
1
PARTIAL SECTION SHOWING
SINGLE SEATED TRIP VALVE USED
IN 2 inch (50 mm) STEAM CHEST

(17)

DETAIL 4-13B
2
PARTIAL SECTION SHOWING
TRIP VALVE USED IN 6 inch
(150 mm) STEAM CHEST
 ELLIOTT CO., INC (YR)
1 Refer to Detail 4-13A.

2 Refer to Detail 4-13B.

3 Indicates part not used on all turbines or variable quantities.

4 Used only on steam chests operating over 250 psig (17 bar) maximum inlet steam
pressure.

Items listed in bold capital letters are found in the Spare Parts List, Chapter 9,
Sales/Service/Parts.

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Chapter 4
Maintenance

26
9

27 5 12
43
10

36

29 7
13
37
28
6

38
44
3 39

13

40
41
42
11 17 41
40

45

30,19

20

21
33
32

14
50

1
18
23,24 48
25

15,16
34

35
22,31
2

46
47
48

 ELLIOTT CO., INC (YR)

FIGURE 4-13
STEAM CHEST ASSEMBLY

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 Chapter 4
Maintenance

A B C D E

L
M M H
L K H

J
 ELLIOTT CO., INC (YR)

*Note: See Turbine Operating Data page for rotor class designation

INCHES MILLIMETERS
MIN. MAX. MIN. MAX.
A Radial Clearance, Shaft Sleeve Seals .010 .0145 0.25 0.37
B Carbon Ring Inside Diameters SEE TABLE 4-2 SEE TABLE 4-2
C Shaft Diameter 3.0000 3.0005 76.20 76.21
* D Diametral Clearance Class 1 & 2 Rotors .0075 .010 0.19 0.25
Class 3 & 4 Rotors .0055 .008 0.14 0.20
* E Shaft Journal Diameter Class 1 & 2 Rotors 2.9320 2.9325 74.47 74.48
Class 3 & 4 Rotors 2.9340 2.9345 74.52 74.53
F Trip Pin / Plunger Clearance .062 1.6
CYR Straight Sided Disk 11.778 11.784 299.16 299.31
* G Axial Dimension Profile Disk 11.624 11.630 295.25 295.40
DYR Straight Sided Disk 11.965 11.971 303.91 304.06
Profile Disk 11.903 11.909 302.34 302.49
H Axial Clearance .054 .064 1.37 1.62
J Axial Clearance .050 .072 1.27 1.83
K Axial Dimension (Straight sided disk only) .930 .950 23.62 24.13
L Axial Clearance .068 .098 1.73 2.49
Axial Clearance for DYRH Turbines .048 .078 1.22 1.98
M Axial Clearance .030 .040 0.76 1.02
Axial Clearance for DYRH Turbines .050 .060 1.27 1.52
NOTE
All clearances are taken with rotor thrust downstream as in
normal operation position.

FIGURE 4-14
COLD CLEARANCE DIAGRAM FOR CYR, DYR, DYRH, DYRM and DYRN TURBINES
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Chapter 4
Maintenance

O D E
A C B

M M
H
L L K H

 ELLIOTT CO., INC (YR)

* Note
See Turbine Operating Data page for rotor INCHES MILLIMETERS
class designation MIN. MAX. MIN. MAX.
A Radial Clearance, Shaft Sleeve Seals .010 .0145 0.25 0.37
B Carbon Ring Inside Diameters SEE TABLE 4-2 SEE TABLE 4-2
Class 1 & 2 Rotors 2.9320 2.9325 74.47 74.48
C Shaft Diameter Class 3 Rotors 2.9340 2.9345 74.52 74.54
Class 3B & Higher 3.2500 3.2505 82.55 82.56
* D Diametral Clearance Class 1 & 2 Rotors .0075 .010 0.18 0.25
Class 3 & Higher .0055 .008 0.13 0.18
* E Shaft Journal Diameter Class 1 & 2 Rotors 2.9320 2.9325 74.47 74.48
Class 3 & Higher 2.9340 2.9345 74.52 74.53
F Trip Pin / Plunger Clearance .062 1.6
* G Axial Dimension Straight Sided Disk 14.684 14.690 372.97 373.13
Profile Disk 14.651 14.657 372.14 372.29
H Axial Clearance .054 .064 1.37 1.62
J Axial Clearance .050 .072 1.27 1.83
K Axial Dimension (Not applicable for Profile Disk) .867 .883 22.02 22.43
L Axial Clearance .068 .098 1.72 2.49
M Axial Clearance .030 .040 0.76 1.01
Class 1 & 2 Rotors .0155 .018 .394 .457
O Diametral Clearance Class 3 Rotors .0135 .016 .343 .406
Class 4 & up Rotors .0145 .017 .368 .432

NOTE
All clearances are taken with rotor thrust downstream as in
normal operation position.

FIGURE 4-15
COLD CLEARANCE DIAGRAM FOR BYRH AND BYRHH TURBINES
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 Chapter 4
Maintenance

R
J*
T
S
U

*Refer to Figures 4-14 and 4-15

 ELLIOTT CO., INC (YR)

inch mm
Min. Max. Min Max
R Disk to Reversing blade Holder - Axial .050 .090 1.27 2.29
S Reversing blade Holder to Second Row .050 .090 1.27 2.29
Shroud - Axial
T Tip Seal Clearance, First Row - Axial .050 .080 1.27 2.03
U Tip Seal Clearance, Second Row - Radial .050 .080 1.27 2.03

Figure 4-16
Reversing blade Holder

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Chapter 4
Maintenance

TIGHTENING BOLTS
Bolts used for pressure and rotating parts shall be tightened to the following torque values.

Table 4-3

BOLTING TORQUE REQUIREMENTS

STANDARD SPLITLINE
FASTENER FT. LBS FASTENER FT. LBS
DIAMETER TORQUE DIAMETER TORQUE
¼" - 20 5 5
⁄8" - 11 85
5
⁄16" - 18 10 ¾" - 10 205
³⁄8" - 16 17 ⁄8" - 9 330
7

7
⁄16" - 14 25 1" - 8 495
½" - 13 40
5
⁄8" - 11 85
¾" - 10 205
7
⁄8" - 9 330
1" - 8 495

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 CHAPTER FIVE
LUBRICATION

INTRODUCTION

This chapter describes the basic oil requirements, care of lubricating oils, and the methods
of lubricating YR Turbines.

Proper lubrication is a primary factor in achieving maximum trouble-free operation. Only

the best grades of oil should be used for turbine lubrication. Using the best oils will help
eliminate costly downtime due to bearing failures and other lubrication related problems.

BASIC OIL REQUIREMENTS

Elliott Company does not recommend specific brands of oil. Elliott equipment owners
should consult reliable oil suppliers regarding their lubrication requirements. The oil
should be a premium quality mineral-based lubricant (PolyAlphaOlefin (PAO)-based when
using synthetic oils) that will readily separate from water and have minimum tendency to
emulsify or foam when agitated. It should have high rust and oxidation resistance and
minimum sludge, lacquer, varnish or resin forming tendencies. In addition to these
requirements, Tables 5-2 and 5-3 contain other necessary information to aid in selecting
the proper lubricating oil for your turbine.

Turbines driving through speed reduction or increasing gears are often pressure lubricated
by the gear lubrication system. (Refer to the gear manufacturer’s instructions and
nameplate for gear oil requirements.) (Consult Elliott Company before deviating from the
values shown on Table 5-2.)

CAUTION
Turbines designed for PAO-based synthetic oil must
not use mineral based oils. Use of oil other than a
PAO-based synthetic oil may result in severe damage
to the bearing cases, bearings and rotor. (Refer to the
data sheet in the “Equipment Data” section of this
manual to determine which type of oil is used on the
unit.)

CARE OF OIL

Lubricating oil should be maintained in first class condition by preventing contamination

from moisture, dust, dirt or other impurities. An oil maintenance analysis program is
recommended for determining the frequency of oil changes. Consult your oil supplier for
assistance in establishing a program that will meet your specific lubrication maintenance
requirements.

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METHODS OF LUBRICATION

The turbines are furnished with either a ring oiled lubrication system or a pressure
lubrication system.

Pressure lubricated turbines equipped with a Class 1 or Class 2 rotor (rotor class
designated on Turbine Data page) are also furnished with oil rings. The oil rings provide
bearing lubrication during turbine start-up and shut-down. This arrangement employs a
standpipe installed in the bearing housing oil drain connection to maintain the proper oil
level for a ring oiled operation.

Turbines equipped with Class 3 or higher rotors are pressure lubricated and use an
auxiliary oil pump for bearing lubrication during turbine start-up and shut-down.
Standpipes and oil rings are not used with this arrangement.

Turbines equipped with a Class 2 or lower rotor and having an exhaust temperature
greater than 400°F (204°C) are designed for PAO-based lubrication if using a ring oiled
lubrication system.

RING OILED LUBRICATION – Refer to Figure 5-1

Standard YR Turbines are ring oil lubricated. The ring oiled lubrication system is a simple
system that employs one (AYR, BYR) or two oil rings to deliver oil to each of the turbine
bearings. The rings, approximately twice the diameter of the shaft journals, are rotated by
the journals and carry oil from the bearing housing reservoirs to the top half bearing liners.
Rotating journals carry the oil to the clearance between the bearing liners and the shaft
journals. Oil drains from the ends of each bearing liner and returns to the bearing housing
reservoirs to be cooled and recycled. Oil discharged from the steam end journal bearing
floods the rotor locating bearing before draining into the bearing housing reservoir. Table
5-4 gives the recommended trip and alarm settings for monitoring bearing and oil
temperatures.

A cooling water tube arrangement, as shown in Figure 5-1, is used to cool the oil in the
bearing housing reservoirs of ring oiled lubricated turbines.

Ring oiled lubrication systems have no means of filtering solids from the oil; therefore,
frequent oil changes are necessary to ensure a clean oil supply to the bearings.

Shielded glass oilers (Figure 5-2), installed on the sides of the bearing housings, maintain
a constant reservoir oil level when the turbine is ring oiled lubricated. Oil must be visible in
the oiler bottles at all times during operation. Empty bottles indicate possible low reservoir
oil levels. Care must also be taken to avoid overfilling the bearing housing reservoirs.
High oil levels will restrict oil ring rotation that may cause inadequate bearing lubrication.

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INSPECTION PLUG
ROTOR SHAFT
OIL RING
JOURNAL
BEARING

OILER

OIL
RESERVOIR
COOLING
WATER
COOLING
CHAMBER

LUBRICATING OIL

COOLING WATER

 ELLIOTT CO., INC (YR)

FIGURE 5-1
RING OILED LUBRICATION

BOTTLE SHIELD

KNURLED
THUMB SCREW

“A” See Table 5-1

OIL LEVEL

LOWER
RESERVOIR

LEVEL 1/8 in. WASHER

ADJUSTER (3.2 mm)
USED WITH THE CYR, DYR,
PLUG CROSS ARMS DYRM, BYRH, BYRHH

 ELLIOTT CO., INC (YR)

FIGURE 5-2
GLASS OILER

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TABLE 5-1
OIL LEVEL RANGE, CAPACITIES and FIGURE 5-2 ‘A’ DIMENSION
Quantity of Oil
Oil Level Range
Ring Oiled System Figure 5-2
YR Frame Size Dimension below
Pints (Liters) per “A” Dimension
unit centerline
bearing case
2.62" (66.5mm) to
AYR * 1 (0.5) .50" (12.7mm)
2.74" (69.5mm)
2.62" (66.5mm) to
BYR 1 (0.5) .94" (23.9mm)
2.74" (69.5mm)
CYR, DYR, DYRM, 3.55" (90mm) to .94" (23.9mm)
3 (1.3)
BYRH, BYRHH 3.68" (93mm) with ¹⁄8" washer
* AYR Re-Design Turbine Unit is easily recognized by “dog-legged” oiler lines (units manufactured after 1968). Units
manufactured prior to 1968, “A” dimension = .94" (23.9mm).

Verify oilers are set properly. To ensure the oil level is correct, turn the level adjuster
cross arms to the height indicated in Table 5-1 (“A” dimension on Figure 5-2). Lock the
cross arms in place by tightening the upper cross arm. Ensure ¹⁄8" washer is present in
the level adjuster assembly as shown in Figure 5-2 for the CYR, DYR, DYRM, BYRH and
BYRHH frames.

To Change Oil in Bearing Housing Reservoir:

1. Remove ¼-inch drain plug from bottom of bearing housing reservoir. Flush oil sump
with high quality solvent and wipe clean with lint free rags.

NOTE
Mechanical cleaning of the bearing housing sumps is not
recommended. Contact Elliott Service Office for
recommendations and cautions.

2. Replace plug after draining bearing housing.

3. Remove oiler bottle from lower reservoir (Figure 5-2).

4. (Refer to Table 5-1 for correct quantity of oil.) Fill bearing housing reservoir by
pouring oil into the lower bearing housing reservoir, until the oil level reaches the
bottom of the level adjuster cross arms in the oiler.

5. Fill oiler bottle with oil and install in the lower reservoir.

NOTE
Ensure bottle is seated on level adjuster cross arms.

6. Tighten knurled thumbscrew to secure bottle in the lower reservoir.

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PRESSURE LUBRICATION
Details of pressure lubrication systems vary widely. Each system is designed to meet
the turbine application requirements. Factors such as the type of driven equipment,
operational and environmental conditions, and individual preferences in the selection of
various components, may affect the specific design of the system.

Pressure lubrication systems are generally similar in that each employs a pump to draw
oil from a reservoir and deliver it filtered and cooled under pressure to the bearings and
other parts requiring lubrication. The oil then drains by gravity flow back to the reservoir
to be re-circulated. Oil system drawings are located in Chapter 10, Technical Drawings,
and show specific details of the oil system supplied on this turbine.

In most cases, the oil supply piping contains an oil filter, oil cooler and a pressure control
device. Twin oil coolers and filters are sometimes used in the pressure lubrication
system. This arrangement allows the cooler or filter to be isolated for maintenance or
repairs without shutting down the system.

Various types of optional monitoring, control, and safety devices can be used with
pressure lubrication systems. Among these devices are pressure and temperature
indicators, pressure and temperature actuated switches, oil flow sight glasses, oil level
indicators, auxiliary pumps, alarms, and emergency shutdown devices. (Refer to the
Accessories Chapter 8 of this manual for applicable details of optional lubrication
equipment.)

Lubrication System Flushing

All units employing forced feed oiling systems should have the entire lubrication system
thoroughly flushed before operation. The importance of this step cannot be over-
emphasized. All dirt, rust, scale, weld slag or other contaminants that have been
introduced into the oil system during storage, transportation and/or fabrication at the job
site must be removed by a continuous flushing operation or, in extreme cases, by
pickling, neutralizing and spraying with a rust-preventative oil.

Oil piping supplied by Elliott Company is cleaned and coated (fogged) with oil to protect
against rust formation. The open ends are plugged before shipment. Piping not
supplied by Elliott Company must also be cleaned before it is connected into the system.

Flushing should begin as soon as the system is assembled and a lubricating oil pump
can be operated. The turbine liner bearings must be removed to allow the oil to flush the
bearing case oil galleries. The flushing should continue until inspection of the filters
indicates that all contaminants have been removed. If an auxiliary oil pump is not
supplied, a temporary pump will be needed to allow flushing the system before the main
oil pump is started.

If the system remains idle for a period of time, it should be flushed before operation. An
alternate method is to circulate oil through the system at regular intervals during the idle
period and to flush the system clean just before start-up.

If a continuously lubricated coupling is used, the oil supply tubing should be

disconnected during oil system flushing.

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Refer to the gear manufacturer’s instructions for specifics. In general, it is

recommended that temporary bypass lines be installed to isolate gears during the
flushing operation. Gear cases, inspection covers, and plugs should be opened only
under the direct supervision of the gear manufacturer’s representative.

Install blanks at the connecting flanges to block off piping to the topworks on hydraulic
diaphragm actuators, pressure-reducing valves, backpressure regulators, and similar
control devices.

CAUTION
Be sure to remove blank-offs and to replace any piping or
tubing sections removed before placing the system into
operation.

After satisfactory system cleanliness is obtained:

1. Remove all temporary strainers, pads and back-up screens from the system.

2. Remove all traces of flushing oil and contaminants deposited by the flushing
operation from the bearing housing, filters and system low points. Install new filter
elements.

3. Remove the oil reservoir cover and clean the reservoir using lint-free wiping cloths.
Replace cover and immediately fill reservoir with clean oil.

4. Clean the bearing housings and journals.

5. Install all orifices in their proper locations, if used.

6. Replace the journal bearings. Apply an oil-resistant sealant to the bearing housing
joints.

7. Prime main and auxiliary oil pumps. Operate the auxiliary pump; bleed the system
of any air. Check for oil leaks at all fittings and connections. Repeat venting the
system when main oil pump is running.

8. After venting, check for leaks; set and check all pressure control valves, controls
and safety devices for proper operation before initial start-up. (Refer to Table 5-2,
and Oil Piping Drawing for settings.)

NOTE
All checks should be made with the oil system at normal
operating temperature.

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Normal Maintenance

1. Daily check oil reservoir level and add oil as required.

2. Monthly check filter pressure drop and replace elements when necessary.
(Check weekly if unit is installed in a harsh environment.)

3. Monthly check operation of auxiliary oil pump by operating pump and returning to
auxiliary duty.

4. Monthly check control valves for leaks at packing glands.

Turnaround Maintenance

1. Clean reservoir.

2. Check oil pumps according to manufacturer’s recommendations.

3. Check oil pump couplings for wear. If the couplings are in good condition, re-
lubricate; otherwise, replace.

4. Check oil pump drivers according to manufacturer’s recommendations.

5. Clean coolers.

6. Replace filter elements.

7. Check control valves according to manufacturer’s recommendations.

8. Prime main and auxiliary oil pumps. Operate the auxiliary pump; bleed the
lubrication system of any air. Check for oil leaks at all fittings and connections.
Repeat venting air when main oil pump is running.

9. After venting, check for leaks. With oil at normal operating temperature, set and
check all pressure control valves, controls and safety devices for proper operation
before start-up. For the setting, refer to both Table 5-4, and the Oil Piping Drawing
located in Chapter 10 Technical Drawings.

SELECTING LUBRICATING OILS

The following tables are to be used as guidelines in selecting lubricating oils for your YR
Turbine. These guidelines are not intended to restrict the oil supplier to a definite set of
numbers to which he must adhere. It is the intent to indicate the general service
requirements and leave the particular recommendations to the oil supplier.

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TABLE 5-2
GUIDELINES FOR SELECTING LUBRICATING OILS
Method of Lubrication Ring Oiled Lubrication Pressure Lubrication
A B
(See Note 1) (See Note 2)
MINERAL BASED OILS
Viscosity, Saybolt Universal
284-352 135-164 135-352
Seconds (Approx. SUS at 100F)
Approximate Metric Viscosity
63.2 – 78.8 28.8-35.2 28.8 – 78.8
(mm 2/s at 40C)
ISO Viscosity Grade 68 32 32/46/68
Viscosity Index Above 94 Above 94 Above 94
400F/ 400F/
Minimum Flash Point 400F/ 204C
(204C) (204C)
Pour Point Under -10F/-12C -6F/-21C -10F/-12C
PolyAlphaOlefin (PAO)-BASED SYNTHETIC OILS (See Note 3)
Test Method
Viscosity, Saybolt Universal
300-340 ASTM D2161
Seconds (Approx. SUS at 100F)
Approximate Metric Viscosity
65.4-74.3 ASTM D445
(mm 2/s at 40C)
Viscosity, Saybolt Universal
55-65 ASTM D2161
Seconds (Approx. SUS at 210F)
Approximate Metric Viscosity
8.8-11.5 ASTM D445
(mm 2/s at 99C)
ISO Viscosity Grade 68 --
Viscosity Index Above 120 ASTM D2270
Minimum Flash Point 450F (232C) ASTM D92
Pour Point Under -35F (-37C) ASTM D97
Refer to Turbine Operating Data Page located in the front of this manual to confirm the ISO viscosity grade of oil
used.
Notes
1. Column “A” (Table 5-2) provides the general guidelines for turbines lubricated by a turbine
shaft driven pump or by the driven machine.

2. Column “B” (Table 5-2) shows the acceptable general guidelines for turbines lubricated from
gear oil systems. Refer to the gear manufacturer’s instructions and nameplate for
gear oil requirements. Consult Elliott Company before deviating from the values shown, to
ensure gear oil requirements are compatible with the turbine.

3. The unit outline drawing and Turbine Operating Data Sheet will specify if synthetic, PAO-
based oil is to be used. Tags on each bearing case will also indicate if synthetic oil is
required. While PAO-based synthetic oil is compatible with mineral oils it should not be
mixed with mineral oil as mixing will degrade the oxidation stability of the synthetic oil.

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TABLE 5-3
OPERATING LIMITS FOR TURBINES
Method of Lubrication Ring Oiled Lubrication Pressure Lubricated
MINERAL BASED OILS
130F 54C 130F 54C
Oil Reservoir
to to to to
Operating Temperature
190F 88C 160F 71C
Minimum Oil Temperature
70F 21C 70F 21C
Before Starting
140F 60C 130F 54C
Oil Temperature
to to to to
From Bearings
190F 88C 170F 77C
Nominal Cooling Water
90F 32C 90F 32C
Temperature
Maximum Cooling Water
100F 38C 100F 38C
Temperature
Refer to Turbine Data Sheet
Nominal Cooling Water Flow 2 gpm 7.5 lpm

Oil Temperature from

n/a n/a 120F 49C
Cooler (to Bearings)
Normal Bearing Oil Pressure, 7 psi 0.5 bar
Gage
n/a n/a to to
Some units may run 15 psi (1.03 bar) to 18
psi (1.24 bar), Refer to Turbine Data Sheet
9 psi 0.6 bar
PAO-BASED SYNTHETIC OILS (See Note 3)
Minimum Oil Temperature before
70F 21C n/a n/a
Starting
130F 54C
Oil Reservoir
to to n/a n/a
Operating Temperature
200F 93C
140F 60C
Oil Temperature from
to to n/a n/a
Bearings
210F 99C
Nominal Cooling Water
90F 32C n/a n/a
Temperature
Maximum Cooling Water
100F 38C n/a n/a
Temperature
Nominal Cooling Water Flow 2 gpm 7.5 lpm n/a n/a
n/a indicates: not applicable

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TABLE 5-4
BEARING TEMPERATURE LIMITS
Bearing Shell
RING OILED Oil Temperature
Temperature*
MINERAL BASED OILS
Maximum
190F 88C 225F 107C
Continuous Operation
Alarm Setting 200F 93C 240F 116C
Trip Setting 220F 104C 260F 127C
PAO-BASED SYNTHETIC OILS
Maximum
200F 93C 235F 113C
Continuous Operation
Alarm Setting 210F 99C 250F 121C
Trip Setting 230F 110C 270F 132C
PRESSURE LUBRICATION Oil Temperature Bearing Shell
Temperature*
Maximum
170F 76C 225F 107C
Continuous Operation
Alarm Setting 180F 82C 240F 116C
Trip Setting 190F 88C 260F 127C
*Temperature taken by contact type sensor on back of the bearing shell.

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 CHAPTER SIX
“UG” GOVERNOR CONTROL SYSTEM

INTRODUCTION

This chapter provides instructions for lubrication, operation, maintenance and adjustment
of the “UG” Governor System. Specific operating and maintenance instructions for the
governor mechanism are supplied in Woodward Instruction Bulletins found in the
“Accessories” section of this manual.

GENERAL DESCRIPTION

All “UG” Governor mechanisms share the same basic components:

1. A self-contained governor oil system, including a built-in oil pump and relief valve.

2. A centrifugal flyweight head and pilot valve assembly to control governor oil flow to
and from a hydraulic power cylinder assembly.

3. A power cylinder driving a rotary output shaft to position the turbine governor valve
linkage.

4. An internal governor compensation system for control stability.

5. An external manual load setting adjustment.

6. External droop adjustment.

The “UG” Governor is bolted and dowelled to the governor drive housing which is attached
to the steam end bearing housing. The governor oil pump, flyweight head and pilot valve
assembly are driven through a worm gear and worm wheel arrangement. The worm gear
is mounted on the trip body and is driven by the turbine rotor shaft. The worm wheel is
attached to the governor drive shaft and meshes with the worm gear. The governor valve
lever and linkage connect the honorary output shaft to the governor valve.

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OIL FILL OIL

OILFILL
FILL
SIGHT GLASS CONNECTION
CONNECTION
SYNCHRONIZING
MOTOR

UG GOVERNOR

WORM
TRIP GEAR COMPENSATION
ROTOR ASS’Y ADJUSTMENT

STEAM GOVERNOR
BEARING BASE
HOUSING

FULCRUM
GOV. DRIVE BRACKET
HOUSING
OIL NOZZLE

GOVERNOR
VALVE LEVER

CONNECTION

GOVERNOR
VALVE

FIGURE 6-1
GOVERNOR SYSTEM ARRANGEMENT

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LUBRICATION

Governor Oil Requirements

Contaminated oil is the greatest single cause of governor malfunctions. Use clean high
grade oil in the governor. Most SAE oils are acceptable and in most cases the oil used to
lubricate the turbine is satisfactory for governor use (See Chapter 5 for selection
guidelines). Check governor oil at regular intervals and change oil at the first sign of
contamination or discoloration.

The governor has a self-contained lubrication system. The main components include an
oil reservoir, a pump and a relief valve to limit the maximum oil pressures in the system.
An oil filler cap is located on the governor cover. An oil level gauge glass is located on the
side of the main body. A drain plug is located near the bottom of the governor casing.

The oil level must be maintained between the lines on the oil level gauge glass during
turbine operation.

CAUTION
Do not overfill the governor reservoir. High oil level
will cause oil foaming. Low oil level can cause
sluggish governor operation and overheating resulting
in damage to the turbine and/or governor.

Governor Drive Lubrication

Pressure lubricated turbines equipped with “UG” Governors use an oil spray nozzle (10,
Figure 6-4) to direct oil into the governor drive gear mesh. The oil spray nozzle is
connected to a 7 to 9 psig (0.5 to 0.6 bar) bearing oil supply line in the turbine lubrication
system as shown in Figure 6-2.

Ring oil lubricated YR turbines equipped with “UG” governors have a lubrication
arrangement (Figure 6-3) that directs oil from the bottom half steam end journal bearing
liner to the governor drive gear mesh.

The bottom half steam end journal bearing liner has a groove which divides the bearing
surface in half. Oil, carried to the bearing by oil rings, flows into the groove. A velocity
head is developed in the groove as the trapped oil is accelerated by the rotating shaft.
Because the end of the groove is just past the point where the bearing oil is at its minimum
film thickness, a pressure dam is created. This pressure dam converts the velocity head
into a pressure head.

A small hole is located in the bearing liner near the end of the groove. Pressurized oil
passes through the hole into a cavity beneath the bearing liner. The cavity is connected
by an external tube to the governor drive housing. The tube end forms a nozzle which
directs a flow of oil into the governor drive gear mesh.

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6
7 4
5

1. CHECK VALVE
2. PUMP
8 3. RELIEF VALVE
12 12 4. FILTER
5. COOLER
9 9 6. GAUGE
10 2 7. PRESSURE SWITCH (OPTIONAL)
8. GOVERNOR
9. TURBINE BEARINGS
10. GEAR MESH
3 11. RESERVOIR
12. ORIFICE
1

11

 ELLIOTT CO., INC. (YR)

FIGURE 6-2
TYPICAL OIL FLOW SCHEMATIC DIAGRAM FOR YR TURBINE
WITH PRESSURE LUBRICATED GOVERNOR DRIVE.

WORM
WORM WHEEL
GEAR

BOTTOM HALF
GOVERNOR
BEARING LINER
DRIVE
(SPECIAL)
HOUSING

TUBE

STEAM END
BEARING
HOUSING

 ELLIOTT CO., INC. (YR)

FIGURE 6-3
SELF LUBRICATED GOVERNOR DRIVE ARRANGEMENT

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Bottom half steam end journal bearing liners used with this governor drive lubrication
arrangement are not interchangeable with exhaust end bearing liners, nor are they
interchangeable with respect to turbine shaft rotation.

A minimum turbine rotor speed of 500 rpm is necessary to provide sufficient oil flow to the
drive gear mesh. Avoid operating the turbine below this speed for extended periods.

OPERATION

Principle Of Operation
The governor drive shaft worm wheel is driven at a speed directly proportional to the
turbine rotor speed. The governor uses mechanical force to sense the turbine speed and
hydraulic force to correct the speed. The hydraulic pressure is generated by an internal
governor oil pump. The pump draws oil from the governor reservoir and discharges it to
spring loaded accumulators which store high pressure oil to help maintain the full work
capacity of the governor. Relief valves, built into the accumulators, maintain the correct
operating oil pressure in the governor oil passages.

A spring loaded, rotating flyweight head senses the turbine speed. When the speed
changes, centrifugal force causes the flyweights to pivot either outward or inward. The
flyweight movement actuates a pilot valve plunger which opens or closes a control port
and directs control oil to or from the power piston. The power piston motion is transmitted
mechanically to the governor output shaft corrected through the governor compensation
system. The governor output shaft positions the connecting linkage to open or close the
governor valve and control the steam flow to the turbine nozzle ring. The governor has
built in droop and a droop setting knob on the front panel. This allows load division
between several generator strings operating in parallel.

Initial Start-Up

1. Fill the governor with oil and check for signs of leakage. Capacity is approximately 6
quarts (5.6 liters).

2. Check the governor linkage for ease of movement.

3. Ensure that linkage jam nuts and set screws are tight.

4. Turn governor speed setting knob counterclockwise to the minimum speed setting.

5. Start the turbine as specified in the initial start-up procedures given in Chapter 3, and
check the governor for oil leakage and vibration.

6. After the turbine is thoroughly warmed up and operating satisfactorily at minimum

speed, slowly increase speed setting by turning the speed setting knob (or lever)
clockwise until the turbine is operating at rated speed.

7. Continue to monitor governor operation for any abnormal conditions.

8. After the turbine has operated satisfactorily at rated speed, check the overspeed trip.

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9. Set the load limit knob to the maximum position.

10. Rotate the speed setting knob clockwise to obtain the highest speed possible.

11. If further speed is needed, overcome the governor with suitable lever to overspeed
trip the turbine.

CAUTION
If the turbine does not trip within 2% of the rated
(nameplate) trip speed, strike the hand trip lever and
adjust the overspeed trip as outlined in Chapter 4.

Routine Start-Up
Start the turbine as specified in “Routine Start-Up” procedures, Chapter 3. Monitor turbine
speed and general governor operation. Make necessary speed control adjustments to
obtain desired turbine speed.

MAINTENANCE

Routine Maintenance
Because of the simplicity of the “UG” Governor System, a minimum of maintenance is
required. Make the following checks:

1. Check the governor oil level daily.

2. Frequently sample the governor oil. Change oil if sample show signs of
contamination.

3. Check the governor linkage for binding, excessive play and loose jam nuts or set
screws.

4. Keep governor linkage clean and well lubricated with a high temperature, water
resistant silicone grease.

Governor Disassembly
Internal governor maintenance is not recommended. It is advisable to replace the
governor if defective. The Woodward Governor Company offers a factory rebuild
exchange plan that enables governor replacement at a minimum cost with the least
possible shutdown time.

If factory rebuilding is not practical, and the governor must be dismantled in the field; refer
to the Woodward Governor Instruction bulletins in the Accessories chapter. These
bulletins provide disassembly and assembly procedures, along with a description of
special tools and replacement parts necessary for making repairs to the UG Governor.

Governor Removal

1. Tag and disconnect the electrical connections from the governor (1, Figure 6-4), if
applicable.

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 Chapter 6
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2. Disconnect the adjustable connecting rod from the terminal shaft lever by removing
shoulder screw from the lever.

3. If turbine is ring oil lubricated; disconnect tube connection (41) and remove oil feed
tube (42) from governor drive housing (2).

4. Remove dowel pins (18) and bolts (16) securing the governor to the drive housing.

5. Carefully lift the governor off the drive housing (2). Exercise care to avoid damaging
worm gear (4) and worm wheel (5).

6. Match mark and remove shims (14 & 15).

Worm Wheel Replacement

1. Remove cotter pin (12, Figure 6-4) and castle nut from the governor driveshaft.

2. Remove bottom shims (19), worm wheel (5), key and top shim (19) from governor
driveshaft.

3. Assemble in reverse order.

Governor Installation

1. Install shims (14 & 15, Figure 6-4) on governor drive housing (2).

2. Carefully place governor (1) on the governor drive housing (2).

3. Install bolts (16) and dowels (18).

NOTE
When installing a new or rebuilt governor; drill and ream
holes for #5 dowels (18) after setting worm wheel tooth
contact and backlash.

4. Connect adjustable connecting rod to the terminal shaft lever by placing shoulder
screw through rod end.

NOTE
If installing new or rebuilt governor, adjust the governor
valve travel as outlined in Chapter 4.

5. Make-up electrical connections for the remote control speed changer.

Worm Wheel Tooth Contact Adjustment

1. Remove cover (7, Figure 6-4) or oil pump (40) and adapter (33, 49), if applicable.

2. Apply a thin coat of Prussian blue to the worm gear (4).

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Chapter 6
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3. Rotate the turbine shaft in the designed direction of rotation by hand to transfer bluing
from worm gear (4) to worm wheel teeth (5).

4. Observe the blued surface of the worm wheel teeth. Contact point should be at the
center of the teeth.

5. If necessary, correct the contact by adding or removing shims (14 & 15) between the
governor base and drive housing (2).

NOTE
Add shims if contact point is above center of teeth.
Remove shims if contact point is below center of teeth.

Worm Wheel Backlash Adjustment

1. Adjust the worm wheel tooth contact as outlined in Worm Wheel Tooth Contact
Adjustment section.

2. Work through the opening provided by removing end cover (7, Figure 6-4) from drive
housing (2) and mount a dial indicator so that the indicator contact point rests against
one of the worm wheel teeth (5).

3. Move the worm wheel back and forth while holding rotor stationary to measure the
clearance between the worm wheel and worm gear mesh. (This clearance is called
“backlash”.) The backlash must be set at .006 to .008 inch (0.15 mm to 0.20 mm).

4. Loosen bolts (16), remove dowels (18) and move the governor (1) laterally on the
drive housing (2) to adjust the backlash.

NOTE
Move the governor toward the turbine shaft to decrease
backlash; away from the shaft to increase backlash.

5. When correct backlash is obtained, drill and ream the governor base drive housing (2)
for taper dowel pins (18).

Turbine Shaft Driven Oil Pump Removal (optional)

1. Remove oil piping from pump (40, Figure 6-4).

2. Remove bolting securing pump to adapter (33, 49).

3. Remove pump from adapter.

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 Chapter 6
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Pump Installation

1. If installing new pump:

a. Install new coupling hub and Woodruff key (9) on trip body (3).

b. Adjust coupling hub so that hub face is even with shaft end.

c. Lock coupling hub on trip body tightening set screws.

2. Install pump on adapter and tighten bolting.

NOTE
Ensure that coupling hubs engage coupling sleeve.

3. Connect oil piping and prime pump by filling suction line with oil.

Overspeed Trip Plunger Replacement

1. Remove hand trip lever from the steam end bearing housing.

2. Remove plug (36, Figure 6-4) and gasket (35) from the bottom half steam end bearing
housing.

3. Remove retaining ring (38), washer (37) and spring (39) from the bottom of the
plunger (34).

4. Pull the plunger (34) from the top of plug (36).

5. Install new plunger (34) in plug and assemble in reverse order.

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PARTS LIST

FIGURE FIGURE
ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY
NO. NO.

6-4-1 Governor 1 41 Tube Connection 2

2 Housing 1 42 Feed Tube 1
3 Trip Body 1 43 Orifice Plug 1
4 WORM GEAR 1 44 Cap Screw 8
5 WORM WHEEL 1 45 Lockwasher 8
6 PIN 1 46 Stud 4
7 Cover 1 47 Nut 4
8 Lockwasher 4 48 Lockwasher 4
9 Woodruff Key 1 49 Adapter 1
10 Oil Feeder 1 50 Cap Screw 8
11 GASKET 1 51 Lockwasher 8
12 COTTER PIN 1 52 Cap Screw 4
13 Machine Bolt 8 53 Elastic Stop Nut 2
14 SHIM, .005 INCH (0.13 mm) 2 54 Rod End 2
15 SHIM, .010 INCH (0.25 mm) 2 55 Terminal Shaft Lever 1
16 Machine Bolt 4 56 Machine Bolt 4
17 Cap Screw 8 57 Cap Screw 1
18 Taper Dowel Pin 2 58 Adjustable Bracket 1
19 SHIM, 0.62 INCH (1.6 mm) 3 59 Jam Nut 2
20 SHOULDER SCREW 2 60 Lockwasher 4
21 Lever 1 61 Lockwasher 1
22 ADJUSTABLE
CONNECTING ROD 1
23 Fulcrum Bracket 1
24 BUSHING 4
25 PIN 2
26 Set Screw 3
27 Cap Screw 4
28 Lockwasher 4
29 PIN 1
30 SHIM, .030 (0.76 mm) 1
31 SHIM, .010 (0.25 mm) 1
32 SHIM, .005 (0.13 mm) 2
33 Adapter 1
34 PLUNGER 1
35 GASKET 1
36 Plug 1
37 Washer 1
38 RETAINER RING 1
39 SPRING 1
40 OIL PUMP
(with coupling & key) 1

Items listed in bold capital letters are found in the Normal Maintenance Parts List; Chapter
9 – Sales/Service/Parts

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UG Governor System
Chpater Six
UG Governorr Control System
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UG GOVERNOR SYSTEM
 CHAPTER SEVEN
TROUBLESHOOTING

INTRODUCTION

This chapter is intended to assist operators by both identifying possible causes of equipment
problems as well as recommending likely solutions. The Elliott Company recommends the
assistance of an authorized Elliott service representative for repairs. Refer to Appendix “B”,
Chapter 9, for a complete list of Elliott Company sales and service locations.

CAUTION
Replacement parts should be purchased from the
Elliott Company. Many vendor parts have been
modified and/or calibrated by the Elliott Company to
ensure compatibility with the design. Parts purchased
directly from vendors may not function properly and
could damage other components.

For applicable parts, in addition to Table 7-1 Troubleshooting Guidelines, refer to the vendor’s
instruction manual located in Chapter 8 Accessories.

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Chapter 7
Troubleshooting

NOTES

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 Chapter 7
Troubleshooting

TABLE 7-1
TROUBLESHOOTING GUIDE
______________________________________________________________________

1. TROUBLE EXCESSIVE VIBRATION

CAUSE: Shaft Misalignment

ACTION: Re-align as necessary. (Chapter 2)

CAUSE: Excessive bearing clearance.

ACTION: Replace bearings. (Chapter 4)

CAUSE: Dry Coupling.

ACTION: Lubricate coupling. (Chapter 2, 7)

CAUSE: Worn or damaged coupling.

ACTION: Repair or replace coupling. (Chapter 2, 7)

CAUSE: Damaged rotor assembly.

ACTION: Replace or repair and balance the rotor assembly. (Chapter 4)

CAUSE: Scale deposits or rotor assembly unbalanced.

ACTION: Clean and balance as necessary. (Chapter 4)

CAUSE: Tight or improper fitting carbon rings. (Labyrinth seals on BYRHH)

ACTION: Inspect carbon rings, labyrinth seals and shaft. Replace as
necessary. (Chapter 4)

CAUSE: Water in the inlet steam supply.

ACTION: Remove the source of water and thoroughly drain steam lines and
turbine casing. (Chapter 2, 3)

CAUSE: Bent rotor shaft.

ACTION: Repair or replace the rotor assembly if run-out exceeds
.002 inch (0.05 mm). (Chapter 4)

CAUSE: Loose or broken hold down bolts.

ACTION: Tighten or replace hold down bolts. (Chapter 2)

CAUSE: Sympathetic vibration. (Adjacent machinery causing vibration)

ACTION: A detailed investigation is required to determine proper corrective
action. (Chapter 2)

CAUSE: Improperly assembled parts.

ACTION: Listen for rubbing noises. Locate the source of noise, dismantle and
make necessary adjustments. (Chapter 4)

CAUSE: Loose rotor discs.

ACTION: Replace or repair and balance rotor assembly. (Chapter 4)
______________________________________________________________________
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Chapter 7
Troubleshooting

TABLE 7-1
TROUBLESHOOTING GUIDE
______________________________________________________________________

2. TROUBLE EXCESSIVE COUPLING WEAR

CAUSE: Lack of proper lubrication.

ACTION: Lubricate as necessary. (Chapter 4)

CAUSE: Improper cold alignment (Does not provide allowance for thermal
expansion).
ACTION: 1. Calculate amount of thermal expansion of equipment supports.
(Chapter 2)
2. Check shaft alignment at operating temperature (hot check) and
correct misalignment to provide collinear alignment when
equipment is at normal operating temperature. (Chapter 2)

CAUSE: Shaft misalignment caused by piping strains imposed on turbine

casing.
ACTION: Inspect piping for proper installation of pipe hangers, springs and
expansion joints. Correct any deficiencies in the piping that do not
allow for thermal expansion or dead weight forces. (Chapter 2)

CAUSE: Warped or distorted foundation.

ACTION: 1. Check foundation for settling and correct as necessary.
(Chapter 2)
2. Check for uneven temperature zones surrounding the foundation
and correct as necessary. (Chapter 2)
______________________________________________________________________

3. TROUBLE TURBINE FAILS TO START

CAUSE: Inadequate steam pressure at turbine inlet.

ACTION: Check that shut-off valves are open between turbine and boiler.
(Chapter 2)

CAUSE: Obstructed steam strainer.

ACTION: Clean strainer. (Chapter 2)

CAUSE: Governor valve stuck in closed position.

ACTION: Inspect governor linkage, valve stem packing and guide bushings.
Replace worn or binding parts. (Chapter 4, 6)

CAUSE: Faulty or improperly set safety or control devices (if furnished).

ACTION: Check that all automatic trip mechanisms, pressure switches and
control devices are set in the proper mode. (Chapter 4, 6)

CAUSE: Trip valve closed.

ACTION: Latch the trip valve re-setting lever. (Chapter 3)
______________________________________________________________________

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 Chapter 7
Troubleshooting

TABLE 7-1
TROUBLESHOOTING GUIDE
_______________________________________________________________________

4. TROUBLE TURBINE DOES NOT COME UP TO SPEED

CAUSE: Binding or interferences in governor valve or linkage.

ACTION: Replace worn or binding parts as necessary. (Chapter 4, 6)

CAUSE: Insufficient governor valve travel.

ACTION: Adjust to provide travel shown on Turbine Operating Data page.
(Chapter 4, 6)

CAUSE: Improper positioning of hand nozzle valve.

ACTION: Position hand valve as shown on the turbine outline. (Chapter 10)

CAUSE: Low inlet steam pressure or temperature.

ACTION: Increase steam conditions to provide the design values shown on
Turbine Operating Data page.

CAUSE: Excessive exhaust pressure.

ACTION: Reduce exhaust pressure to provide value shown on Turbine
Operating Data page.

CAUSE: Load exceeds turbine rating.

ACTION: Reduce load to that which is designated on Turbine Operating Data
page.

CAUSE: Restricted steam flow at turbine inlet.

ACTION: 1. Check that shut-off valves are fully open. (Chapter 2, 4)
2. Check steam strainer and clean as necessary. (Chapter 4)

CAUSE: Steam nozzles and blading fouled and/or eroded.

ACTION: Clean or replace parts as required. (Chapter 4)

CAUSE: Governor malfunction.

ACTION: Adjust, repair or replace governor. (Chapter 4, 6, 8)

CAUSE: Reversing bucket missing or in backwards.

ACTION: Reinstall in proper direction. (Chapter 4)

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Chapter 7
Troubleshooting

TABLE 7-1
TROUBLESHOOTING GUIDE
_______________________________________________________________________

5. TROUBLE EXCESSIVE STEAM USAGE

CAUSE: Improper positioning of hand nozzle valve.

ACTION: Position hand valve as outlined on the turbine outline. (Chapter 10)

CAUSE: Low inlet steam pressure or temperature.

ACTION: Increase steam conditions to provide the design values as shown on
Turbine Operating Data page.

CAUSE: Excessive exhaust pressure.

ACTION: Reduce exhaust pressure to provide value shown on Turbine
Operating Data page.

CAUSE: Load exceeds turbine rating.

ACTION: Reduce load to that which is designated on Turbine Operating Data
page.

CAUSE: Nozzles and/or turbine blades eroded or damaged.

ACTION: Inspect, repair or replace rotor assembly and/or nozzle ring.
(Chapter 4)

CAUSE: Reversing bucket missing or in backwards.

ACTION: Reinstall in proper direction. (Chapter 4)
_______________________________________________________________________

6. TROUBLE ERRATIC SPEED CONTROL

CAUSE: Worn or sticking governor valve and/or linkage.

ACTION: Replace worn parts as necessary. (Chapter 4, 6, 8)

CAUSE: Incorrect governor valve travel.

ACTION: Adjust the governor valve and linkage to provide the designed valve
travel shown on Turbine Operating Data page.

CAUSE: Governor malfunction.

ACTION: Repair or replace governor. (Chapter 6)

CAUSE: Fluctuations in steam conditions or load.

ACTION: Correct steam condition or driven machine. (Turbine Operating
Data)

______________________________________________________________________

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 Chapter 7
Troubleshooting

TABLE 7-1
TROUBLESHOOTING GUIDE
_______________________________________________________________________

7. TROUBLE OVERSPEED TRIP NOT FUNCTIONING PROPERLY

CAUSE: Trip mechanism improperly adjusted.

ACTION: Adjust the trip mechanism. (Chapter 4)

CAUSE: Defective trip mechanism.

ACTION: Replace worn or damaged parts. (Chapter 4)

CAUSE: Trip valve stem binding.

ACTION: Inspect valve stem and guide bushing. Clean or replace worn parts.
(Chapter 4)

CAUSE: Trip linkage binding.

ACTION: Replace worn linkage parts and lubricate as necessary. (Chapter 4)

CAUSE: Hand trip lever corroded or has incorrect latch engagement.

ACTION: Clean and adjust latch. (Chapter 4)

CAUSE: Excessive vibration.

ACTION: See “Excessive Vibration” in section 1 of this table 7-1.
_______________________________________________________________________

8. TROUBLE TURBINE DOES NOT COOL AFTER SHUT DOWN

CAUSE: Inlet steam shut off leaking.

ACTION: Check that valve is tightly closed and firmly seated. (Chapter 2, 3)

CAUSE: Exhaust shut-off valve leaking. (non-condensing turbine)

ACTION: Check that valve is tightly closed and firmly seated. (Chapter 2, 3)

CAUSE: Steam entering turbine through drain leak off lines.

ACTION: Pipe all drain lines to an open sump or sewer. (Chapter 2)

CAUSE: Steam entering turbine through intermediate leak-off line.

(BYRHH only)
ACTION: Close stop valve in intermediate leak off line between packing cases
and header pipe.
_______________________________________________________________________

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Chapter 7
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TABLE 7-1
TROUBLESHOOTING GUIDE
_______________________________________________________________________

9. TROUBLE EXCESSIVE BEARING WEAR

CAUSE: Excessive bearing temperature.

ACTION: See “Excessive Bearing Temperature” in Table 7-1, Item 10.

CAUSE: Damaged oil rings.

ACTION: Replace oil rings. (Chapter 4)

CAUSE: Low oil level

ACTION: Replenish bearing housing reservoir oil supply. (Chapter 3, 5)

CAUSE: Dirty lubricating oil.

ACTION: Change oil and clean bearings. (Chapter 4, 5)

CAUSE: Rough journal surfaces.

ACTION: Stone or repair the journals or replace the rotor assembly.
(Chapter 4)

CAUSE: Water in lubricating oil.

ACTION: See “Excessive Steam Leakage past Carbon Rings”;
Table 7-1, Item 11

CAUSE: Excessive vibration.

ACTION: See “Excessive Vibration” in Table 7-1, Item 1.

CAUSE: Shaft misalignment.

ACTION: See “Excessive Coupling Wear” in Table 7-1, Item 2.

CAUSE: Internal bearing misalignment.

ACTION: Check bearing housings for damage. Correct alignment. (Chapter 4)
_______________________________________________________________________

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 Chapter 7
Troubleshooting

TABLE 7-1
TROUBLESHOOTING GUIDE
_______________________________________________________________________

10. TROUBLE EXCESSIVE BEARING TEMPERATURE

CAUSE: Worn bearings.

ACTION: Replace bearings. Determine and correct cause of bearing wear.
See “Excessive Bearing Wear” in Table 7-1, Item 9.

CAUSE: Fouled cooling water chambers.

ACTION: Clean cooling water chambers. (Chapter 4)

CAUSE: Incorrect water flow to bearing housing cooling chambers.

ACTION: Regulate cooling water flow. (Chapter 2, 3)

CAUSE: Excess oil viscosity

ACTION: Change oil in accordance with viscosities shown in Chapter 5.
_______________________________________________________________________

11. TROUBLE EXCESSIVE STEAM LEAKAGE PAST CARBON RINGS

CAUSE: Worn or damaged carbon rings.

ACTION: Replace carbon ring assemblies. (Chapter 4)

CAUSE: Dirt or foreign matter in sealing glands.

ACTION: Clean sealing glands. (Chapter 4)

CAUSE: Weak or broken retainer springs.

ACTION: Replace carbon ring assemblies. (Chapter 4)

CAUSE: Shaft area under carbon ring scored, fouled or corroded.

ACTION: Clean and polish, or spray metal and re-machine shaft area under
carbon rings. (Chapter 4)

CAUSE: Restrictions in sealing gland leak-off drain lines.

ACTION: Check and correct any restrictions in the lines, or improperly
designed piping. (Chapter 2)

CAUSE: Excessive gland sealing steam pressure. (Condensing Turbines)

ACTION: Reduce gland sealing steam pressure. (Chapter 3)

CAUSE: Intermediate leak off pressure too high due to worn labyrinth seals or
header pressure too high. (BYRHH only)
ACTION: Replace labyrinth seals. (Chapter 4) Reduce header pressure.
(Chapter 2)

CAUSE: Dirt or foreign matter on spacer ring sealing surfaces.

ACTION: Clean spacer rings. (AYR only)
_______________________________________________________________________
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Chapter 7
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TABLE 7-1
TROUBLESHOOTING GUIDE
_______________________________________________________________________

12. TROUBLE EXCESSIVE LEAKAGE AT TRIP VALVE STEM

CAUSE: Obstructed leak-off line.

ACTION: Clean out lines. (Chapter 2)

CAUSE: Trip valve stem lock nut loose.

ACTION: Tighten snug to bushing. (Chapter 4)
(Chapter 2)

CAUSE: Stem bushings or stem worn.

ACTION: Replace worn parts. (Chapter 4)

CAUSE: Backseating spring weak.

ACTION: Replace spring. DO NOT ADJUST VALVE STEM. (Chapter 4)

CAUSE: Incorrect backseat adjustment.

ACTION: Adjust Trip valve backseat. (Chapter 4)

_______________________________________________________________________

13. TROUBLE EXCESSIVE LEAKAGE AT GOVERNOR VALVE SYSTEM

CAUSE: Obstructed leak-off line.

ACTION: Clean out line. (Chapter 2)

CAUSE: Follower loose.

ACTION: Tighten follower. (Chapter 4)

CAUSE: Stem or bushing worn.

ACTION: Replace worn parts. (Chapter 4, 6)

CAUSE: Packing worn.

ACTION: Replace packing. (Chapter 4)

_______________________________________________________________________

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 CHAPTER EIGHT
ACCESSORIES

INTRODUCTION

This chapter provides information on accessory items included with the unit. Engineered
drawings, instruction manuals, and data sheets are included as required for each
accessory component. The drawing numbers may include a suffix or group number
identifying applicable equipment on the drawing. Be sure to use the suffix listed when
making reference to a drawing.

If this manual is in an electronic format (CD-ROM), scroll down for a list of the Accessory
information contained in this chapter.

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Chapter 8
Accessories

NOTES

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 Chapter 8
Accessories
Form 188-C (05/28/02)

ACCESSORIES
F602328

Index Description Drawing/Document Number

No.
1. Governor Outline Drawing P4045D160002I
Instruction Manual 03040G
Oils for Hydraulic Controls Instruction Manual 25071J
2. Tachometer Outline Drawing P82M471
Instruction Manual SPD-100
Magnetic Pickup Outline Drawing 436023-9
Cable Outline Drawing P8405B550-048

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 Product Manual 03040
(Revision G, 12/2014)
Original Instructions

UG Dial Governor

UG-5.7/UG-8/UG-10 Dial

Installation and Operation Manual

 Read this entire manual and all other publications pertaining to the work to be
performed before installing, operating, or servicing this equipment.
Practice all plant and safety instructions and precautions.
General
Precautions Failure to follow instructions can cause personal injury and/or property damage.

This publication may have been revised or updated since this copy was produced.
To verify that you have the latest revision, check manual 26455, Customer
Publication Cross Reference and Revision Status & Distribution Restrictions, on
Revisions the publications page of the Woodward website:
www.woodward.com/publications

The latest version of most publications is available on the publications page. If

your publication is not there, please contact your customer service representative
to get the latest copy.

Any unauthorized modifications to or use of this equipment outside its specified

mechanical, electrical, or other operating limits may cause personal injury and/or
property damage, including damage to the equipment. Any such unauthorized
Proper Use modifications: (i) constitute "misuse" and/or "negligence" within the meaning of
the product warranty thereby excluding warranty coverage for any resulting
damage, and (ii) invalidate product certifications or listings.

If the cover of this publication states "Translation of the Original Instructions"

please note:
The original source of this publication may have been updated since this
Translated translation was made. Be sure to check manual 26455, Customer Publication
Publications Cross Reference and Revision Status & Distribution Restrictions, to verify whether
this translation is up to date. Out-of-date translations are marked with . Always
compare with the original for technical specifications and for proper and safe
installation and operation procedures.

Revisions—Changes in this publication since the last revision are indicated by a black line
alongside the text.

Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken.
Manual 03040
Copyright © Woodward 1982–2014
All Rights Reserved
Manual 03040 UG Dial Governor

Contents

WARNINGS AND NOTICES ............................................................................III

ELECTROSTATIC DISCHARGE AWARENESS ................................................. IV
CHAPTER 1. GENERAL INFORMATION ........................................................... 1
Introduction .............................................................................................................1
Description ..............................................................................................................1
References .............................................................................................................2
CHAPTER 2. INSTALLATION PROCEDURES.................................................... 4
Introduction .............................................................................................................4
Receiving ................................................................................................................4
Storage ...................................................................................................................4
Mounting Requirements .........................................................................................4
Linkage Attachments ..............................................................................................6
Oil Supply ...............................................................................................................7
CHAPTER 3. PRINCIPLES OF OPERATION ................................................... 11
Introduction ...........................................................................................................11
Component Description ........................................................................................11
Operation of the UG Dial Governor ......................................................................16
CHAPTER 4. GOVERNOR OPERATION AND ADJUSTMENTS .......................... 19
Introduction ...........................................................................................................19
Initial Operation for a New Governor ....................................................................19
Adjustments ..........................................................................................................19
Compensation Adjustments..................................................................................19
Initial Operation for a Repaired or Reassembled Governor .................................21
Test Procedures ...................................................................................................23
Test Completion ...................................................................................................26
CHAPTER 5. TROUBLESHOOTING ............................................................... 27
Introduction ...........................................................................................................27
Troubleshooting ....................................................................................................27
Definitions .............................................................................................................28
Preliminary Inspection ..........................................................................................28
Additional Information for Steam Turbines, Gas and Gasoline Engines ..............32
Governor Field Repairs ........................................................................................33
Removal of Governor from Engine .......................................................................33
CHAPTER 6. REPLACEMENT PARTS ........................................................... 36
Replacement Parts Information ............................................................................36
CHAPTER 7. AUXILIARY EQUIPMENT .......................................................... 47
Introduction ...........................................................................................................47
Synchronizer Motor and Solenoid Shutdown .......................................................47
PM Synchronizer Motor with Housing ..................................................................49
Low Lube Oil Pressure Shutdown ........................................................................50
Magnetic Speed Pickup ........................................................................................50
Micro Switches and Wiring Harness.....................................................................51
CHAPTER 8. PRODUCT SUPPORT AND SERVICE OPTIONS ........................... 52
Product Support Options ......................................................................................52
Product Service Options .......................................................................................53
Returning Equipment for Repair ...........................................................................53
Replacement Parts ...............................................................................................54
Engineering Services............................................................................................54

Woodward i
UG Dial Governor Manual 03040

Contents

Contacting Woodward’s Support Organization ....................................................54

Technical Assistance ............................................................................................55
REVISION HISTORY ....................................................................................56

Illustrations and Tables

Figure 1-1. UG-8 Dial Governor ............................................................................ vi

Figure 1-2. Recommended Output Shaft Travel Adjustment .................................2
Figure 1-3. UG Dial Governor Outline Drawing ......................................................3
Figure 2-1. Linkage Arrangement (for non-linear fuel systems) .............................7
Figure 3-1. UG Dial Governor Schematic Diagram ..............................................13
Figure 4-1. Maximum/Minimum Speed Stop Adjustment on the Governor ..........24
Figure 5-1. Common Bench Tools........................................................................34
Figure 5-2. Normal Field Repair Tools .................................................................35
Figure 6-1a. Parts Illustration for the UG Dial Governor ......................................38
Figure 6-1b. Parts Illustration for the UG Dial Governor ......................................40
Figure 6-1c. Parts Illustration for the UG Dial Governor.......................................42
Figure 6-1d. Parts Illustration for the UG Dial Governor ......................................44
Figure 6-1e. Parts Illustration for the UG Dial Governor ......................................46
Figure 7-1. UG Cover with Bodine Motor and Shutdown Solenoid ......................47
Figure 7-2. Installing Cover with Bodine Synchronizer Motor ..............................48
Figure 7-3. UG-8 Dial Governor Equipped with Bodine Synchronizer Motor .......48
Figure 7-4. Top View of Weatherproof Housing with PM Synchronizer Motor and
Shutdown Solenoid ..........................................................................49
Figure 7-5. UG-8 Governor with PM Motor, Shutdown Weatherproof Housing ...49
Figure 7-6. Low Lube Oil Pressure Shutdown......................................................50
Figure 7-7. Magnetic Speed Pickup .....................................................................50
Figure 7-8. Micro Switches and Wiring .................................................................51
Figure 7-9. Wiring Harness on Cover ...................................................................51

Table 2-1. Oil Chart ................................................................................................8

Table 2-2. Viscosity Comparisons ..........................................................................8
Table 4-1. Test Stand Tools .................................................................................22
Table 5-1. Troubleshooting Chart .........................................................................29
Table 5-2. Governor Output Shaft Travel vs Butterfly Valve Travel .....................33
Table 5-3. List of Common Bench Tools ..............................................................34
Table 5-4. List of Normal Field Repair Tools ........................................................35

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 Manual 03040 UG Dial Governor

Warnings and Notices

Important Definitions
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
 DANGER—Indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
 WARNING—Indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
 CAUTION—Indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
 NOTICE—Indicates a hazard that could result in property damage only
(including damage to the control).
 IMPORTANT—Designates an operating tip or maintenance suggestion.

The engine, turbine, or other type of prime mover should be

equipped with an overspeed shutdown device to protect against
runaway or damage to the prime mover with possible personal injury,
Overspeed / loss of life, or property damage.
Overtemperature / The overspeed shutdown device must be totally independent of the
Overpressure prime mover control system. An overtemperature or overpressure
shutdown device may also be needed for safety, as appropriate.

The products described in this publication may present risks that

could lead to personal injury, loss of life, or property damage. Always
wear the appropriate personal protective equipment (PPE) for the job
Personal Protective at hand. Equipment that should be considered includes but is not
limited to:
Equipment
 Eye Protection
 Hearing Protection
 Hard Hat
 Gloves
 Safety Boots
 Respirator
Always read the proper Material Safety Data Sheet (MSDS) for any
working fluid(s) and comply with recommended safety equipment.

Be prepared to make an emergency shutdown when starting the

engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
Start-up property damage.

On- and off-highway Mobile Applications: Unless Woodward's control

functions as the supervisory control, customer should install a
system totally independent of the prime mover control system that
Automotive monitors for supervisory control of engine (and takes appropriate
action if supervisory control is lost) to protect against loss of engine
Applications
control with possible personal injury, loss of life, or property damage.

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To prevent damage to a control system that uses an alternator or

battery-charging device, make sure the charging device is turned off
before disconnecting the battery from the system.
Battery Charging
Device

Electrostatic Discharge Awareness

Electronic controls contain static-sensitive parts. Observe the
following precautions to prevent damage to these parts:
 Discharge body static before handling the control (with power to
the control turned off, contact a grounded surface and maintain
Electrostatic contact while handling the control).
Precautions  Avoid all plastic, vinyl, and Styrofoam (except antistatic versions)
around printed circuit boards.
 Do not touch the components or conductors on a printed circuit
board with your hands or with conductive devices.
To prevent damage to electronic components caused by improper
handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.

Follow these precautions when working with or near the control.

1. Avoid the build-up of static electricity on your body by not wearing clothing
made of synthetic materials. Wear cotton or cotton-blend materials as much
as possible because these do not store static electric charges as much as
synthetics.
2. Do not remove the printed circuit board (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:
 Do not touch any part of the PCB except the edges.
 Do not touch the electrical conductors, the connectors, or the
components with conductive devices or with your hands.
 When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.

iv Woodward
Manual 03040 UG Dial Governor

Woodward v
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Figure 1-1. UG-8 Dial Governor

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Manual 03040 UG Dial Governor

Chapter 1.
General Information

Introduction
The UG Dial governor is available in three different work outputs:
 UG-5.7—7.1 Nm (5.2 lb-ft)
 UG-8—13.2 Nm (9.7 lb-ft)
 UG-10—15.9 Nm (11.7 lb-ft)

The UG-5.7 and UG-8 both use 827 kPa (120 psi) oil pressure, and the UG-10
uses 1034 kPa (150 psi).

Basic operation, adjustment, troubleshooting, and replacement of parts are

similar for the UG-5.7, UG-8, and UG-10.

Description
The UG is a mechanical-hydraulic governor for controlling diesel, gas, or dual
fuel engines, or steam turbines. The UG is mechanically linked to the fuel racks
or to the fuel valves, depending on the system.

The maximum travel of the output (terminal) shaft is 42°.The recommended

travel of the output shaft is 28° from no load to full load, which allows sufficient
overtravel at each end so that the governor can shut down the prime mover and
also give maximum fuel when required. See Figure 1-2 for recommended output
shaft travel adjustment.

Normally, the UG operates isochronously (constant speed) regardless of load on

the engine, except as described in Chapter 3, Principles of Operation.

Speed droop is incorporated in the UG Dial governor to divide and balance load
between units driving the same shaft or paralleled in an electrical system.

A load limit control is also a standard feature on the UG Dial governor. It limits
the amount of fuel supplied by restricting the travel of the governor output shaft.
An indicator dial shows the governor output shaft limit position.

The load limit control may also be used for shutting down the prime mover by
turning it to zero.

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* UG-5.7—7.1 Nm (5.2 lb-ft)

* UG-8—13.2 Nm (9.7 lb-ft)
* UG-10—15.9 Nm (11.7 lb-ft)

Figure 1-2. Recommended Output Shaft Travel Adjustment

References
The publications listed below are available on Woodward’s website
(www.woodward.com). Some of the manuals are briefly covered in Chapter 7,
Auxiliary Equipment.

Pub. Pub.
Type Number Title
Manual 03013 Shutdown Solenoid for UG Governors
Manual 03016 Low Lube Oil Pressure Shutdown for UG Governors
Product Spec. 03029 UG-5.7/8/10 Governor
Manual 03035 PM Speed Adjusting Motor
Manual 03505 Speed Adjusting (Synchronizing) Motor Parts Catalog
and Lubrication Guide
Manual 25071 Oils for Hydraulic Controls
Manual 25075 Commercial Preservation Packaging for Storage of
Mechanical-Hydraulic Controls
Manual 36052 Magnetic Speed Pickup for PG, UG-8, and UG-40
Governors
Manual 36684 Booster Servomotor
Application Note 50516 Governor Linkage for Butterfly Throttle Valves
Repair Manual 56103 UG Dial Governor Repair Procedure

2 Woodward
Manual 03040 UG Dial Governor

Figure 1-3. UG Dial Governor Outline Drawing

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UG Dial Governor Manual 03040

Chapter 2.
Installation Procedures

Introduction

This chapter provides information necessary for receiving, storage, mounting,

and start-up adjustments.

Receiving
When you receive your UG governor, it will be bolted to a wooden platform in a
vertical position. After testing the governor at the factory, it is drained of oil. This
leaves a light film of oil covering the internal parts, preventing rust. No internal
cleaning is required before installation.

Some drive shafts are sprayed with a light film of oil while others (depending on
customer requirements) are covered with soft seal. Before installation, remove
the soft seal with a rag saturated with mineral spirits.

Storage
If a governor is being stored for any period of time, please refer to Woodward
manual 25075, Commercial Preservation Packaging for Storage of Mechanical-
Hydraulic Controls.

Mounting Requirements
1. Make sure the drive shaft rotates freely.

2. Select the correct length of coupling between the governor and the prime
mover drive.

3. Mount the governor squarely on its mounting pad.

4. Make sure there is no force pushing the drive shaft into the governor.

5. See the outline drawing (Figure 1-3) for mounting hole sizes and governor
dimensions.

6. Make sure the coupling rotates freely but without backlash. Incorrect
alignment of the governor shaft to the coupling, or not enough clearance
between any of the parts, can result in excessive wear and/or seizure of
parts. It can also cause an undesirable high frequency vibration or “jiggle” in
the governor output shaft (see Definitions in Chapter 5 for more
information).

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Manual 03040 UG Dial Governor
The standard UG governor drive gives few installation problems if the alignment
of the governor shaft to the drive coupling is kept.

In the event of a misaligned or broken drive shaft, an overspeed

condition or runaway engine can develop. An overspeeding or
runaway engine can result in extensive damage to the equipment,
personal injury and/or loss of life.

If an optional keyed drive is used when installing the governor, take care to avoid
the following undesirable conditions:

a. Rough gear teeth:

Rough gear teeth, or shaft out of round, can cause vibrations which can
be transmitted to the governor and cause a jiggle in the governor
output shaft. The jiggle can be transmitted to the fuel control resulting
in an undesirable condition. Replace gears if necessary.

b. Incorrect shimming:
Check backlash and re-adjust if necessary to obtain proper mesh
without binding or excessive backlash. Refer to the prime mover
manufacturer’s specifications for the correct amount of backlash.

7. Mount the governor flush with the engine drive pad. If the engine drive pad
is at an angle (from 0° to 45° maximum), the UG must be installed with the
front panel in the upper position. Use a gasket between the governor and
the engine drive pad.

Be sure there is adequate space available around the governor to provide

easy access for installing the control linkage, filling the governor with oil, and
adjusting the speed and compensation system. See the outline drawing
(Figure 1-3) for mounting hole sizes and governor dimensions.

The recommended rated speed range for the governor drive is 1000 to 1500 rpm.
The drive power requirement is 249 W (1/3 hp) at normal speed and operating
temperature. The UG governor may be driven either clockwise or
counterclockwise.

Operating temperature range for the UG governor is –29 to +99 °C (–20 to +210 °F).

8. When installing bevel gears onto a keyed drive shaft, check the gear play
between the drive wheel and the driven wheel very carefully.

Re-adjust the shims above and below the driven gear wheel such that there
is no loading of the driven gearwheel.

Failure to properly adjust the shims and gear play will result in a
frozen governor and major damage.

a. The correct position for these shims and the correct gear play (also
called flank clearance) are provided by the engine manufacturer.
b. It may be necessary to remove the drive from the engine if the bevel
gears cannot otherwise be accessed.
c. Do not tighten the governor base bolts immediately, but test the gear
play several times. Tighten the bolts fully only when there is some gear
play.
d. If the gear play becomes zero before the bolts are tightened, remove
one or more shims above the gear wheel.

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Linkage Attachments
Adjustment of the fuel linkage must provide for control of fuel from “OFF” to
“FULL FUEL” within the limits of the 42° of governor output shaft travel. It must
also provide for approximately 30° output shaft travel between “NO LOAD” and
“FULL LOAD”.

Attach the fuel rack linkage to the governor output shaft. There must be no lost
motion or binding in this linkage. Adequate locking methods must be employed
on the linkage connections.

Be sure to allow sufficient overtravel at each end of the terminal shaft.

Failure to provide sufficient overtravel at maximum fuel position can
prevent the prime mover from giving maximum fuel when required.
Failure to provide sufficient overtravel at minimum fuel position can
prevent the governor from shutting down the prime mover and result
in possible damage to equipment and personal injury.

A linear linkage arrangement is used in applications where the governor output

shaft positioning is directly proportional to the torque output of the prime mover.
Thus, the governor output shaft travel will be directly proportional to the amount
of fuel delivered to the prime mover.

A linear linkage is a linkage arrangement which provides as much movement of

the governor output shaft per increment of valve movement at light loads as it
does at heavy loads.

In applications where a governor is controlling a butterfly valve, such as on a gas

engine, a linear linkage should not be used.

This is due to the inherent design of the butterfly valve which requires only a
small amount of valve travel (for example, 10°) to bring an engine from no load to
half load. By contrast, this design requires a much greater movement of valve
travel (for example, 30°) to bring the engine from half load to full load.

In order to improve governing control at light loads, a compensating linkage is

devised (“non-linear” linkage). This linkage provides greater movement of the
governor per increment of valve movement at light loads than it does at heavy
loads. Figure 2-1 illustrates the relationship between governor output shaft and
butterfly positions obtained with simple linkage of maximum non-linearity. When
installing this linkage, make sure that the two following conditions are obtained
when the linkage is in the no-load position:

1. The lever which is attached to the governor and the connecting link is in line
with the governor output shaft and the point of attachment of the connecting
link to the butterfly lever.

2. The butterfly lever must be at 90° with the connecting link.

See also Table 5-2 for a satisfactory relationship between governor output shaft
travel and butterfly valve travel in a non-linear system.

For more information on non-linear linkage, please refer to Woodward

Application Note 50516, Governor Linkage for Butterfly Throttle Valves.

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Manual 03040 UG Dial Governor

Figure 2-1. Linkage Arrangement (for non-linear fuel systems)

Oil Supply
Use an oil depending on operating temperature for the governor (see Table 2-1).

Primary concern is for the oil properties in the governor.

Fill the governor with approximately two quarts of oil to the mark on the oil sight
glass. After the engine is started and the governor is at operating temperature,
add oil if necessary. Oil must be visible in the glass under all operating
conditions.

Use the information given in Tables 2-1 and 2-2 as a guide in the selection of a
suitable lubricating/hydraulic oil. Oil grade selection is based on the operating
temperature range of the governor. Also, use this information to aid in
recognizing and correcting common problems associated with oils used in
governors.

For applications where the governor shares the oil supply with the engine, use
the oil recommended by the engine manufacturer.

Governor oil is both a lubricating oil and a hydraulic oil. It must have a viscosity
index that allows it to perform over the operating temperature range, and it must
have the proper blending of additives that cause it to remain stable and
predictable throughout this range.

Governor oil must be compatible with seal materials (particularly nitrile,

polyacrylic, and fluorocarbon). Many automotive and gas engine oils, industrial
lubricating oils, and other oils of mineral or synthetic origin meet these
requirements. Woodward governors are designed to give stable operation with
most oils with the viscosity, at the operating temperature, between 50 and 3000
SUS (Saybolt Universal Seconds). At the normal operating temperature, the
viscosity should be between 100 to 300 SUS. Poor actuator response or
instability may be an indication that the oil viscosity is outside this range.

Woodward 7
UG Dial Governor Manual 03040

Table 2-1. Oil Chart

Table 2-2. Viscosity Comparisons

8 Woodward
Manual 03040 UG Dial Governor
Excessive component wear or seizure in a governor indicates the possibility of:

1. Insufficient lubrication caused by:

a. An oil that flows slowly when it is cold, especially during start-up.
b. No oil in the governor.

2. Contaminated oil caused by:

a. Dirty oil containers.
b. A governor exposed to heating up and cooling down cycles, which
creates condensation of water in the oil.

3. Oil not suitable for the operating conditions caused by:

a. Changes in ambient temperature.
b. An improper oil level which creates foamy, aerated oil.

Operating a governor continuously beyond the high limit temperature of the oil
will result in oil oxidation. This is identified by varnish or sludge deposits on the
governor parts. To reduce oil oxidation, lower the actuator operating temperature
with a heat exchanger or other means, or change to an oil more oxidation-
resistant at the operating temperature.

A loss of stable governor control and possible prime mover

overspeed may result if the viscosity exceeds the 50 to 3000 SUS
range. An overspeeding and/or runaway prime mover can result in
extensive damage to the equipment, personal injury and/or loss of
life.

Specific oil viscosity recommendations are given on the oil chart (Table 2-1).
Select a readily available good brand of oil, either mineral or synthetic, and
continue using that same brand. Do NOT mix the different classes of oils. Oil that
meets the API (American Petroleum Institute) engine service classification in
either the “S” group or the “C” group, starting with “SA” or “CA” through “SF” and
“CD” is suitable for governor service. Oils meeting performance requirements of
the following specifications are also suitable: MIL-L-2104A, MIL-L-2104B, MIL-L-
2104C, MIL-L-46152, MIL-L-46152A, MIL-L-46152B, MIL-L-45199B.

Replace the governor oil if it is contaminated, also change it if it is suspected of

contributing to the governor instability. Drain the oil while it is still hot and
agitated; flush the governor with a clean solvent having some lubricating quality
(such as fuel oil or kerosene) before refilling with new oil. If drain time is
insufficient for the solvent to completely drain or evaporate, flush the governor
with the same oil it is being refilled with to avoid dilution and possible
contamination of the new oil. To avoid recontamination, the replacement oil
should be free of dirt, water, and other foreign material. Use clean containers to
store and transfer oil.

Observe the manufacturer’s instructions or restrictions regarding the

use of solvents. If no instructions are available, handle with care. Use
the cleaning solvent In a well ventilated area away from fires or
sparks.

Failure to follow the safety instructions above can result in

dangerous fires, extensive damage to equipment, personal injury
and/or loss of life.

Woodward 9
UG Dial Governor Manual 03040
Oil that has been carefully selected to match the operating conditions and is
compatible with governor components should give long service between oil
changes. For governors operating under ideal conditions (minimum exposure to
dust and water and within the temperature limits of the oil), oil changes can be
extended. If available, a regularly scheduled oil analysis is helpful in determining
the frequency of oil changes.

Any persistent or recurring oil problems should be referred to a qualified oil

specialist for solution.

The recommended continuous operating temperature of the oil is 60 to 93 °C

(140 to 200 °F). The ambient temperature limits are –29 to +93 °C (–20 to +200
°F). Measure the temperature of the governor on the outside lower part of the
case. The actual oil temperature will be slightly warmer, approximately 6 °C
(10 °F).

10 Woodward
Manual 03040 UG Dial Governor

Chapter 3.
Principles of Operation

Introduction
Basic UG operation is similar for all types. The only difference is in the method of
setting the speed. Auxiliary devices provide different functions but do not alter the
basic operation of the governor.

Along with the text, a schematic diagram (Figure 3-1) is provided for visual
means of understanding the operation of the UG Dial governor. This schematic
shows a basic design and does not include any auxiliary equipment.

Component Description
Before getting into the operation of the UG, a brief description of the components
will facilitate understanding the operation.

Oil Pump
The purpose of the oil pump (14) is to provide oil pressure for the governor.

The pump gets its oil from the self-contained sump (15). The oil pump is a
positive displacement gear pump with four check valves (13) for either direction
of rotation. One pump gear is part of the rotating bushing, and the other is part of
the laminated drive. The rotating bushing is driven by the governor drive shaft
which is driven by the prime mover. As the bushing rotates, it rotates the
laminated drive. The oil pump gears can be driven either clockwise or
counterclockwise.

Oil flow is directed through the check valve system into the accumulator system
(11).

Accumulator
The purpose of the accumulator (11) is to store oil under pressure for the
operation of the UG governor. The accumulator (two cylinders) also acts as a
pressure relief valve if oil pressure increases above 827 kPa/120 psi (UG-5.7 and
UG-8) or 1034 kPa/150 psi (UG-10).

The accumulator (11) consists of two spring loaded pistons. Oil is pumped into
the cylinders and pressure is increased as the accumulator springs are
compressed. When the oil pressure exceeds 827 kPa/120 psi (UG-5.7 and
UG-8), or 1034 kPa/150 psi (UG-10), oil is released back to sump through a relief
port (12) in each cylinder.

Oil flows from the accumulator through passages to the top of the power piston
and to the pilot valve system.

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UG Dial Governor Manual 03040

Power Piston
The purpose of the power piston (9) is to rotate the governor output shaft to the
increase or decrease fuel position.

The power piston is a differential type with oil pressure on both sides of the
piston. The top end of the power piston is connected to the governor output shaft
(6) through a power lever and link assembly.

The bottom of the power piston has a larger area than the top of the piston.
Therefore, less oil pressure is needed on the bottom than on the top to maintain
the piston stationary. If the oil pressure is the same on both the top and bottom of
the piston, the piston moves up to rotate the governor output shaft in the increase
fuel direction. The piston moves down only when oil under the piston is released
to sump.

Oil to and from the bottom of the power piston is regulated by the pilot valve
system.

Pilot Valve System

The purpose of the pilot valve plunger and bushing is to control the flow of oil to
or from the bottom of the power piston.

The pilot valve system includes the rotating bushing (38) and the pilot valve
plunger (39). The bushing (38) is rotated by the drive shaft (36) while the pilot
valve plunger is held stationary. Through this rotation, friction between the pilot
valve and bushing is reduced. The pilot valve plunger has a control land that
regulates oil flow through ports in the bushing.

When the pilot valve plunger (39) is lowered, high pressure oil flows under the
power piston (9), raising it. When the pilot valve plunger is raised, oil is released
to sump from under the power piston (9), lowering it. The higher pressure on top
of the power piston(9) forces the piston down. When the pilot valve plunger (39)
is in its centered position, the control land covers the control port as shown in the
schematic (Figure 3-1), and there is no movement of the power piston.

The movement of the pilot valve plunger (39) is controlled by the ballhead system
(23) and the dashpot compensation pistons (34) and (35).

Ballhead System
The purpose of the ballhead system (23) is to sense speed changes of the prime
mover as compared to the speed setting reference given by the speeder spring
(25) and to position the pilot valve plunger (39).

The ballhead system includes a ballhead (23), flyweights (24), a speeder spring
(25), a thrust bearing (30), a speeder plug (29),and a speed setting rod (21).

As the governor drive shaft (36) rotates, the gear on the laminated drive (32)
turns and rotates the ballhead gears (23). The flyweights (24) are attached to the
ballhead with pivot pins, and a thrust bearing (30) rides on the toes of the
flyweights (24). The speeder spring (25) is held in position against the thrust
bearing (30) by the speeder plug (29). The speeder plug (29) is used to set a
pressure on the speeder spring (25).

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Manual 03040 UG Dial Governor

Figure 3-1. UG Dial Governor Schematic Diagram

Woodward 13
UG Dial Governor Manual 03040
As the ballhead (23) rotates, the flyweights (24) pivot outward due to the
centrifugal force. At the same time the speeder spring (25) forces the thrust
bearing (30) downward on the flyweight toes. This downward force opposes the
centrifugal force of the flyweights. Increasing the drive speed increases the
centrifugal force. Compressing the speeder spring (25) with the speeder plug
(29) increases the downward force applied to the flyweight toes, and in turn,
increases the governor speed setting. The prime mover must run faster to
generate a centrifugal force greater than the speeder spring force to balance the
system again.

Speeder spring force or speed setting (25) is controlled manually through the
synchronizer (speed setting) adjusting knob (5). It can also be controlled from a
remote area if the governor is equipped with a speed setting motor (1).

Compensation System
The purpose of the compensation system is to give stability to the governor and
obtain steady state speed control. Also, when correctly adjusted, the
compensation system effectively regulates the amount of fuel necessary to bring
the engine to the required output to adjust to a decrease or increase in load.

The compensation system creates a small temporary change of speed setting

with governor output shaft movement to produce a stabilizing speed droop
characteristic in the governor. The change of speed setting is followed by a slow
return of speed setting to its original value. Compensation is simply another word
for temporary speed droop characteristic.

The compensation system includes a large dashpot compensation piston (34), a

small dashpot compensation piston (35), a floating lever (31), a compensation
adjusting lever (22) with a pivotable fulcrum (18), and a needle valve (33). See
Figure 3-1.

The large dashpot compensation piston (34) is connected to the governor output
shaft (6) by a compensation adjusting lever (22). A pivotable fulcrum (18) rides
on the compensation adjusting lever (22). Changing the fulcrum’s (18) position
allows the compensation lever (22) to control the amount of stroke available for
the large dashpot compensation piston (34).

The small dashpot compensation piston (35) is connected through a floating

lever (31) to the pilot valve plunger (39) and the speeder rod (21).

Moving the large dashpot compensation piston (34) down forces oil under the
small dashpot compensation piston (35). As the small dashpot compensation
piston (35) is forced upward, it lifts the pilot valve plunger (39) to close off the
control port which stops the flow of oil to the bottom of the power piston (9).

The needle valve (33) is a variable orifice which controls the flow of oil between
both the large (34) and the small dashpot compensation (35) pistons, and the oil
sump.

Compensation must be properly adjusted to the particular engine

and load to provide stable operation (see Chapter 4, Compensation
Adjustments).

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Manual 03040 UG Dial Governor

Load Limit Control

The purpose of the load limit control is to hydraulically and mechanically limit the
load that can be placed on the engine by restricting the travel of the governor
output shaft in the increase fuel direction, and consequently the amount of fuel
supplied to the engine.

The load limit control may also be used for shutting down the engine by turning it
to zero.

Do not manually force prime mover linkage to increase fuel without

first turning the load limit control knob to maximum position (10).
Failure to do so may cause damage and/or failure of governor
internal parts.

The load limit control consists of an indicator disc (7) geared to a load limit rack
(8). The control knob is also attached to the load limit cam (16).

Load is limited mechanically by positioning the load limit knob (cam 16). When
the load indicator reaches the preset point, the pilot valve plunger (39) is lifted,
stopping any further increase in fuel.

Turning the load limit control to zero to shut down the engine turns the cam (16)
forcing the load limit (shutdown) lever (20) and shutdown strap (17) down. As the
right end of the load limit (shutdown) lever (20) is forced downward, it pivots
about its fulcrum and lifts the pilot valve plunger (39), releasing oil from under the
power piston (9). Pressure oil acting on top of the power piston (9) forces it
downward, rotating the governor output shaft (6) to minimum fuel and causing
the prime mover to shut down.

Synchronizer
The synchronizer is the speed adjusting control, and is used to change engine
speed for a single unit. On engines paralleled with other units, it is used to
change engine load.

The upper knob (called “SYNCHRONIZER” on most models or “SPEED

SETTING KNOB” on later models) is the control knob.

The lower knob (“SYN. INDICATOR”) has no function of its own but has an
indicator disc which shows the number of revolutions of the synchronizer (speed
setting) control knob.

Speed Droop
Speed droop, or simply droop, is one method of creating stability in a governor.
Droop is also used to divide and balance load between units driving the same
shaft or paralleled in the electrical system.

Droop is the decrease in speed that occurs when the governor output shaft
moves from the minimum to the maximum fuel position in response to a load
increase, expressed as a percentage of rated speed.

If instead of a decrease in speed, an increase takes place, the governor shows a

negative droop. Negative droop will cause instability in a governor.

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UG Dial Governor Manual 03040
Too little droop can cause instability in the form of hunting, surging, or difficulty in
response to a load change. Too much droop can result in slow governor
response in picking up or dropping off a load.

Using an example where the governor speed is 1500 rpm at no load and 1450
rpm at full load, droop can be calculated with the formula:

No load speed – full load speed

%Droop = x 100
full load speed

1500 rpm – 1450 rpm

%Droop = x 100 = 3.5%
1450 rpm

If the decrease in speed is greater than 50 rpm when the governor output shaft
moves from the minimum to the maximum fuel position, droop greater that 3.5%
is shown by the governor. If the decrease in speed is less than 50 rpm, droop
less than 3.5% is shown by the governor.

If the governor output shaft does not use the full 30° of available
travel from “NO LOAD” to “FULL LOAD”, droop will also be reduced
proportionately.

Marks on the droop adjustment scale on the dial panel are reference numbers
only, and do not represent droop percentages. Thus the 100 mark does not
represent 100% droop. It represents the maximum droop percentage available
on that particular UG governor model.

Speed droop consists of a control knob, cam, and linkage, which when preset,
varies the compression of the speeder spring as the output shaft rotates.
Increasing the fuel reduces speeder spring compression and, in turn, the
governor speed setting. The unit gradually reduces its speed as load is applied.
This relationship between load and speed acts as a resistance to load changes
when the unit is interconnected with other units either mechanically or
electrically.

Reducing droop to zero allows the unit to change load without changing speed.
Normally, set zero droop on units running alone. On interconnected units, set the
least amount of droop possible to provide satisfactory load division.

For ac generating units tied in with other units, set droop sufficiently high
(reference numbers 30 to 50 on the dial) to prevent interchange of load between
units. If one unit in the system has enough capacity, set its governor on zero
droop, and it will regulate the frequency of the prime mover system. If its capacity
is not exceeded, this unit will handle all load changes.

Operate the SYNCHRONIZER knob of the governor with zero droop to adjust the
system’s frequency. Operate the SYNCHRONIZER knobs of the governors that
have speed droop to distribute load between units.

Operation of the UG Dial Governor

General Information
Refer to Figure 3-1 with the text to better understand the operation of the UG Dial
governor. This schematic diagram is of a basic design and does not include any
auxiliary equipment.

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Manual 03040 UG Dial Governor
Changes in governor speed setting produce the same governor movements as
do changes in load on the engine. The description that follows is based upon
speed changes caused by load changes.

Decrease in Load
When the prime mover is running on speed, the flyweights (24) are in a vertical
position for normal steady state operation. The pilot valve plunger (39) is
centered over the control port of the rotating bushing, and the control land stops
the flow of pressure oil through the bushing (38) control port. There is no
movement of the power piston (9), and no movement of the governor output shaft
(6).

When a decrease in load occurs and the same fuel setting is maintained, speed
increases. This generates the following sequence of governor movements:

1. As speed increases, the centrifugal force of the flyweights (24) increases

and becomes stronger than the force of the speeder spring (25).

2. The flyweights (24) tip outward and raise the speeder rod (21) and the right
end of the floating lever (31).

3. This raises the pilot valve plunger (39), opening the control port in the
rotating bushing (38). Oil is released from the bottom of the power piston (9)
to sump.

4. Pressure oil on the top side of the power piston (9) moves it downward,
rotating the governor output shaft in the decrease fuel direction.

5. Linkage from the governor output shaft (6) lowers the compensation
adjusting lever (22), which rotates at the fulcrum (18), raising the large
dashpot compensation piston (34).

6. Suction is thus applied to the chamber of the small dashpot compensation

piston (35), lowering the left end of the floating lever (31).

7. This lowers the pilot valve plunger (39) closing the control port (37).

8. As sump oil flows through the needle valve (33) from the sump into the
dashpot compensation piston assembly (34 and 35), the small dashpot
compensation piston (35) is returned to its normal centered position by the
compensation spring at the same rate as the speeder rod (21). This keeps
the pilot valve plunger (39) in its centered position.

9. The control port in the rotating bushing (38) is kept closed by the land on the
pilot valve plunger (39).

10. This stops the governor output shaft and power piston movement in the new
decreased fuel position. This is the position needed to run the prime mover
at the selected speed setting with the new load.

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UG Dial Governor Manual 03040

Increase in Load
When an increase in load occurs and the same fuel setting is maintained, speed
decreases. This generates the following sequence of governor movements:

1. As speed decreases, the centrifugal force of the flyweights (24) decreases

and the opposing speeder spring (25) force is now greater than the
centrifugal force of the flyweights (24).

2. The flyweights (24) tip inward and lower the speeder rod (21) and the right
end of the floating lever (31).

3. This lowers the pilot valve plunger (39), opening the control port in the
rotating bushing (38). Pressure oil is released through the control port into
the lower cylinder of the power piston (9).

4. The power piston is forced upward by the pressure oil acting on the larger
lower surface area of the power piston, and the governor output shaft is
rotated in the increase fuel direction.

5. Linkage from the governor output shaft (6) lifts the compensating adjusting
lever (22), which rotates at the fulcrum (18), lowering the large dashpot
compensation piston (34).

6. Pressure oil is applied to the bottom side of the small dashpot compensation
piston (35), raising the left end of the floating lever (31).

7. This raises the pilot valve plunger (39) closing the control port (37).

8. As pressure oil flows through the needle valve (33) from the dashpot
compensation piston assembly (34 and 35), the small dashpot
compensation piston (35) is returned to its normal centered position by the
compensation spring, at the same rate as the speeder rod (21). This keeps
the pilot valve plunger (39) in its centered position.

9. The control port in the rotating bushing (38) is kept closed by the land on the
pilot valve plunger (39).

10. This stops the governor output shaft and power piston movement in the new
increased fuel position. This is the position needed to run the prime mover
at the selected speed setting with the new load.

In both cases, a decrease or increase in load, the compensation system operates

in opposite directions. The compensation or amount of movement of the large
dashpot compensation piston (34) is controlled by the compensation adjustment,
that is, the position of the fulcrum (18).

The rate at which the small dashpot compensation piston (35) is returned to
normal is controlled by the needle valve adjustment, that is, the rate of flow of oil
through the needle valve (33).

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Manual 03040 UG Dial Governor

Chapter 4.
Governor Operation and Adjustments

Introduction
This chapter describes initial operation and basic adjustments of the UG Dial
governor when placing a new or repaired governor into service.

Initial Operation for a New Governor

Before initial operation of the UG Dial governor, check that all previous
installation steps have been correctly accomplished and that all linkages are
secure and properly attached. See Chapter 2, Installation Procedures. Also, read
all of Chapter 4.

Fill the governor with oil to the top mark on the oil sight glass. Close the needle
valve carefully (clockwise) using a Phillips screwdriver and open it
(counterclockwise) 1/2 to 3/4 turn. Loosen the nut holding the compensation
adjusting pointer enough to move the pointer and set the pointer in the center of
the scale. Tighten the nut.

If replacing a governor, the initial compensation setting can be the same as the
governor just removed.

Be prepared to make an emergency shutdown when starting the

engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.

Use the prime mover manufacturer’s instructions to start the engine.

Adjustments
Normally, the only adjustments for putting a new governor into service are
bleeding entrapped air and adjusting compensation to obtain satisfactory stability
and response. All other operating adjustments were made during factory
calibration in accordance with the manufacturer’s specifications and should not
require further adjustments.

Do not attempt internal adjustment of the governor unless you are

thoroughly familiar with the proper procedures.

Compensation Adjustments
The compensation needle valve and pointer are adjustable parts of the
compensation system. Their settings directly affect governor stability.

Compensation must be properly adjusted to the particular engine and load to

provide stable operation.

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UG Dial Governor Manual 03040
When the prime mover is started for the first time after the governor has been
filled with oil, the governor may be stable at constant speed, yet may need
adjustment. High overspeeds and underspeeds after load changes and slow
return to normal speed indicate the need for compensation adjustment.

Maximum compensation settings generally provide stable steady

state operation, but result in greater offspeeds on load changes.

After the oil in the governor has reached its normal operating temperature, make
the following compensation adjustments without load on the prime mover to be
certain that the governor gives optimum control. See Figure 1-1 for location of the
adjustment parts.

1. To bleed trapped air from the governor oil passages, first loosen the nut
holding the compensation adjusting pointer and set the pointer at its
extreme upward position for maximum compensation. Tighten the nut.

Next, remove the needle valve access plug and open the needle valve two
turns counterclockwise. Use a Phillips screwdriver to avoid damage to the
threads inside the bore and to the needle valve.

Damage to the threads or to the needle valve will cause the governor to
change fuel rhythmically. This is called governor hunt. See Chapter 5 for
more information on hunting.

There are two screwdriver slots in the needle valve, a shallow and a deep
slot, located at right angles to each other. The deeper slot is used to expand
the head of the needle valve and increase friction to prevent vibrations from
changing the needle valve setting. If a plain screwdriver must be used, be
sure to use the shallow slot of the needle valve.

Allow the prime mover to hunt for approximately 30 seconds to bleed

trapped air from the governor oil passages.

2. Loosen the nut holding the compensation pointer and set the pointer as far
as it will go towards minimum compensation. Tighten the nut.

3. Gradually close the needle valve until hunting just stops. If hunting does not
stop, open the needle valve one turn and move the compensation pointer up
by one mark on the front panel indicator scale. Again gradually close the
needle valve until hunting stops.

If hunting does not stop, set the needle valve 1/4 turn open and repeat
setting the compensation pointer up by one mark. Retest the governor until
hunting stops.

The objective of the compensation adjustment procedure is to find

the particular settings for the compensation needle valve and
compensation adjustment pointer at which the prime mover will
return quickly to speed (needle valve adjustment) after a speed
disturbance with only a slight over- or undershoot (compensation
pointer adjustment).

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Manual 03040 UG Dial Governor
4. From this setting, open the needle valve one turn and momentarily disturb
governor stability by turning the load limit knob to increase the load slightly
and bringing it back quickly to its original position. Gradually close the
needle valve until the governor returns to speed with only a small overshoot
or undershoot and:
a. The needle valve is between 1/8 to 1/4 turn open on a governor with an
oil sight glass located in the center of the dial panel.
b. The needle valve is between 3/8 and 3/4 turn open on a governor with
an oil sight glass located on the side of the governor.

Compensation adjustment determines offspeed and needle valve adjustment

determines recovery time.

For most responsive governor control, use as little compensation as

possible. Too much compensation causes excessive speed
overshoots and undershoots upon load changes.

Closing the needle valve more than indicated in (a) and (b) above
makes the governor slow to return to normal speed after a load
change.

Opening the needle valve more than indicated above decreases

governor stability and can cause hunting.

Once the needle valve adjustment is correct, it is not necessary to change the
setting except for large, permanent changes in temperature which affect
governor oil viscosity.

When the compensation adjustment is correct, tighten the compensation pointer

nut and install the needle valve access plug with a copper washer. The plug and
the washer will seal oil seepage around the needle valve.

Initial Operation for a Repaired or Reassembled

Governor
After disassembly or repair, it is very important to test the governor on a test
stand. If a test stand is not available, testing of the governor can be done on the
engine.

If testing of the governor is done on the engine, the operator must be

careful to manually control engine speed until he has proven that the
governor will control engine speed.

Attach a serration wrench to the output shaft in addition to the

normal linkage to manually control engine speed with the serration
wrench.

When satisfied that the governing system is fully operational, remove

the serration wrench.

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 UG Dial Governor Manual 03040
If accurate tests and adjustments are to be made, it is best to use a test stand
since it is difficult to make them when the governor is mounted on an engine.
Write or phone Woodward for a test specification for the governor part number
shown on the nameplate fastened to the governor.

Table 4-1 is a list of tools that are necessary only if a large number of governors
is being tested. For a small number of governors, only the pressure gauge is
needed to check oil pressure during testing.

Table 4-1. Test Stand Tools

Tool Description Woodward Number Application

Woodward Test Stand Engine simulator. Drives governor. Supplies pressure
oil. Includes gauges for testing.
Electronic Counter and Indicates governor drive speed. Must have an output
Frequency Pickup of at least 60 cycles per revolution on a one second
time base. Must indicate speed to within ±1 rpm.
Readouts of display time must not exceed 5 seconds.
Pressure Gauge (0–1380 To check governor oil pressure.
kPa/0–200 psi)
Dial Indicator 8995-037 To check and adjust droop setting.

Before installation, be sure speed droop is not negative. To check droop, first set
the speed droop control knob to zero.

1. Put a dial indicator (tool 8995-037) on the governor with the indicator rod
touching the top of the speed setting gear.

2. Place the serration wrench on the governor output shaft.

3. Rotate the governor output shaft from minimum to maximum fuel position,
and check the dial indicator.

4. No movement of the indicator is zero droop. If movement is greater than

0.05 mm (0.002 inch), adjustment is needed (Clockwise movement of the
indicator is positive droop. Counterclockwise movement of the indicator is
negative droop).

Loosen the locknut (190) on the speed droop screw (189) and turn the screw
counterclockwise to reduce droop. Turn the screw clockwise to increase droop.

When zero droop is obtained (0.05 mm/0.002 inch or less counterclockwise

movement), tighten the locknut again (190).

Check the adjustment again by moving the governor output shaft from minimum
to maximum fuel position. Droop can be zero or positive, it must not be negative.
Check the final droop setting with the governor operating on the prime mover as
shown in “Test Procedures” in this chapter.

Before operating a repaired governor for the first time, check that all installation
steps have been correctly completed. See Chapter 2, Installation Procedures.
Also, read all of Chapter 4.

Be prepared to make an emergency shutdown when starting the

engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.

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Manual 03040 UG Dial Governor

Test Procedures
1. Remove the pipe plug (33) in the base of the governor on the side to the left
of the needle valve plug (30), and attach a 0–1380 kPa/0–200 psi pressure
gauge. (See Figure 1-3 for Pressure Test Point.)

2. Install the governor on a test stand or on the engine pad. See Chapter 2,
Installation Procedures.

3. Fill the governor with oil. See Chapter 2, Oil Supply. The oil level must be to
the mark on the oil sight glass.

4. If the governor is being tested on the engine, start the prime mover
according to the instructions from the manufacturer.

Run the governor until it is at operating temperature.

5. Check that the governor has a 758–827 kPa (110–120 psi) oil pressure
(UG-5.7/UG-8) or 965–1034 kPa (140–150 psi) oil pressure (UG-10) at
normal operating speed.

6. Close the needle valve (32) and open it just enough to cause a small hunt,
using a Phillips screwdriver. If a plain screwdriver must be used, make sure
to use only the shallow slot of the needle valve to avoid damage to the
threads inside the bore and to the needle valve.

Let the prime mover hunt for approximately 30 seconds to remove trapped
air from the governor oil passages.

7. Close the needle valve and open it again one half turn. If the governor
continues to hunt, repeat step 6.

8. Adjust the compensation system. See Compensation Adjustments in this

chapter.

Maximum speed for constant operation of the UG Dial governor is

1500 rpm.

9. While the engine is running, re-check the governor for zero droop. Turn the
speed droop knob to zero and run the governor at normal operating speed
near 0% load. Then load the engine near 100% load. Speed must be within
0 to 3 rpm lower.

If the engine cannot be run at full load and must be run at partial load only,
the rpm decrease must be proportional to the partial load.

10. If adjustment is needed to obtain zero droop, follow this procedure:

Loosen the locknut (190) on the speed droop screw (189) and turn the
screw (189) counterclockwise to reduce droop. Turn the screw clockwise to
increase droop. Tighten the locknut.

Repeat the above procedure until speed is within 0 to 3 rpm lower when
running the engine from no load to full load positions.

Woodward 23
UG Dial Governor Manual 03040
11. To prevent speed setting changes because of engine vibrations, a friction
drive (255) is installed in the speed setting mechanical drive of the UG
governor.

The friction drive (255) must be tight enough to avoid a speed setting
change due to vibrations, and also tight enough to permit the speed setting
motor, if used, to turn the speed setting gear.

If the friction drive is too tight, the synchronizer (speed setting) knob can no
longer be turned manually.

To adjust the friction on the friction drive, first remove the governor cover
(214), then the retaining ring (250) on the friction drive using a No. 1 Truarc
pliers. Do not let the cover (214) or the spring (252) fall into the governor as
the friction drive cover is under spring compression.

Check the torque of the friction drive and set it at 0.17 to 0.28 Nm (1.5 to
2.5 lb-in) with manual speed setting or 0.45 to 0.62 Nm (4.0 to 5.5 lb-in)
with speed setting motor. To increase friction, turn the nut on the shaft
clockwise while holding the speed setting knob. To decrease friction, turn
the nut counterclockwise.

12. Reassemble the friction drive.

13. Set the maximum and/or minimum speed limit on the governor. This
adjustment can also be made with the prime mover running. To make the
adjustment, first remove the governor dial plate (see Figure 4-1).

Figure 4-1. Maximum/Minimum Speed Stop Adjustment on the Governor

24 Woodward
Manual 03040 UG Dial Governor
Turn the synchronizer (speed setting) knob clockwise to increase the speed
setting of the governor from its specified maximum plus 10 rpm.

If the friction drive slips before reaching the required high speed setting,
mark the intermediate (278) and the synchronizer (269) (speed setting)
indicator gears, disengage the synchronizer (speed setting) gear (269),
index it one tooth counterclockwise to allow a higher speed setting, and
engage gear again.

The amount of rpm change is not the same if the speeder screw (177) has a
coarse thread (0.7 threads/mm or 18 threads/inch) or a fine thread (1.3
threads/mm or 32 threads/inch).

Re-engage the synchronizer indicator gear (269) with the high-speed stop
pin, engaging the intermediate gear (278) to prevent further increase in
speed. The high-speed stop pin is the pin closest to the gear center.

On governors equipped with an electric speed adjusting motor, be sure the

motor can run the governor up to its maximum-speed stop and down to its
minimum speed. Reset the torque on the friction drive, if necessary, as in
step 11 above.

On governors equipped with a two-position high-speed stop (overspeed test

device), set the overspeed-test speed as described above, then the lever
catch will provide the normal high-speed stop for the governor. If necessary,
set the high-speed stop to the lever engaged position and then disengage
the lever and advance to the normal high-speed stop position to achieve the
overspeed-test speed.

14. To set the minimum speed limit, turn the synchronizer (speed setting knob)
counterclockwise to decrease the speed setting of the governor to its
minimum speed position.

15. Set the synchronizer knob at zero on the dial.

16. Set the synchronizer indicator dial panel pointer at zero.

17. Position the synchronizer indicator knob about 1.6 mm (0.06 inch) from the
surface of the dial. This prevents the knob from binding the synchronizer
system gear train.

18. On governors equipped with micro switches, operate the governor at the
required high and low speeds to verify correct positioning of the cams that
operate the micro switches.

Adjust the cams by loosening the screws and turning the cams on the shaft.
Tighten the screws again.

19. On governors equipped with solenoid shutdown, please refer to Woodward

manual 03013 for set-up procedures.

20. Turn the load limit knob to zero. The load limit indicator must move to zero.
The governor output shaft will move to its minimum fuel position. Reset the
load limit knob to maximum load.

21. Shut down the engine. Remove the pressure gauge and install a 1/8" socket
pipe plug. Apply a pipe sealer to the threads, and torque the pipe plug to 10
Nm (90 lb-in).

22. Install the governor cover and dial plate.

Woodward 25
UG Dial Governor Manual 03040

Test Completion
For operation of units running alone, set droop at zero. Reducing droop to zero
allows the unit to change load without changing speed (zero droop operation is
also called isochronous operation).

On units connected in parallel or to a single shaft, set the least amount of droop
possible to provide satisfactory load division. Droop allows load division between
two or more prime movers that drive the same shaft or are paralleled in an
electrical system.

For ac generating units tied in with other units, set droop sufficiently high
(reference number 30 to 50 or more on the dial) to prevent interchange of load
between units.

If one unit in the system has enough generating capacity, set its governor on
zero droop, and it will regulate the frequency of the prime mover system. If its
capacity is not exceeded, this unit will handle all load changes.

Operate the SYNCHRONIZER knob of the governor with zero droop to adjust the
system’s frequency. Operate the SYNCHRONIZER knobs of the governors that
have speed droop to distribute load between units.

When two units are set up for optimum single unit performance, paralleling
problems can be encountered. For example, governor response can be too fast
on one governor, requiring too high a speed droop setting to prevent a constant
load interchange between the two governors. When this occurs, the
compensation setting should be moved towards maximum, reducing the single
unit transient performance capability but allowing stable parallel operation within
the allowable speed droop range. Also, check the amount of output shaft travel
on each governor. Too little output shaft travel on a governor can require too high
a droop setting on that governor to obtain steady state control.

Compensation must be properly adjusted to the particular engine

and load to provide stable operation (see Compensation
Adjustments).

When UG governors are used on generator sets operating in parallel and the
lead unit is shifted to slave and vice versa, zero droop must be set on the lead
unit to maintain the frequency for which it is set, and droop must be set on the
slave unit for load distribution between the two units.

For more information on load sharing, please refer to manual 25195, Governing
Fundamentals.

26 Woodward
Manual 03040 UG Dial Governor

Chapter 5.
Troubleshooting

Introduction
This chapter provides instructions for troubleshooting.

It is impossible to anticipate every kind of problem that is encountered in the field.

This manual covers the most common problems experienced. Poor governing
may be due to faulty governor performance, or it may be due to the governor
attempting to correct for faulty operation of the prime mover or the equipment
driven. The effect of any auxiliary equipment on the overall control required of the
governor must also be considered.

Be prepared to make an emergency shutdown when starting the

engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.

Troubleshooting
Oil
Keep the governor oil level to-the mark on the oil sight glass with the unit
operating. The correct oil level is 19 to 32 mm (0.75 to 1.25 inch) below the top of
the governor case.

Dirty oil causes most governor problems. Use clean new or filtered oil. Oil
containers used must be perfectly clean. Oil contaminated with water breaks
down rapidly, causing foaming, and corrodes internal governor parts.

Compensating Adjustment and Needle Valve

The compensating adjustment and needle valve must be correctly adjusted with
the governor controlling the engine or turbine, even though the compensation
may have been previously adjusted at the factory or on governor test equipment.

Although the governor may appear to be operating satisfactorily because the unit
runs at constant speed without load, the governor still may not be correctly
adjusted to the load and to the engine it is to control.

High overspeeds and low underspeeds, or slow return to speed, after a load
change or speed setting change, are some of the results of an incorrect setting of
the compensating adjustment and needle valve.

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UG Dial Governor Manual 03040

Definitions
Use the troubleshooting chart (Table 5-1) on the following pages to determine the
probable causes of faulty operation and to correct these problems.

Terms used in the chart are defined as follows:

Hunt—A rhythmic variation of speed which can originate in the governor or in the
prime mover. (See Table 5-1, Par. 1A, for troubleshooting information.) A hunt
usually has a frequency of less than 5 cycles per minute.

Surge—A sudden variation of speed occurring at periodic intervals which can

also originate in the governor or in the prime mover. (See Table 5-1, Par. 1A, for
troubleshooting information.)

Jiggle—A high frequency vibration of the governor output shaft and fuel linkage.
Do not confuse this with normal controlling action of the governor. A jiggle has a
frequency of more than 50 cycles per minute.

Preliminary Inspection
Governor problems are usually revealed in speed variations of the prime mover,
but it does not necessarily follow that such variations are caused by the
governor. When improper speed variations appear, the following procedure
should be performed:

1. Check the load to be sure the speed changes are not the result of load
changes beyond the capacity of the prime mover.

2. Check engine operation to be sure all cylinders are firing properly and that
the fuel injectors are in good operating condition and properly calibrated.

3. Check the linkage between the governor and fuel racks or valve. There must
be no binding or lost motion.

4. Check the setting of the needle valve and compensation adjustment. (See
Chapter 4, Compensation Adjustments.)

5. Check that the oil is clean and oil level is correct at operating temperature.

The source of most problems in any hydraulic governor stems from dirty oil.
Grit and other impurities can be introduced into the governor with the oil, or
form when the oil begins to break down (oxidize) or becomes sludgy.

The internal moving parts are continually lubricated by the oil within the unit.
Valves, pistons, and plungers will stick and even “freeze” in their bores, due
to grit and impurities in the oil.

If this is the case, erratic operation and poor response can be corrected (if
wear is not excessive) by flushing the unit with fuel oil or kerosene.

The use of commercial solvents is not recommended as they may damage

seals or gaskets.

Change the oil and flush the governor twice a year if possible.

28 Woodward
 Manual 03040 UG Dial Governor
To change oil, remove the drain plug and drain out the old oil. Flush the
governor by filling it with fuel oil, and with the prime mover running at low
speed, cycle the governor by opening the needle valve two or three turns.

Let the governor hunt for a minute or two, then stop the engine and drain the
governor. Flush the governor once again. Refill the governor with oil (see
Chapter 2, Oil Supply).

Restart the engine and reset the compensation adjustment and needle
valve.

6. Check that the drive to the governor is correctly aligned and free of
roughness, side loading, and excessive backlash.

Table 5-1. Troubleshooting Chart

Problem Possible Cause Correction

1. The prime mover A. The problem may be Block the throttle, fuel racks or steam valve in the
hunts or surges. originating in the governor or direction of increase fuel. (Never block the governor
prime mover. output shaft in the direction that would prevent a
complete shutdown.) The same blocking action can
be performed by using the load limit knob on the
governor panel.

If hunting and/or surging continues while the

governor output shaft is blocked, the problem is in
the prime mover.

If, after removing the block, hunting and/or surging

starts again, the problem can be in the governor or
in the prime mover. Go through the compensation
adjustment procedure for the governor (see Chapter
4, Compensation Adjustments). If the problem is still
there, replace the governor with a replacement
governor. Go through the compensation adjustment
procedure for the replacement governor. If the
hunting and/or surging continues, the problem is in
the prime mover.
B. Compensation adjustments Adjust needle valve and compensation adjusting
incorrect. pointer.
C. Dirty oil (sludge) in governor. Drain oil, clean governor, and refill.
D. Low oil level, which permits Add oil to the mark on oil sight glass. If oil level
air to enter and cause foaming. decreases and no external oil leaks can be seen on
This is evident in the governor the governor, check the drive shaft for oil leak.
as spongy operation.
If foaming continues, drain oil and refill using a
different type oil.
E. Oil varnish, which causes Repair governor.
sticking of parts.
F. Lost motion in engine linkage Repair linkage and/or pumps.
or fuel pumps.
G. Binding in engine-to- Repair and realign linkage and/or pumps.
governor linkage or fuel pumps.
H. Governor output shaft travel Adjust travel until proper travel is obtained.
too short to provide full fuel.
I. Spring on yield linkage to fuel Install heavier spring.
racks too weak.

Woodward 29
 UG Dial Governor Manual 03040

Problem Possible Cause Correction

1. The prime mover J. Low oil pressure. Normal Return governor to factory for repair.
hunts or surges. operating pressure is 758 to
(continued) 827 kPa (110 to 120 psi) for the
UG-5.7 and UG-8; 965 to 1034
kPa (140 to 150 psi) for the
UG-10. (See outline drawing,
Figure 1-3, for pressure test
point location.)

Pump check valves are not

seating or accumulator springs
weak.
K. Power piston is sticking. Check for side play or binding of output shaft.
L. Voltage regulator not Check voltage regulator. Operate in voltage droop or
operating properly. manual. Do not disconnect voltage regulator. Adjust,
repair, or replace voltage regulator.
M. Fuel linkage incorrectly set. Rework or reset the linkage from governor to unit to
This might occur if the governor obtain the linear relationship.
has been changed or removed
and replaced. Relationship of
governor travel to power output
of engine should be linear.
N. Faulty linkage. Linkage should be free of binding and lost motion
throughout service life of unit. Check yield links,
shutdown arrangements, etc, to be sure that prime
mover torque changes for very small increments of
governor output shaft travel. Stability and good
steady-state performance will suffer unless this
condition is met.
O. Incorrect non-linear Adjust linkage from governor to gas valve to obtain
relationship between governor linear relationship between governor travel and
travel and power output of the engine output. See Figure 2-1. Also, see application
prime mover. Engine may hunt note 50516.
with light loads and be stable
with a heavy load.
P. Gas or steam pressure too Adjust gas or steam pressure.
high.
Q. Engine misfiring (bad fuel Check pyrometer readings of each cylinder and
injector or low pilot fuel on dual- make necessary repairs or adjustments.
fuel engine).
R. Load limit indicator binding Damaged indicator disc or nameplate must be
on nameplate or load limit shaft corrected or replaced. Load limit shaft must be
bent. replaced if bent.
S. Negative droop when speed Droop calibration out of adjustment. Reset (see
droop knob at zero. Chapter 4, Governor Operation and Adjustments).
T. Governor worn. Return governor to factory for repairs.
2. Fuel racks do not A. Low oil pressure in governor. See Item 1J.
open quickly when B. Cranking speed too low. May be necessary to use a booster servomotor. See
cranking prime mover. manual 36684, Booster Servomotor.
C. Booster servomotor (if used) Check action of automatic air starting valve. See
not functioning properly. manual 36684, Booster Servomotor.

30 Woodward
 Manual 03040 UG Dial Governor

Problem Possible Cause Correction

3. Jiggle at governor A. Rough engine drive or Inspect drive mechanism.
output shaft. governor drive. a. Check alignment of gears.
b. Inspect for rough gear teeth, eccentric gears,
or excessive backlash in gear train.
c. Check gear keys and nuts or set screws
holding drive gears to shafts.
d. Check for bent drive shaft.
e. Check serrated or spline coupling for wear and
alignment.
f. Tighten chain between crankshaft and
camshaft (if used).
g. Check engine vibration damper (if used).

If a keyed drive is used, backlash must be checked and the gear shimmed so that
there is no binding and the backlash is not too great. This should be done each
time a new or replacement governor is installed.

If a serrated drive is used, concentricity of shaft to coupling should be

maintained. Coupling should be as long as possible to permit greater flexibility.
B. Governor is not aligned Loosen governor mounting screws and move the
properly. governor slightly on its mounting pad to align the
drive shaft with its coupling.
C. Failure of flexible drive in Return governor to factory for repairs.
flyweight head.
D. Other possible causes are: Return governor to factory for repairs.
–dirty or worn ballhead bearing
–rough or worn gear teeth or
–bent speeder spring
–damaged drive shaft seal Replace seal retainer.
retainer
E. Air in governor system can Bleed air (see Chapter 4, Test Procedures).
cause a jiggle during start-ups
or transients.
4. Load does not A. Speed droop adjustment Readjust droop to divide load properly.
divide properly on incorrect.
interconnected prime Increase droop to resist picking up (or dropping off)
movers. load.

Decrease droop to increase picking up (or dropping

off) load.
B. Speed settings of the Adjust speed setting so both prime movers run at
governors are not the same. the same speed.
5. The prime mover is A. Needle valve adjustment Readjust compensating needle valve. Open further if
slow to respond to a incorrect. possible to do so without causing instability when
speed change or a running without load. Compensation pointer may be
load change. too far toward maximum.
B. Governor is not sensitive in Friction or wear on flyweight toes—sludge in
measuring speed change governor, return to factory.
(deadband).
C. Low oil pressure in governor. Return governor to factory to inspect pump and
check valves if oil pressure is low.
D. Engine may be overloaded. Reduce load.
E. Restricted fuel supply. Clean fuel supply filters.
F. Load limit knob set to restrict Increase load limit setting.
fuel.

Woodward 31
 UG Dial Governor Manual 03040

Problem Possible Cause Correction

6. The prime mover A. Fuel racks will not open far Adjust engine-to-governor fuel linkage.
will not pick up rated enough, or governor at end of
full load. its stroke and the load indicator Adjust load limiting device or fuel pump stops.
is set at 10.
Check compression of load limit friction spring. Low
compression may permit load limit cam to gradually
work toward reduced load position.
B. Restricted fuel supply. Clean fuel supply filters.

Gas pressure low. Gas with different calorific value.

C. Voltage regulator (if used) Readjust or repair.
not functioning.
D. Engine misfiring. Check pyrometer readings of each cylinder and
make necessary repairs or adjustments.
E. Slipping clutch or belts Make adjustments.
between engine and driven
load.
F. Load limit knob set to restrict Increase load limit setting.
fuel.
7. Governor does not Slipping clutch. Binding or worn Increase compression on clutch spring. Repair or
respond to bevel gears. return governor to factory.
synchronizer motor
switch.
8. The speed of the Droop is negative when Reset droop. See Chapter 4, Governor Operation
prime mover adjustment is zero on the and Adjustments.
increases with an panel. Droop calibration out of
increase in load. adjustment.

Additional Information for Steam Turbines, Gas and

Gasoline Engines
The engine torque versus throttle position for a steam turbine gives a wide
variety of non linear relations. Each type must be compensated for with the
correct compensating linkage to bring the error output shaft movement back into
a near linear relation with the prime mover torque output. Please refer to the
prime mover manufacturer's handbook for the correct linkage selection and
installation.

The torque vs throttle position curve for a gas and gasoline engine which is
controlled through a butterfly valve is always very non-linear. When adapting a
governor to this type of engine, if the linkage is made linear, operation at idle
and light loads is never very stable.

The proper procedure for adapting a governor to this engine with the butterfly
valve is to make the linkage so that it requires greater movement of the governor
per increment of butterfly movement at light load than it does at high load.

This linkage tends to linearize the relation between engine-developed torque and
governor output shaft position (see Figure 2-1).

The table below shows a satisfactory angular position of the governor output
shaft for different openings of the butterfly valve in order to have a more stable
operation at idle and at light loads.

32 Woodward
Manual 03040 UG Dial Governor
Table 5-2. Governor Output Shaft Travel vs Butterfly Valve Travel

Governor Output Butterfly Valve

Shaft Travel Shaft Travel
0° 0°
6° 3°
12° 9°
15° 20°
18° 30°
24° 82°

Governor Field Repairs

Seals and bearings of the governor output shaft and drive shaft can be replaced
in the field.

Seals and bearing replacement require only a partial disassembly of the

governor. See Figures 5-1 and 5-2, and tables 5-3 and 5-4, for a list of common
bench tools and normal field repair tools.

Seals and bearings can be replaced without these tools, however replacement of
parts is made easier if these tools are available.

Order tools from Woodward (see Chapter 8, Service Options). Include in order:
1. The tool description
2. The tool number or part number of the tool required
3. The manual number (this manual 03040)

Removal of Governor from Engine

To replace a governor on the engine, or to replace seals or bearings on the
governor, remove the governor from the engine as follows:

Use care in handling and resting of the governor on the work area.
Do not strike or rest the governor on the end of the drive shaft as
damage may result to the drive shaft, oil seal, bearing, or other
internal parts or surfaces. Set the governor on wooden block(s) to
protect the drive shaft when performing maintenance operations.

1. Drain the oil from the governor and install the drain plug again. Some
governors are equipped with a drain cock for draining.

2. Clean exterior surfaces using a cloth moistened with cleaning solvent.

3. Disconnect auxiliary device wiring, and pneumatic or hydraulic tubing

connections if applicable.

4. Before detaching the output shaft and speed setting linkages, mark both
shaft and lever so they may be easily reinstalled at their original positions.

5. Remove the four stud nuts holding the governor to the mounting pad and lift
the governor off. Remove the gasket between the governor and governor
mounting pad.

Woodward 33
 UG Dial Governor Manual 03040
6. Set the governor on wooden blocks to protect the drive shaft. Be very
careful to avoid striking the end of the drive shaft. Damage to internal parts
of the governor may result.

Table 5-3. List of Common Bench Tools

Ref. Tool
Tool Description Number Number Application
T-handle hex wrench 7/16” 1 189440 Various bolts on UG
T-handle Allen wrench 3/16” 2 8995-047 To install 1/8” pipe plugs
Standard Allen wrench 5/64” 3 8995-048 For No. 8:32 headless set screw
Bench block 4 011971 To press out small bearings and
bushings
No. 2 Phillips head screwdriver 5 8995-049 Various screws on UG
Hooked scribe 6 189792 Removing and installing cotter pins

Figure 5-1. Common Bench Tools

34 Woodward
 Manual 03040 UG Dial Governor
Table 5-4. List of Normal Field Repair Tools

Ref. Tool
Tool Description Number Number Application
William pliers 7 8995-023 Replace retaining ring on drive shaft
Bearing seater 8 8995-024 Replace drive shaft bearing
Seal protector (use with 030952) 9 030951 Fit on output shaft to protect seal
Dial indicator w/ base 10 8995-017 To check droop adjustment
Seal installing tool (Micarta type) 11 030952 Install output shaft seals (for extra long
shafts only)
Bushing driver 12 8995-028 To adjust output shaft bushings
Serration wrench 13 030943 Turning output shaft or drive shaft
Torque wrench w/ 7/16” socket 14 8995-038 25 lb-in torque on drive shaft bearing
retainer plate screws

Figure 5-2. Normal Field Repair Tools

Woodward 35
UG Dial Governor Manual 03040

Chapter 6.
Replacement Parts

Replacement Parts Information

When ordering replacement parts, include the following information:
 Governor serial number and part number shown on nameplate
 Manual number (this is manual 03040)
 Parts reference number in parts list and description of part or part name

Refer to repair manual 56103 for correct and safe procedures when
disassembly and assembly are required. Personal injury may result if
accumulator springs are released suddenly. Use an arbor press to
release or to install the compressed accumulator spring.

36 Woodward
Manual 03040 UG Dial Governor

Parts List for Figure 6-1a

Ref. No. Part Name ........................................... Quantity
03040-1 Retainer ring, 1.283" OD ................................... 2
03040-2 Washer, 1.185" OD ........................................... 2
03040-3 Accumulator spring ........................................... 2
03040-3A Accumulator spring (used in UG-10 only).......... 2
03040-4 Accumulator piston ............................................ 2
03040-5 Soc hd pipe plug, 1/8" ....................................... 1
03040-6 Soc hd pipe plug, 1/8" ....................................... 1
03040-7 Cotter pin, .060 x 1/2"........................................ 1
03040-8 Laminated drive shaft assembly ........................ 1
03040-9 Sleeve retainer .................................................. 1
03040-10 Spirol pin ........................................................... 1
03040-11 Retainer ring .671 ID ......................................... 1
03040-12 Washer .............................................................. 1
03040-13 Driver assembly ................................................ 1
03040-14 Laminated drive spring .................................... 12
03040-15 Pump gear assembly ........................................ 1
03040-16 Straight pin ........................................................ 1
03040-17 Large dashpot compensation piston ................. 1
03040-18 Large dashpot compensation spring ................. 1
03040-19 Large dashpot compensation link...................... 1
03040-20 Oilite bushing .................................................... 2
03040-21 Retainer ring, 1.283" OD ................................... 2
03040-22 Pilot valve bushing ............................................ 1
03040-23 Check valve....................................................... 4
03040-24 Dowel pin .......................................................... 2
03040-25 Dowel pin .......................................................... 2
03040-26 Base .................................................................. 1
03040-27 Washer .............................................................. 5
03040-28 Cap screw, 1/4-28 x 1.000” ............................... 5
03040-29 Pipe plug, 1/8" soc hd ....................................... 1
03040-30 Needle valve plug .............................................. 1
03040-31 Washer .............................................................. 1
03040-32 Needle Valve ..................................................... 1
03040-33 Pipe plug, 1/8" soc hd ....................................... 1
03040-34 Power piston ..................................................... 1
03040-35 Controlet............................................................ 1
03040-36 Soc hd pipe plug, 1/8" ....................................... 1
03040-37 Soc hd pipe plug, 1/8" ....................................... 1
03040-38 Ballhead drive gear ........................................... 1
03040-39 Connecting lever ............................................... 1
03040-40 Straight pin ........................................................ 1
03040-41 Cotter pin, .030 x 3/8"........................................ 2
03040-42 through 49 ................................................... Not Used

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UG Dial Governor Manual 03040

Figure 6-1a. Parts Illustration for the UG Dial Governor

38 Woodward
Manual 03040 UG Dial Governor

Parts List for Figure 6-1b

Ref. No. Part Name ........................................... Quantity
03040-50 Plug ................................................................... 1
03040-51 Output shaft (optional) ....................................... 1
03040-52 Set screw, 1/4-28 x 5/16" .................................. 2
03040-53 Output shaft bushing ......................................... 2
03040-54 Oil seal, 1.128 OD ............................................. 2
03040-54A Compensation adjustment lever pin stop .......... 2
03040-55 Washer, 7/16 x 5/8 x 1/32" ................................ 1
03040-56 Compensation adj. pointer ................................ 1
03040-57 Washer, .328 x .562 x .064 thick ....................... 1
03040-58 Elastic stop nut 5/16-24 ..................................... 1
03040-59 Keyed drive shaft .............................................. 1
03040-60 Key .188 x .190 x 1.062" ................................... 1
03040-61 Spacer ............................................................... 1
03040-62 Nut, 5/8-18 castle .............................................. 1
03040-63 Cotter pin, 1/8 x 1-1/2" ...................................... 1
03040-64 Pilot valve plunger ............................................. 1
03040-65 Spring seat ........................................................ 1
03040-66 Pilot valve spring ............................................... 1
03040-67 Drive shaft ......................................................... 1
03040-68 Ball bearing ....................................................... 1
03040-69 Snap ring ........................................................... 1
03040-70 Bearing retainer plate ........................................ 1
03040-71 Dr hd cap screw, 1/4-28 x 5/8" .......................... 3
03040-72 Oil seal, 1.379" OD............................................ 1
03040-73 Oil seal retainer ................................................. 1
03040-74 Seal retainer gasket .......................................... 1
03040-75 Small dashpot compensation piston assembly.. 1
03040-76 Small dashpot compensation spring ................. 2
03040-77 Small dashpot spring seat (not shown) ............. 1
03040-78 Small dashpot compensation piston guide ........ 1
03040-79 Hex lock nut, 1/4-28 .......................................... 1
03040-80 Dashpot nut ....................................................... 1
03040-81 Shutdown lever bracket ..................................... 1
03040-82 Spring ................................................................ 1
03040-83 Washer, .178 ID ................................................ 1
03040-84 Cotter pin........................................................... 1
03040-85 Headed pin ........................................................ 1
03040-86 Shutdown lever ................................................. 1
03040-87 Washer .............................................................. 2
03040-88 Screw ................................................................ 2
03040-89 Cotter pin........................................................... 1
03040-90 Washer .............................................................. 1
03040-91 Power piston link ............................................... 1
03040-92 Cotter pin........................................................... 1
03040-93 Power lever ....................................................... 1
03040-94 Taper pin, No.3 x 1-1/4" .................................... 2
03040-95 Pin ..................................................................... 1
03040-96 Cotter pin, .060 x 3/4"........................................ 1
03040-97 Compensation lever .......................................... 1
03040-98 Straight pin ........................................................ 1
03040-99 Drilled straight pin ............................................. 1
03040-100 Cotter pin, .060 x 3/4"........................................ 1
03040-101 Straight pin ........................................................ 1
03040-102 Compensation link ............................................. 1
03040-103 Compensation lever fulcrum.............................. 1
03040-104 Compensation lever assembly .......................... 1
03040-105 Preformed Packing Ring, .301 1 D x .070" ........ 1
03040-106 Case .................................................................. 1
03040-107 Output shaft....................................................... 1
03040-108 through 149 ............................................... Not Used

Woodward 39
UG Dial Governor Manual 03040

Figure 6-1b. Parts Illustration for the UG Dial Governor

40 Woodward
Manual 03040 UG Dial Governor

Parts List for Figure 6-1c

Ref. No. Part Name ........................................... Quantity
03040-150 Friction spring pin .............................................. 1
03040-151 Load limit speed droop spring ........................... 1
03040-152 Load limit cam ................................................... 1
03040-153 Speed droop cam assembly .............................. 1
03040-153A Washer, .265 ID x .438 OD x .207-.197 thick .... 1
03040-154 Rack pin ............................................................ 6
03040-155 Load indicator gear (includes items 285 & 286) 1
03040-156 Load limit lever .................................................. 1
03040-157 Load limit strap .................................................. 1
03040-158 Load limit rack ................................................... 1
03040-159 Dial panel .......................................................... 1
03040-160 Ballhead cover .................................................. 1
03040-161 Flyweight ........................................................... 2
03040-162 Flyweight bearing .............................................. 4
03040-163 Flyweight pin ..................................................... 2
03040-164 Torsion spring ................................................... 1
03040-165 Torsion spring (early model).............................. 1
03040-166 Ball bearing ....................................................... 1
03040-167 Ballhead gear assembly .................................... 1
03040-168 Spirol pin ........................................................... 4
03040-169 Spring damped ballhead ................................... 1
03040-170 Speeder rod ...................................................... 1
03040-171 Ballhead assembly ............................................ 1
03040-172 Speeder rod spring ............................................ 1
03040-173 Thrust bearing ................................................... 1
03040-174 Flexloc stop nut ................................................. 1
03040-175 Speeder spring assembly .................................. 1
03040-176 Speeder gear .................................................... 1
03040-177 Speeder screw .................................................. 1
03040-178 Shakeproof washer, No.8 .................................. 2
03040-179 Phil. hd screw, 8-32 x .375 ................................ 2
03040-180 Speed setting screw pin .................................... 1
03040-181 Cotter pin, .030 x .375 ....................................... 1
03040-182 Washer, .375 OD .............................................. 1
03040-183 Speed droop link ............................................... 1
03040-184 Cotter pin, .030 x .375 ....................................... 2
03040-185 Drilled straight pin ............................................. 1
03040-186 Speed droop lever ............................................. 1
03040-187 Speed droop fulcrum ......................................... 1
03040-188 Speed setting screw guide ................................ 1
03040-189 Speed droop screw ........................................... 1
03040-190 Nut, 8-32 ........................................................... 1
03040-191 Extension spring ................................................ 1
03040-192 Speed droop lever screw................................... 1
03040-193 Washer, .500 OD .............................................. 1
03040-194 Cotter pin, .060 x .500 ....................................... 1
03040-195 Speed droop lever ............................................. 1
03040-196 through 199 ............................................... Not Used

Woodward 41
UG Dial Governor Manual 03040

Figure 6-1c. Parts Illustration for the UG Dial Governor

42 Woodward
Manual 03040 UG Dial Governor

Parts List for Figure 6-1d

Ref. No. Part Name ........................................... Quantity
03040-200 115 Vac/dc Bodine motor .................................. 1
03040-201 Motor seal spring............................................... 1
03040-202 Phil fl hd screw, 10-32 x .375 ............................ 4
03040-203 Oil Cup .............................................................. 1
03040-204 Phillips hd screw, 10-32 x 1/2" .......................... 8
03040-205 Lock washer, No.10 .......................................... 8
03040-206 Cover gasket ..................................................... 1
03040-207 Soc hd pipe plug, 1/8" ....................................... 1
03040-208 Base gasket ...................................................... 1
03040-209 Washer .............................................................. 4
03040-210 Cap screw, 1/4-28 x 1.000” ............................... 4
03040-211 Front panel gasket ............................................ 1
03040-212 Elbow, 1/8" ........................................................ 1
03040-213 Oil sight glass .................................................... 1
03040-214 Cover ................................................................ 1
03040-215 Motor bracket .................................................... 1
03040-216 Shakeproof washer, No.8 .................................. 4
03040-217 Phil rd hd screw, 8-32 x .312 ............................. 4
03040-218 Oil filler cap (optional) ....................................... 1
03040-219 Cover (optional)................................................. 1
03040-220 through 249 ............................................... Not Used

Woodward 43
UG Dial Governor Manual 03040

Figure 6-1d. Parts Illustration for the UG Dial Governor

44 Woodward
Manual 03040 UG Dial Governor

Parts List for Figure 6-1e

Ref. No. Part Name ........................................... Quantity
03040-250 Retainer............................................................. 1
03040-251 Friction drive cover ............................................ 1
03040-252 Friction drive spring ........................................... 1
03040-253 Elastic stop nut, .250-28 .................................... 1
03040-254 Friction drive spring ........................................... 1
03040-255 Friction drive case ............................................. 1
03040-256 Drive plate ......................................................... 1
03040-257 Roll pin, .094 dia. x.500 ..................................... 1
03040-258 Needle bearing .................................................. 1
03040-259 Needle bearing .................................................. 1
03040-260 Needle bearing .................................................. 1
03040-261 Horiz. synch. adj. gear ...................................... 1
03040-262 Taper pin, 6/0 .................................................... 1
03040-263 Needle bearing .................................................. 1
03040-264 Synch. adj. shaft................................................ 1
03040-265 Lock washer, No.10 .......................................... 8
03040-266 Socket hd screw 10-32 x 5/8" ............................ 8
03040-267 Synchronizer indicator shaft .............................. 1
03040-268 Spring clip ......................................................... 1
03040-269 Synchronizer indicator gear............................... 1
03040-270 Indicator pointer ................................................ 2
03040-271 Set screw .......................................................... 4
03040-272 Knob .................................................................. 1
03040-273 Plug ................................................................... 1
03040-274 Dial plate ........................................................... 1
03040-275 Knob .................................................................. 1
03040-276 Taper pin, 6/0 x .750 ......................................... 3
03040-277 Shaft .................................................................. 1
03040-278 Idler shaft gear assembly .................................. 1
03040-279 Straight pin ........................................................ 1
03040-280 Oil seal .............................................................. 1
03040-281 Knob .................................................................. 1
03040-282 Load limit comp. spring ..................................... 1
03040-283 Washer, .365 OD .............................................. 1
03040-284 Preformed Packing Ring, .239 ID x.070 ............ 1
03040-285 Bushing included in item 209 ............................ 1
03040-286 Bushing included in item 209 ............................ 1
03040-287 Oil seal .............................................................. 1
03040-288 Knob .................................................................. 1
03040-289 Roll pin, .094 dia. x.500 ..................................... 1
03040-290 Speed droop collar ............................................ 1
03040-291 Load limit speed droop spring ........................... 1
03040-292 Oil seal .............................................................. 1
03040-293 Phillips hd screw, 8-32 x 3/8” ............................ 6
03040-294 Set screw 6-32 .................................................. 1
03040-295 Cover-friction ..................................................... 1
03040-296 Friction disc ....................................................... 1
03040-297 Washer, .750 OD .............................................. 1
03040-298 Friction washer spring ....................................... 1
03040-299 Screw-speed adjust ........................................... 1

Woodward 45
UG Dial Governor Manual 03040

Figure 6-1e. Parts Illustration for the UG Dial Governor

46 Woodward
Manual 03040 UG Dial Governor

Chapter 7.
Auxiliary Equipment

Introduction
A number of optional auxiliary features and devices are available for use with the
UG Dial Governor. These devices permit the governor to perform other
secondary functions such as fuel limiting, low lube oil pressure shutdown, or
effect a shutdown through an electrical solenoid. Auxiliary equipment should be
supplied as original equipment on the governor. It Is recommended that the
customer contact Woodward if field installations are desired.

The following paragraphs provide a brief description of the auxiliary equipment

available and list the manuals where detailed information may be obtained.

Synchronizer Motor and Solenoid Shutdown

Early models of the synchronizer (speed setting) motor use an ac-dc Bodine
motor, externally mounted, and available in any of the following voltages: 12, 24,
32, 48, 64, 115, 125, 230, and 250. Late models use a PM (permanent magnet)
motor using a 115 Vac, or 24 and 32 Vdc, internally mounted.

Figure 7-1 shows a UG cover equipped with solenoid shutdown. It also shows
the synchronizer (speed setting) motor as used on the UG Dial governor.

Figure 7-1. UG Cover with Bodine Motor and Shutdown Solenoid

Two models of the shutdown solenoid are available. One provides shutdown
when energized, and the other when de-energized. Each can be equipped with
or without latch. See manual 03013 for set-up procedures and parts breakdown.

Be prepared to make an emergency shutdown when starting the

engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.

Woodward 47
UG Dial Governor Manual 03040
The synchronizer (speed setting) motor is available separately or with the
solenoid shutdown. It provides the ability to remotely control the governor's
speed setting. Thus, alternator frequencies can be matched or, when operating in
droop mode, load distribution may be changed as required, remotely. Refer to
manual 03505 for the parts reference and lubrication guide.

Figure 7-2 shows the method for installing the cover (267) when equipped with a
motor. Turn the synchronizer knob to align the clutch with the motor's shaft as the
cover is lowered into position.

Figure 7-2. Installing Cover with Bodine Synchronizer Motor

Figure 7-3 shows the completed UG-8 Dial governor equipped with a Bodine
synchronizer motor.

Figure 7-3. UG-8 Dial Governor Equipped with Bodine Synchronizer Motor

48 Woodward
Manual 03040 UG Dial Governor

PM Synchronizer Motor with Housing

Figure 7-4 shows a UG-8 Dial governor with a permanent magnet synchronizer
motor (speed setting motor) and a shutdown solenoid, enclosed in a
weatherproof housing.

At rest, the permanent magnet motor acts as a brake to resist speed changes
due to vibrations.

The weatherproof housing for the PM synchronizer motor can also be equipped
with a shutdown solenoid. There are several supply voltages available for the
solenoid. Contact Woodward for additional information. A conduit connection and
a pin-type connector are also available.

Figure 7-4. Top View of Weatherproof Housing with PM Synchronizer Motor and
Shutdown Solenoid

Figure 7-5 shows the UG-8 governor with PM motor and weatherproof housing.

Figure 7-5. UG-8 Governor with PM Motor, Shutdown Weatherproof Housing

Woodward 49
UG Dial Governor Manual 03040
An explosion-proof housing (UL listed) is also available for use in hazardous
areas. The housing is equipped with a 24 Vdc permanent magnet motor and, as
an option, a 24 Vdc shutdown solenoid (energize-to-shutdown type only).

Low Lube Oil Pressure Shutdown

Figure 7-6 shows a low lube oil pressure shutdown. This device stops the prime
mover when engine oil pressure falls below a safe level. There is no additional
external linkage required.

For more information and parts illustration, see manual 03016.

Figure 7-6. Low Lube Oil Pressure Shutdown

Any failure that would cause the governor to be inoperative would

also cause the shutdown solenoid to be inoperative.

Magnetic Speed Pickup

The magnetic speed pickup monitors governor speed without having to provide
an additional drive pad on the engine. Figure 7-7 shows the assembly on a UG
governor.

For more information, see manual 36052.

Figure 7-7. Magnetic Speed Pickup

50 Woodward
Manual 03040 UG Dial Governor

Be prepared to make an emergency shutdown when starting the

engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.

Micro Switches and Wiring Harness

Micro switches are mounted on the synchronizer indicator shaft as shown in
Figures 7-8 and 7-9. Also shown are the wiring connections and terminal strip.

Figure 7-8. Micro Switches and Wiring Figure 7-9. Wiring Harness on Cover

The micro switches are used in one of two ways.

1. They energize a light which indicates the motor has reached its minimum or
maximum speed-setting position.

2. Instead of energizing a light, they may be used to shut off the electric motor
after reaching the minimum or the maximum speed-setting position.

When used to shut off the electric motor, micro switches also protect the
synchronizer (speed setting) motor should the operator run the speed adjustment
to its limit.

The external wiring to the governor is not provided by Woodward and should be
wired into the connector for the particular application as required.

Woodward 51
UG Dial Governor Manual 03040

Chapter 8.
Product Support and Service Options

Product Support Options

UG governors have the same overhaul interval as the prime mover.

If you are experiencing problems with the installation, or unsatisfactory

performance of a Woodward product, the following options are available:
1. Consult the troubleshooting guide in the manual.
2. Contact the OE Manufacturer or Packager of your system.
3. Contact the Woodward Business Partner serving your area.
4. Contact Woodward technical assistance via email
([email protected]) with detailed information on the
product, application, and symptoms. Your email will be forwarded to an
appropriate expert on the product and application to respond by telephone
or return email.
5. If the issue cannot be resolved, you can select a further course of action to
pursue based on the available services listed in this chapter.

OEM or Packager Support: Many Woodward controls and control devices are
installed into the equipment system and programmed by an Original Equipment
Manufacturer (OEM) or Equipment Packager at their factory. In some cases, the
programming is password-protected by the OEM or packager, and they are the best
source for product service and support. Warranty service for Woodward products
shipped with an equipment system should also be handled through the OEM or
Packager. Please review your equipment system documentation for details.

Woodward Business Partner Support: Woodward works with and supports a

global network of independent business partners whose mission is to serve the
users of Woodward controls, as described here:
 A Full-Service Distributor has the primary responsibility for sales, service,
system integration solutions, technical desk support, and aftermarket
marketing of standard Woodward products within a specific geographic area
and market segment.
 An Authorized Independent Service Facility (AISF) provides authorized
service that includes repairs, repair parts, and warranty service on
Woodward's behalf. Service (not new unit sales) is an AISF's primary
mission.
 A Recognized Engine Retrofitter (RER) is an independent company that
does retrofits and upgrades on reciprocating gas engines and dual-fuel
conversions, and can provide the full line of Woodward systems and
components for the retrofits and overhauls, emission compliance upgrades,
long term service contracts, emergency repairs, etc.

A current list of Woodward Business Partners is available at

www.woodward.com/directory.

52 Woodward
Manual 03040 UG Dial Governor

Product Service Options

Depending on the type of product, the following options for servicing Woodward
products may be available through your local Full-Service Distributor or the OEM
or Packager of the equipment system.
 Replacement/Exchange (24-hour service)
 Flat Rate Repair
 Flat Rate Remanufacture
Replacement/Exchange: Replacement/Exchange is a premium program
designed for the user who is in need of immediate service. It allows you to
request and receive a like-new replacement unit in minimum time (usually within
24 hours of the request), providing a suitable unit is available at the time of the
request, thereby minimizing costly downtime.
This option allows you to call your Full-Service Distributor in the event of an
unexpected outage, or in advance of a scheduled outage, to request a
replacement control unit. If the unit is available at the time of the call, it can
usually be shipped out within 24 hours. You replace your field control unit with
the like-new replacement and return the field unit to the Full-Service Distributor.
Flat Rate Repair: Flat Rate Repair is available for many of the standard
mechanical products and some of the electronic products in the field. This
program offers you repair service for your products with the advantage of
knowing in advance what the cost will be.
Flat Rate Remanufacture: Flat Rate Remanufacture is very similar to the Flat
Rate Repair option, with the exception that the unit will be returned to you in “like-
new” condition. This option is applicable to mechanical products only.

Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned for repair,
please contact your Full-Service Distributor in advance to obtain Return
Authorization and shipping instructions.
When shipping the item(s), attach a tag with the following information:
 return number;
 name and location where the control is installed;
 name and phone number of contact person;
 complete Woodward part number(s) and serial number(s);
 description of the problem;
 instructions describing the desired type of repair.

Packing a Control
Use the following materials when returning a complete control:
 protective caps on any connectors;
 antistatic protective bags on all electronic modules;
 packing materials that will not damage the surface of the unit;
 at least 100 mm (4 inches) of tightly packed, industry-approved packing
material;
 a packing carton with double walls;
 a strong tape around the outside of the carton for increased strength.

To prevent damage to electronic components caused by improper

handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.

Woodward 53
 UG Dial Governor Manual 03040

Replacement Parts
When ordering replacement parts for controls, include the following information:
 the part number(s) (XXXX-XXXX) that is on the enclosure nameplate;
 the unit serial number, which is also on the nameplate.

Engineering Services
Woodward’s Full-Service Distributors offer various Engineering Services for our
products. For these services, you can contact the Distributor by telephone or by
email.
 Technical Support
 Product Training
 Field Service
Technical Support is available from your equipment system supplier, your local
Full-Service Distributor, or from many of Woodward’s worldwide locations,
depending upon the product and application. This service can assist you with
technical questions or problem solving during the normal business hours of the
Woodward location you contact.
Product Training is available as standard classes at many Distributor locations.
Customized classes are also available, which can be tailored to your needs and
held at one of our Distributor locations or at your site. This training, conducted by
experienced personnel, will assure that you will be able to maintain system
reliability and availability.
Field Service engineering on-site support is available, depending on the product
and location, from one of our Full-Service Distributors. The field engineers are
experienced both on Woodward products as well as on much of the non-
Woodward equipment with which our products interface.
For information on these services, please contact one of the Full-Service
Distributors listed at www.woodward.com/directory.

Contacting Woodward’s Support Organization

For the name of your nearest Woodward Full-Service Distributor or service
facility, please consult our worldwide directory published at
www.woodward.com/directory.
You can also contact the Woodward Customer Service Department at one of the
following Woodward facilities to obtain the address and phone number of the
nearest facility at which you can obtain information and service.
Products Used In Products Used In Products Used In
Electrical Power Systems Engine Systems Industrial Turbomachinery
Facility---------------- Phone Number Facility---------------- Phone Number Systems
Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800 Facility---------------- Phone Number
China ----------- +86 (512) 6762 6727 China ----------- +86 (512) 6762 6727 Brazil ------------- +55 (19) 3708 4800
Germany: Germany------- +49 (711) 78954-510 China ----------- +86 (512) 6762 6727
Kempen ---- +49 (0) 21 52 14 51 India --------------- +91 (129) 4097100 India --------------- +91 (129) 4097100
Stuttgart-- +49 (711) 78954-510 Japan -------------- +81 (43) 213-2191 Japan -------------- +81 (43) 213-2191
India --------------- +91 (129) 4097100 Korea -------------- +82 (51) 636-7080 Korea -------------- +82 (51) 636-7080
Japan -------------- +81 (43) 213-2191 The Netherlands - +31 (23) 5661111 The Netherlands - +31 (23) 5661111
Korea -------------- +82 (51) 636-7080 United States ---- +1 (970) 482-5811 Poland--------------- +48 12 295 13 00
Poland--------------- +48 12 295 13 00 United States ---- +1 (970) 482-5811
United States ---- +1 (970) 482-5811

For the most current product support and contact information, please visit our
website directory at www.woodward.com/directory.
54 Woodward
 Manual 03040 UG Dial Governor

Technical Assistance
If you need to contact technical assistance, you will need to provide the following information.
Please write it down here before contacting the Engine OEM, the Packager, a Woodward
Business Partner, or the Woodward factory:

General
Your Name

Site Location

Phone Number

Fax Number

Prime Mover Information

Manufacturer

Engine Model Number

Number of Cylinders
Type of Fuel (gas, gaseous, diesel,
dual-fuel, etc.)
Power Output Rating
Application (power generation, marine,
etc.)
Control/Governor Information
Control/Governor #1

Woodward Part Number & Rev. Letter

Control Description or Governor Type

Serial Number

Control/Governor #2

Woodward Part Number & Rev. Letter

Control Description or Governor Type

Serial Number

Control/Governor #3

Woodward Part Number & Rev. Letter

Control Description or Governor Type

Serial Number

Symptoms
Description

If you have an electronic or programmable control, please have the adjustment setting positions or
the menu settings written down and with you at the time of the call.

Woodward 55
UG Dial Governor Manual 03040

Revision History

Changes in Revision G—
 Added bevel gear installation step to Chapter 2, Mounting Requirements

Changes in Revision F—
 Added overhaul interval information to Chapter 8

56 Woodward
 We appreciate your comments about the content of our publications.
Send comments to: [email protected]

Please reference publication 03040G.

PO Box 1519, Fort Collins CO 80522-1519, USA

1000 East Drake Road, Fort Collins CO 80525, USA
Phone +1 (970) 482-5811  Fax +1 (970) 498-3058

Email and Website—www.woodward.com

Woodward has company-owned plants, subsidiaries, and branches,

as well as authorized distributors and other authorized service and sales facilities throughout the world.
Complete address / phone / fax / email information for all locations is available on our website.
 Manual 25071
(Revision J, 3/2002)
Original Instructions

Oils for
Hydraulic Controls

Reference Manual
 Read this entire manual and all other publications pertaining to the work to be
performed before installing, operating, or servicing this equipment.
Practice all plant and safety instructions and precautions.
General
Precautions Failure to follow instructions can cause personal injury and/or property damage.

This publication may have been revised or updated since this copy was produced.
To verify that you have the latest revision, check manual 26311 , Revision Status &
Distribution Restrictions of Woodward Technical Publications, on the publications
Revisions page of the Woodward website:
www.woodward.com/publications

The latest version of most publications is available on the publications page. If

your publication is not there, please contact your customer service representative
to get the latest copy.

Any unauthorized modifications to or use of this equipment outside its specified

mechanical, electrical, or other operating limits may cause personal injury and/or
property damage, including damage to the equipment. Any such unauthorized
Proper Use modifications: (i) constitute "misuse" and/or "negligence" within the meaning of
the product warranty thereby excluding warranty coverage for any resulting
damage, and (ii) invalidate product certifications or listings.

If the cover of this publication states "Translation of the Original Instructions"

please note:
The original source of this publication may have been updated since this
Translated translation was made. Be sure to check manual 26311 , Revision Status &
Publications Distribution Restrictions of Woodward Technical Publications, to verify whether
this translation is up to date. Out-of-date translations are marked with . Always
compare with the original for technical specifications and for proper and safe
installation and operation procedures.

Revisions—Changes in this publication since the last revision are indicated by a black line
alongside the text.

Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken.
Manual 25071
Copyright © Woodward 1986–2002
All Rights Reserved
Manual 25071 Oils for Hydraulic Controls

Contents

WARNINGS AND NOTICES ............................................................................ II

ELECTROSTATIC DISCHARGE AWARENESS ..................................................III
CHAPTER 1. GENERAL INFORMATION ........................................................... 1
Introduction .............................................................................................................1
Oil Characteristics ..................................................................................................1
Oil Lubrication Properties .......................................................................................2
Performance Additives ...........................................................................................3
Lubrication Protective Additives .............................................................................3
CHAPTER 2. HOW TO SELECT AN OIL........................................................... 5
General Information ................................................................................................5
Proper Oil Selection................................................................................................7
Automatic Transmission Fluids ..............................................................................8
Synthetic Oils ..........................................................................................................8
Remarks ...............................................................................................................11
CHAPTER 3. OIL MAINTENANCE ................................................................. 12
General Information ..............................................................................................12
Oil Change Intervals .............................................................................................12
When to Change Governor Oil .............................................................................14
Contaminated Governor Oil ..................................................................................14
Oil Filters...............................................................................................................14
Oil Lacquering ......................................................................................................16

Illustrations and Tables

Figure 2-1. Oil Chart ...............................................................................................9

Figure 2-2. Viscosity Comparisons .........................................................................9

Woodward i
 Oils for Hydraulic Controls Manual 25071

Warnings and Notices

Important Definitions
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
 DANGER—Indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
 WARNING—Indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
 CAUTION—Indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
 NOTICE—Indicates a hazard that could result in property damage only
(including damage to the control).
 IMPORTANT—Designates an operating tip or maintenance suggestion.

The engine, turbine, or other type of prime mover should be

equipped with an overspeed shutdown device to protect against
runaway or damage to the prime mover with possible personal injury,
Overspeed / loss of life, or property damage.
Overtemperature / The overspeed shutdown device must be totally independent of the
Overpressure prime mover control system. An overtemperature or overpressure
shutdown device may also be needed for safety, as appropriate.

The products described in this publication may present risks that

could lead to personal injury, loss of life, or property damage. Always
wear the appropriate personal protective equipment (PPE) for the job
Personal Protective at hand. Equipment that should be considered includes but is not
limited to:
Equipment
 Eye Protection
 Hearing Protection
 Hard Hat
 Gloves
 Safety Boots
 Respirator
Always read the proper Material Safety Data Sheet (MSDS) for any
working fluid(s) and comply with recommended safety equipment.

Be prepared to make an emergency shutdown when starting the

engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
Start-up property damage.

On- and off-highway Mobile Applications: Unless Woodward's control

functions as the supervisory control, customer should install a
system totally independent of the prime mover control system that
Automotive monitors for supervisory control of engine (and takes appropriate
action if supervisory control is lost) to protect against loss of engine
Applications
control with possible personal injury, loss of life, or property damage.

ii Woodward
Manual 25071 Oils for Hydraulic Controls

To prevent damage to a control system that uses an alternator or

battery-charging device, make sure the charging device is turned off
before disconnecting the battery from the system.
Battery Charging
Device

Electrostatic Discharge Awareness

Electronic controls contain static-sensitive parts. Observe the
following precautions to prevent damage to these parts:
 Discharge body static before handling the control (with power to
the control turned off, contact a grounded surface and maintain
Electrostatic contact while handling the control).
Precautions  Avoid all plastic, vinyl, and Styrofoam (except antistatic versions)
around printed circuit boards.
 Do not touch the components or conductors on a printed circuit
board with your hands or with conductive devices.
To prevent damage to electronic components caused by improper
handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.

Follow these precautions when working with or near the control.

1. Avoid the build-up of static electricity on your body by not wearing clothing
made of synthetic materials. Wear cotton or cotton-blend materials as much
as possible because these do not store static electric charges as much as
synthetics.
2. Do not remove the printed circuit board (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:
 Do not touch any part of the PCB except the edges.
 Do not touch the electrical conductors, the connectors, or the
components with conductive devices or with your hands.
 When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.

Woodward iii
Oils for Hydraulic Controls Manual 25071

iv Woodward
Manual 25071 Oils for Hydraulic Controls

Chapter 1.
General Information

Introduction
This manual serves as a general guide for anyone involved in the selection of oils
for use in Woodward governors or actuators.

One of the primary functions required of an oil is to stand up to high loadings and
high temperatures, while remaining a good lubricant. Oil, as it emerges from the
refinery process, is a slippery liquid, but it lacks additives vital to its intended
functions.

These additives turn a liquid into a lubricant that fights heat, cold, contamination,
corrosion, rust, wear, and other environmental and mechanical hazards.
Lubricant additives are grouped into three general categories according to the
functions they perform:
 protect the lubricated surface
 improve lubricant performance
 protect the lubricant

Surface protective additives include anti-wear agents, corrosion and rust

inhibitors, and detergents and dispersants. Performance additives include pour
point depressants, seal swell agents, and viscosity index improvers. Lubricant
protective additives cover anti-foamants, anti-oxidants, and metal deactivators.

Oil Characteristics
There are four important characteristics to be considered in an oil: viscosity, pour
point, shear stability, and thermal stability.

Viscosity
All natural lubricants thin as they warm, and thicken as they cool. The magnitude
of this change is measured by the Viscosity Index (VI). The higher the VI number,
the less effect temperature has on viscosity change. An oil with a VI of 200 is
very good in this respect.

Pour Point
The pour point of an oil is a measure of its low temperature suitability. Chemical
compounds, called pour point depressants, are used to allow the oil to flow even
at low operating temperature when the oil has thickened.

Shear Stability
Oil viscosity can also change due to shear. Actual mechanical shearing of long
chain polymers in oil will act to lower both the actual viscosity at any given
temperature and the Viscosity Index.

Woodward 1
Oils for Hydraulic Controls Manual 25071

Thermal Stability
Oil viscosity changes will also occur with long-term operation at high
temperatures. In this case, the oil will thicken due to oxidation and evaporation of
the lighter molecules.

Multi-viscosity oils extend the operating temperature range while still maintaining
proper viscosity. However, they have relatively poor thermal and shear stability
resulting in shorter useful life. A good alternative is synthetic oils, since they have
good temperature viscosity characteristics. Synthetic oils are covered in Chapter
2.

Oil Lubrication Properties

Oil lubrication properties are greatly improved by the addition of a variety of
chemical compounds such as anti-wear agents, corrosion and rust inhibitors, and
detergents and dispersants.

If information is needed about the additive contents of an oil, it may be advisable

to check with an oil company representative.

Anti-wear Agents
Mechanical wear from metal-on-metal rubbing or abrasives is normally prevented
by hydrodynamic lubrication with an oil film thick enough to keep the parts
separated. But under certain conditions such as high load, low speed, and low
lubricant viscosity, the lubricant film may rupture and allow metal-to-metal
contact. This condition may exist between thrust bearing surfaces or between
closefitting pump gears and gear pockets.

To prevent wear due to metal-to-metal contact, anti-wear additives found in most

lubricants form a coating which will yield under the shear stress imposed by
minimum lubrication. However, heat from friction between mating surfaces
provides energy for a chemical reaction between the additive and metal surfaces
that result in a protective coating.

Corrosion and Rust Inhibitors

Another important lubrication property of an oil is that it must be able to resist rust
and corrosion and be compatible with seal material.

If a lubricating oil becomes contaminated with moisture, corrosion can develop.

In the case of governors using engine oil, the oil may become contaminated with
the acidic products of combustion.

Detergents and Dispersants

Detergents are compounds used to control deposits at high temperature, while
dispersants are used to control the formation of sludge at low temperature.
Dispersants absorb contaminant particles and keep them in suspension so they
cannot agglomerate and form sludge.

2 Woodward
Manual 25071 Oils for Hydraulic Controls

Performance Additives
Oil performance characteristics also can be greatly improved with additional
compounds such as pour point depressants, seal swell agents, and Viscosity
Index improvers.

If information is needed about the additive contents of an oil, it may be advisable

to check with an oil company representative.

Pour Point Depressants

Pour point depressants are compounds which allow the oil to flow even at low
operating temperature when the oil has thickened. These natural properties of oil
are determined by the crude itself and by the refinery process.

Seal Swell Agents

A number of seals are used throughout a governor to keep the dirt out and the oil
in. Seals are made of many compounds including nitrile and silicon. Currently,
the trend in seal material is to Viton which can withstand prolonged temperatures
to 204 °C (400 °F).

Viscosity Index Improvers

The rate at which mineral oils thin out is described by a mathematical relationship
between their viscosities at 100 °F (38 °C) and 210 °F (99 °C), which is referred
to as Viscosity Index (VI).

Oils with a high VI exhibit less viscosity change with temperature than oils with a
low VI. A lubricant that is expected to perform over a wide temperature range
must usually have a high VI. The VI of oils has received much attention because
ease in starting the engine requires low viscosity at low temperatures, and
normal operation requires an adequate oil film at normal operating temperature.

Wide temperature-range viscosity requirements of oils has been met by treating

the oil with an additive known as a VI improver. VI improvers also improve shear
stability.

Polymeric VI improvers are more likely, however, to be broken apart by shear

forces between moving surfaces. Once this type of permanent shear has
occurred, the polymer contributes less to high-temperature thickening. Therefore,
high VI oils using polymeric VI improvers require a polymer that will continue to
provide adequate thickening at high temperature.

Lubrication Protective Additives

Special additives also are used to increase the lubrication protection given by
oils. Such additives include anti-foamants, anti-oxidants, and metal deactivators.

If information is needed about the additive contents of an oil, it may be advisable

to check with an oil company representative.

Woodward 3
Oils for Hydraulic Controls Manual 25071

Anti-Foamants
When subjected to sufficient agitation, all oils will entrap air and produce foam.
This, in turn, causes more problems. Oil reaction increases exposure of the oil to
oxygen, which increases the rate of oxidation.

Air and foam also reduce lubricant efficiency as a coolant and as a hydraulic
fluid. Retained air changes oil to a compressible fluid and may cause operational
problems. To eliminate foaming, additives with a lower surface tension than the
oil, and low solubility in the lubricants are used. This weakens and ruptures the
oil film surrounding the bubbles.

Anti-Oxidants
The oxidation process is complex and is highly undesirable. Often, additives that
reduce oil oxidation also reduce corrosion.

Decomposition of the oil may also occur, forming a variety of compounds such as
aldehydes, alcohols, and acids. These compounds may further oxidize and react
with each other to form more compounds. Some of these compounds may be
soluble in oil, resulting in a viscosity increase; others may be insoluble and form
varnish or sludge.

Oxidation is affected by many factors: temperature, lubricated materials, crude

source, and refining process. The choice of the anti-oxidant agent used is based
on tests of a particular oil.

Metal Deactivators
Additives that are used as corrosion and rust inhibitors form coatings on metal
surfaces which also act as metal deactivators. Metal deactivators also inhibit
oxidation by coating metals such as lead, copper, and iron, which could act as
oxidation catalysts.

4 Woodward
Manual 25071 Oils for Hydraulic Controls

Chapter 2.
How to Select an Oil

General Information
There are several important factors to consider in the selection of an oil for
proper governor operation. Following is a list of those factors and how they affect
governor operation.

Viscosity
In governor applications, a change in viscosity can seriously affect performance.
If the oil is too thin, the governor can become unstable. If the oil is too thick, the
governor will become sluggish and unresponsive.

The higher the VI (Viscosity Index) number, the less effect temperature has on
viscosity change. Our recommended range of viscosities for proper governor
operation is from 50 to 3000 SUS with a nominal 150 SUS being ideal. With this
in mind, proper oil selection would be that with 150 SUS at operating temperature
and a high VI

A loss of stable governor control and possible prime mover

overspeed may result if the viscosity exceeds the 50 to 3000 SUS
range. An overspeeding and/or runaway prime mover can result In
extensive damage to the equipment, personal Injury, and/or loss of
life.

Pour Point
We recommend an oil with a pour point 8 to 11 Celsius degrees (15 to 20
Fahrenheit degrees) below the lowest starting temperature anticipated. This
avoids possible pump cavitation and slow response. In arctic conditions, it may
be necessary to install an oil heater. Contact Woodward for information
concerning the specific requirements of your installation.

Shear Stability
In applications where severe service is expected or long spans between oil
changes are required, an oil with a high shear stability should be selected. Check
with an oil company representative for information regarding the shear stability of
a particular oil.

Thermal Stability
For service conditions expecting long-term high-temperature operation, an oil
with high thermal stability should be selected. Multi-viscosity oils extend the
operating temperature range while still maintaining proper viscosity. However,
they have relatively poor thermal and shear stability, resulting in shorter useful
life. A good alternative is synthetic oils. These products have good temperature
viscosity characteristics and good thermal and shear stability.

Woodward 5
Oils for Hydraulic Controls Manual 25071
A heat exchanger can be used to lower the operating temperature of a governor.

Corrosion and Rust Inhibitors

Another important factor in the selection of an oil for proper governor or actuator
operation is that it must be able to resist rust and corrosion.

Corrosion is a particular problem in governors because the oil may become

contaminated with moisture. In the case of governors using engine oil, the oil
may become contaminated with the acidic products of combustion.

Sludge Dispersion
Dispersants are especially useful in protecting engines that rarely reach normal
operating temperature. This type of service leads to the formation of sludge,
which coats parts and can block internal oil passages in the governor.

Seal Compatibility
Oils used in governors must be compatible with these materials. While significant
shrinkage or softening of seals cannot be tolerated, a slight swelling is often
desirable. If the base oil cannot cause sufficient swelling, a seal swell agent may
be used.

Oil Oxidation
When subjected to sufficient agitation, all engine/governor oils will entrap air and
produce foam. This, in turn, causes more problems. Oil reaction increases
exposure of the oil to oxygen, which increases the rate of oxidation. Air and foam
also reduce lubricant efficiency as a coolant and as a hydraulic fluid. Retained air
changes oil to a compressible fluid and may cause a perfectly adjusted governor
to become unstable. To eliminate foaming, additives with a lower surface tension
than the oil and low solubility are added to the lubricant used. The additives
weaken and rupture the oil film surrounding the bubbles.

Anti-wear Additives
Oils containing anti-wear additive packages provide more protection during
periods of boundary lubrication, when true hydrodynamic lubrication is not
possible, due to high loads, low speed, excessive temperatures, etc. This
additional lubrication is possible due to the formation of protective films on metal
surfaces.

Zinc dialkyldithiophosphates (ZDPs) are often used as anti-wear additives and

are found in many common hydraulic and engine oils. Governors do not normally
require anti-wear additives, but under certain marginal lubrication conditions may
benefit from their use.

6 Woodward
Manual 25071 Oils for Hydraulic Controls

ZDP is corrosive to silver and tends to attack it. Oils with a ZDP anti-
wear additive are not recommended for use in the PGEV governor
with an oil-filled side plate. The PGEV governor contains a load-
control resistor with silver contacts. Increased silver contamination
of the oil and wear of the load-control resistor contacts may result
from using an oil with a ZDP anti-wear additive. PGE governors and
PGEV governors without an oil-filled side plate may continue to use
oils with a ZDP anti-wear additive, as the oil does not come into
contact with the silver contacts.

Proper Oil Selection

There are two essential factors that need to be considered in the selection of an
oil for proper governor operation. The first one is the SUS viscosity range of the
oil, and the second one is the operating temperature of the governor in its
ambient environment.

Oil Viscosity Range

The recommended range of viscosities for governor operation is from 50 to 3000
SUS at normal governor operating temperature.

This range is shown in the “Legend” (at the bottom of the Oil Chart) and in the Oil
Chart as the “Acceptable Operating Range”. The higher the viscosity number, the
less effect temperature has on viscosity change.

Woodward governors are designed to give stable operation with most oils if oil
viscosity at the operating temperature span is within a range of 50 to 3000 SUS.
The ideal range of viscosities for governor operation is from 100 to 300 SUS at
normal governor operating temperatures. The governor oil operating
temperatures are shown on a scale from –40 to +116 °C (–40 to +240 °F) on top
of the Oil Chart. This range is represented by the white sections in the legend
and in the Oil Table as the “Ideal Operating Range”.

Governor Operating Temperature

The recommended oil temperature for continuous governor operation is 60 to 93
°C (140 to 200 °F). Measure the temperature of the governor or actuator on the
outside lower pan of the case. The actual oil temperature will be slightly warmer,
about 6 Celsius degrees higher (10 Fahrenheit degrees higher). The ambient
temperature range is –29 to +93 °C (–20 to +200 °F).

Governor operation must not be attempted below the pour point of

the oil as the governor can become sluggish and unresponsive.
Seizure of governor internal parts can also result, causing loss of
governor control with resulting damage to equipment and/or
personal injury.

Woodward 7
Oils for Hydraulic Controls Manual 25071

How to Read the Oil Chart

(Figure 2-1)

The cross-hatched sections to the left of the white section in the legend and in
the Oil Chart designate the low temperature limits acceptable for operation for
limited periods of time only.

The hatched sections designated “Pour Point” in the legend and in the Oil Chart
indicate the temperature range where oil gets progressively thicker to reach its
pout point. The approximate pour point is represented by the low temperature
end of the hatched section (left-hand end).

If the oil is too thick, the governor can become sluggish and unresponsive. An oil
with a pour point 8 to 11 Celsius degrees (15 to 20 Fahrenheit degrees) below
the lowest starting temperature anticipated is recommended.

The cross-hatched sections to the right of the white sections in the legend and in
the Oil Chart designate the high temperature limits acceptable for operation for
limited periods of time only. The right-hand end of these sections represents the
approximate degradation temperature of the oil.

Prolonged use at temperatures above this point, without frequent oil change, may
result in governor failure. To avoid governor operation close to the point of oil
degradation, change to an oil more temperature resistant or lower the governor
operating temperature with a heat exchanger, or both.

Under extreme ambient operating temperatures, such as tropical or arctic

operating conditions, it may be necessary to install a heat exchanger or an oil
heater. Contact Woodward for information concerning the specific requirements
of your installation.

Automatic Transmission Fluids

Automatic transmission fluids, such as AT FLUID TYPE F, AT FLUID TYPE A,
OR DEXRON II, are suitable for governor use. Automatic transmission fluid can
be used at temperatures lower than most petroleum oils and at temperatures to
149 °C (300 °F) for short periods. However, at elevated temperatures, internal
governor leakage may develop. Any transmission fluid approved by a
transmission manufacturer should be suitable in a governor, providing viscosity
requirements are met.

Synthetic Oils
Most synthetic lubricants are excellent for governor use, provided they meet
viscosity requirements. Synthetics provide better lubrication than conventional
oils under severe demands, particularly at high speeds or broad temperature
ranges. They are not generally recommended as an alternative to straight
mineral oil in standard applications.

8 Woodward
Manual 25071 Oils for Hydraulic Controls

Figure 2-1. Oil Chart

Figure 2-2. Viscosity Comparisons

Woodward 9
Oils for Hydraulic Controls Manual 25071
The major advantages of the synthetic family of oils over straight petroleum oils
in governor applications are a wider temperature range, a high resistance to
oxidation, and a very low volatility. The disadvantages are cost and more limited
availability in some areas. As with any oil, it is not recommended that these be
mixed with each other or with petroleum oils.

Some classes of synthetic oils may not be compatible with

diaphragms, gaskets, and seals. Serious damage to diaphragms,
gaskets, and seals can result, requiring replacement of parts. If in
doubt, contact Woodward for specific recommendations.

Synthetic lubricants are classed according to chemical source: for example, the
silicones, the polyglycols, the synthesized hydrocarbons, and the organic esters.

Silicone Lubricants
The name "silicones" has been broadly applied to several different base fluids,
and they are available in a wide range of viscosities.

The main advantage over petroleum oils comes from the formulations that
provide very high viscosity index (usually in the 200 to 300 range), high
resistance to oxidation, and very low volatility.

Polysulfide additives have greatly improved the load-carrying capacity and anti-
wear properties of silicone lubricants. Silicone oils have little effect on most
rubbers, but this is not the case with other oils. Systems previously lubricated
with other oils should be cleaned and flushed.

Silicone oils are used in high temperature, high pressure hydraulic systems, air
compressors, and gear boxes. The cost of these oils is competitive with other
synthetic oils.

Polyglycol Lubricants
Examples of polyglycol lubricants are the glycols, polyethers, and polyalkylene
glycols. These are the least expensive of the synthetics.

They have excellent viscosity-temperature characteristics, have a low volatility

comparable with silicones, and have a good lubricating quality. They are also
compatible with other synthetic lubricants, and they readily accept additives for
further improvement of their properties.

Polyglycols are not compatible with petroleum oils and are not acceptable for
governor use in that they attack paint and other non-metallic materials, although
they have little effect on rubber.

Synthesized Hydrocarbons
Synthesized hydrocarbons are high performance oils that are made from a
petroleum-derived raw material and not from the refining of petroleum.

10 Woodward
Manual 25071 Oils for Hydraulic Controls
Several types of synthesized hydrocarbons (SHC) are now available. SHC oils
are compatible with petroleum oils and the systems for which petroleum oils are
designed. These oils do not deteriorate rapidly at high temperatures and do not
congeal readily at low temperatures. SHC base fluids are free of aromatics,
sulfur, and wax normally present in conventional mineral oils.

Organic Esters
Organic esters are formed by reacting of alcohol and certain types of acids. The
two categories of esters used mostly for synthetic oils are dibasic acid ester and
polyol esters. Characteristics of organic esters are much the same as the
synthesized hydrocarbons.

Remarks
In applications where the Woodward governor or actuator shares the oil supply
with the engine, use the oil recommended by the engine manufacturer. Protect
governors or actuators using engine oil with a suitable filter. Refer to the
appropriate governor manual for filter size requirements.

Governors with a self-contained oil supply, or using a self-contained oil sump, do

not require an oil containing detergents or dispersants since they do not have the
“hot spots” found in internal combustion engines, and do not have the
contaminants resulting from the internal combustion. As a result, oil that has
been carefully selected to match the operating conditions, and is compatible with
governor seals, is suitable for governor operation.

Providing all other necessary characteristics are met, most detergent oils are
satisfactory for use in governors and actuators. The oil that meets the
requirements and is locally available should be selected.

In addition to oils listed in the Oil Chart, oils which meet the API (American
Petroleum Institute) engine service classification in either the “S” group or the “C”
group (starting with “SA” and “CA” through the current API standard) are suitable
for governor service. Oils meeting performance requirements of the following US
military specifications are also suitable:
 MIL-L-2104A
 MIL-L-2104B
 MIL-L-2104C
 MIL-L-46152
 MIL-L-46152A
 MIL-L46152B
 MIL-L-45199B

Woodward 11
Oils for Hydraulic Controls Manual 25071

Chapter 3.
Oil Maintenance

General Information
Oil maintenance is essential to long and reliable governor operation. Regular oil
changes must be maintained, but there are also other important factors to
consider.

Once a class of oil is selected, continue using that oil. Adding or changing oil of
one class to another class without thoroughly cleaning a hydraulic system may
cause operational problems such as foaming, filter plugging, and sludge
formation. Some classes of oil may not be compatible with diaphragms, gaskets,
or seals.

Any water, regardless of the quantity, in a governor should immediately be

removed and the oil changed. Water, even in trace amounts, contributes
significantly to early bearing failure as well as forming oxides that also contribute
to failures.

Clean oil is a necessity, whether filling the governor for the first time or whether
adding make-up oil. Clean oil cannot remain clean if the container or pouring
spout is not clean. Partially used cans of oil should not be used unless kept
covered in a clean area. Cleanliness of oil and container cannot be overstressed.

Most governors with self-contained sumps do not have filters or screens, and this
makes it essential that contaminants are not introduced into the governor through
the oil. Make sure to protect governors using engine oil with a suitable filter.
Refer to the appropriate governor manual for filter size requirements.

The effects of oil on governors using engine oil are determined by filter changes
and engine oil condition. If engine manufacturer's oil recommendations are
closely followed, satisfactory service should result.

Oil Change Intervals

Self-Contained Oil Sump
The “best time” to change oil is difficult to determine. The best time, of course, to
change the oil is just before the oil is worn out, but before any damage to the
machine has occurred.

This condition is best determined by oil analysis, but because the cost of doing
this exceeds the cost of a quart or two of governor oil, it is not a practical solution
on a continual basis. Analysis can be used to set up a maintenance schedule
which should remain in effect as long as the original conditions do not change.
Experience with other hydraulic equipment similar to governors can also be used
as a guideline. Conditions such as operating temperature, atmospheric
conditions which include dirt, moisture, etc., or anything that may change the
composition of the oil, or shorten its useful life, should be taken into account
when determining the frequency of oil changes.

Anytime a known contaminant gets into the governor, the governor should be
drained, flushed, and refilled with clean oil as soon as possible.

12 Woodward
Manual 25071 Oils for Hydraulic Controls
Particles of dirt and water in the oil are the greatest causes of governor or
actuator failures. Particular care should be taken to keep dirt and moisture out of
opened or stored governors and opened control lines.

Breakdown of oil or depletion of additives is another frequent cause of governor

failure. The presence of sludge, varnish, sediment, or a dirty filter is a good
indication that an oil change is required. It is also an indication that perhaps a
different oil should be used, especially if it has only been a short time since the
last oil change.

A varnish buildup is an indication that governor operating temperatures are

exceeding the capability of the oil. This problem can usually be solved by going
to an oil with good high temperature characteristics or by installing a heat
exchanger. Low operating temperatures may lead to the formation of sludge.
Sludge is a complex mixture of products from sources such as fuel combustion,
water, carbon, and oxidized oil that has agglomerated and is no longer soluble in
oil.

Sludging may be controlled by raising the governor operating temperature,

increasing the frequency of oil changes, or by changing to a different type of oil.
Fluids, such as automatic transmission fluids, may prove to be more resistant to
sludge than some engine oils.

Oil that has been carefully selected to match the operating conditions and is
compatible with governor seals should give long service between oil changes.
For governors operating under ideal conditions (minimum exposure to dust and
water, within the temperature limits of the oil), oil changes can be extended to
two or more years. If available, a regularly scheduled oil analysis is helpful in
determining the frequency of oil changes.

Engine Oil Governors

Oil change intervals are dependent upon the various operating conditions of the
engines and the sulfur content of the diesel fuel used.

Oil change intervals are normally recommended by the engine manufacturer for
the engine. However, if governor problems develop due to oil breakdown or
contaminated oil, the frequency of oil changes should be increased for a specific
lubricant.

A conservative recommendation of high temperature degradation threshold for a

variety of lubricant types is listed below.

Degradation Begins
Fluid Family °C °F
Natural petroleum 93 200
Polyglycols 107 225
Diesters 121 250
Synthetic hydrocarbons 121 250
Polyol esters 135 275
Methyl silicons 149 300
Phenyl silicons 204 400
Halogenated silicons 218 425
Polyphenyl ethers 246 475
Fluoroethers 288 550

Woodward 13
Oils for Hydraulic Controls Manual 25071

When to Change Governor Oil

Oil should be changed if:
 Appearance is different than when new.
 Oil feels gritty when rubbed between fingers.
 Oil smells different than when new. (NOTE: some oil may smell burned and
still be acceptable. Check with oil company representatives.) If in doubt,
change oil.
 Any water, antifreeze, or other incompatible material contaminates the oil.
 Viscosity has changed; increased or decreased.
 Excessive wear of parts occurs.
 If governor has been run at temperatures exceeding the recommended limit
for the type of oil use.
 If governor operating temperatures have changed, bringing fluid viscosity
outside of ideal operating condition.

Contaminated Governor Oil

Replace the governor oil if it is contaminated. Also change it if it is suspected of
contributing to governor instability. Drain the oil while it is still hot and agitated.
Flush the governor with a lighter weight of the same oil or with a solvent having
some lubricating quality before refilling with new oil.

Be sure the solvent is compatible with seals. Serious damage to

diaphragms, gaskets, and seals can result, requiring replacement of
parts. If in doubt, contact Woodward for specific recommendations.

If the drain time is insufficient for the solvent to completely drain or evaporate,
flush the governor with a lighter weight of the same oil it is being refilled with to
avoid dilution and possible contamination of the new oil. To avoid
recontamination, the replacement oil should be free of dirt, water, and other
foreign material. Use clean containers to store and transfer oil.

Observe manufacturer's instructions or restrictions regarding the

use of solvents. If no instructions are available, handle with care. Use
the cleaning solvent in a well ventilated area away from fires or
sparks.

Failure to follow above safety instructions can result in dangerous

fires, extensive damage to equipment, personal injury and/or loss of
life.

Oil Filters
Industrial surveys show that 80% of all governor problems are caused by dirty or
contaminated oil. Although particles of dirt are always present, good properly-
maintained filtration controls dirt particles effectively.

Proper use of filtration not only pays for itself, but it also reduces the overall cost
of operation and maintenance. Compared to the cost of downtime, proper
filtration is a good investment.

14 Woodward
Manual 25071 Oils for Hydraulic Controls

Selection Of Filter Element

It is relatively easy to under-filter or to over-filter because of the wide range of
contaminants and the wide range of filter materials available to control them.

Filter material which is too coarse allows dangerous contamination. Filter

material which is too fine requires replacement too often, or if not changed, filters
operate in the bypass mode and all protection is gone.

Filter Element Specifications

Beta Ratio
The Beta Ratio is a numerical representation of the efficiency of a filter. It is the
number of particles of a given size found upstream of a filter divided by the
number of same-size particles found downstream, as described by the multi-pass
test method recognized by ANSI, NFPA, and ISO (ANSI/B93.31-1973).

βx = __N(up)__, where x = particle size (in µm)

N(down)

Thus β10 = 2 means that the filter will remove 1 particle greater than 10 µm for
every 2 particles greater than 10 µm entering the filter.

In the above example, assume 10 000 particles greater than 10 µm were counted
upstream, and 5000 particles greater than 10 µm were counted downstream.
Then,

β10 = __10 000__ = 2

5000

Some filter literature may show a rating as:

βx = 2/20/75, x = 6/11/15
which means: β6 = 2, β11 = 20, β15 = 75.

The first three numbers (2/20/75) are the Beta ratings at the particle size of the
second three numbers (6, 11, and 15 µm respectively).

Efficiency
The efficiency of a filter at a given particle size can be derived by the formula:

Efficiency = (1–1/β) x 100%

So, if β10 = 2
Efficiency at 10 µm = (1–1/2) x 100% = 50%

Woodward 15
Oils for Hydraulic Controls Manual 25071
Here is an efficiency table for “x” size particles:

βx = 1.01 is 1% efficient
βx = 1.1 is 9% efficient
βx = 1.5 is 33% efficient
βx = 2.0 is 50% efficient (nominal)*
βx = 5.0 is 80% efficient
βx = 10.0 is 90% efficient
βx = 20.0 is 95% efficient
βx = 75.0 is 98.7% efficient (absolute)*
βx = 1000.0 is 99.9% efficient
βx = 3000.0 is 99.97% efficient
*—The filtration industry is coming to accept a nominal rating as 50% efficient at removing
a given particle size, and an absolute rating as at least 98.6% efficient at removing a given
particle size.

Filter Capacity
Filter capacity is the amount of contaminant (measured in grams) that a filter
element will hold before reaching a specified differential pressure. Everything
else being equal, the capacity indicates the service life of the element. The
greater the capacity, the longer the life.

Oil Compatibility
Filtering elements are compatible with petroleum base lubricating oils. When
using synthetic fluids, it is advisable to check with a filter company representative
regarding compatibility of specific elements.

Oil Lacquering
Hydro-mechanical governors can be affected by a condition known as oil
“lacquering”. If not prevented, lacquering can lead to various possible failure
modes, with the potential for the governor to stick in the max fuel or min fuel
position.

Lacquering can lead to governor failure, with the potential for engine
overspeed. In a marine application, a vessel could be unable to
maintain headway. Preventing lacquering, and having a backup
governing/safety system, are essential for safety.

Lacquering is defined as the condition in which the governor is coated internally

by a residue from the oil (often referred to as varnish or sludge). The deposits
form a hard layer which is difficult and time-consuming to remove (the cost of
cleaning a lacquered governor can be as high as 40% of the new price of such a
unit.). Lacquering is generally accompanied by a smell similar to burnt oil.

The results can range from sticking pilot valves to plugged oil passages and
orifices.

Lacquering is generally caused by the oil breaking down, which can be caused
by:
 too high an oil temperature;
 too long an interval between oil changes;
 water condensing inside the governor during cooldown periods (water in oil
can cause hydrolysis which is a known failure mode for oils).

16 Woodward
Manual 25071 Oils for Hydraulic Controls
Oil selection is important, as some oils are less prone to lacquering than others.
It is up to the plant operator/vessel owner and the oil supplier to establish the
correct oils and change intervals for each application. Such a selection should
consider operating temperature, oil change interval, and other operating
conditions known to the plant operator/vessel owner. A proper selection can
achieve suitable economies of cost and change interval while also preventing
lacquering.

Any governor can be affected, depending on oil change interval, operating

temperature, and oil type. Some governor types work their oils harder than
others.

Since Woodward is cannot be aware of the operating conditions of each

application, here are some general recommendations:
 Oil Temperature—Woodward recommends that the oil temperature for
continuous operation be between 60 and 93 °C (140 and 200 °F).
 Oil Change Interval—Because oil change interval must take into
consideration all operating conditions, the correct oil change interval must
be established between the plant operator/vessel owner and the oil supplier.
 Oil Selection—Woodward specifies two essential factors that need to be
considered in the selection of an oil for proper governor operation:
 viscosity range—allowed is 7.5 cSt (50 SUS) to 650 cSt (3000 SUS);
ideal is 20 cSt (100 SUS) to 65 cSt (300 SUS).
 operating temperature—recommended is an oil temperature for
continuous operation between 60 and 93 °C (140 and 200 °F).

Failure to avoid lacquering of oil inside a governor is considered to

be a misuse outside Woodward control. Such misuse is not covered
by Woodward warranty.

If a governor has become lacquered, it is imperative that this

situation be diagnosed and corrected as soon as possible. A
lacquered governor should not be used, since this can have serious
consequences.

Carefully consider the choice of governor oil with your oil supplier. When
choosing an oil interval, start with shorter than expected intervals and slowly try
longer intervals. Monitor the condition of the oil, especially the build-up of
deposits, to ensure that the oil remains within the operating conditions defined by
the oil supplier.

Woodward 17
 We appreciate your comments about the content of our publications.
Send comments to: [email protected]

Please reference publication 25071J.

PO Box 1519, Fort Collins CO 80522-1519, USA

1000 East Drake Road, Fort Collins CO 80525, USA
Phone +1 (970) 482-5811  Fax +1 (970) 498-3058

Email and Website—www.woodward.com

Woodward has company-owned plants, subsidiaries, and branches,

as well as authorized distributors and other authorized service and sales facilities throughout the world.
Complete address / phone / fax / email information for all locations is available on our website.
 SPD-100 Series

Signal-Powered

Digital
Tachometer

Heavy-duty. Ideally suited for

indoor and outdoor applications.
Solid-state. Lighted version
available.

2-Year *THIRD PARTY

APPROVALS,
Warranty next page.

FEATURES
Signal and power derived totally from
magnetic pickup or pulser. Standard SAE case size fits panels with
3-3/8 inch (86 mm) openings.
Intrinsically safe. Can be used in
hazardous environments with approved Gasketed and spray-proof.
Dynalco pickups. (See THIRD PARTY
APPROVALS, next page.) Ideal for OEM use.

No power supply connections. High Can be paralleled with governors and/

immunity to electrical noise. or speed switches.

Can be field-calibrated. Can share existing pickups or pulsers;

draws only microamperes.
High accuracy: 1 rpm resolution.
Ground-free terminals have no polarity;
High shock and vibration resistance. easy installation.

©1999 Dynalco Controls 1199F

3690 N.W. 53rd Street, Fort Lauderdale, FL 33309 U.S.A.

(954) 739-4300 • Fax: (954) 484-3376 • Website: www.dynalco.com
SPECIFICATIONS
EXTERNAL POWER REQUIREMENTS GATE TIME RANGES
All models are signal-powered. Lighted SPD-100 Series : field-selectable from 0.26
versions: 12 or 24 Vdc, depending on model. to 5.7 seconds.
SPD-108 Series: field-selectable from 0.13
DISPLAY to 2.85 seconds.
Four active digits (0 to 9999), non-blinking This accommodates calibrations for an
LCD display; character height of 0.5 inches extremely broad range of corresponding
(14 mm). Display contrast increases with pulses per second.
increasing ambient light.
MAGNETIC PICKUPS
INPUT SIGNAL VOLTAGE Dynalco Magnetic Pickups M102 and
From pickups, pulsers, shaft encoders, etc. M107 are used with the SPD-100 Series in
Minimum signal amplitude: 2.5 Vrms. most applications. Refer to Dynalco
Maximum permissible signal: 15 Vrms. Magnetic Pickup brochure for various types
The SPD-100 automatically limits pickup and characteristics.
signals at approximately 10 volts peak-to- For low-speed applications, or to permit
peak. Input impedance is 100 Ω in series operation with larger gaps, the ultrahigh
with a 6 volt Zener diode. sensitivity M142 can be used.
For intrinsically safe applications Dynalco
INPUT SIGNAL FREQUENCY Controls offers various models, with the
Maximum input signal frequency of 20,000 M202 and M134 the most frequently used.
Hz. Lowest frequency range limited by gate
time and corresponding numerical display. WEIGHT
ISOLATED CIRCUIT 1 lb (0.45 kg)
All circuitry is totally floating, i.e. totally
isolated and insulated from the case and
from ground.

TEMPERATURE RANGE
Operating:
–5oF to +175oF (–20oC to +80oC).
Storage: *THIRD PARTY APPROVALS
–40oF to +195oF (–40oC to +90oC).
SPD-100 and SPD-108
Canadian Standards Association
VIBRATION
(CSA): Class I, Division 1, Groups
MIL STD 810C; Method 514.2; Curve Q;
A, B, C, & D with M134, M135,
Procedure V; Modified to 500 Hz upper limit.
M139, M203, M204, M205. Class
5 Hz to 10 Hz @ 0.2 inches D.A.; 10 Hz to 18
LR45322 I, Division 1, Groups C & D with
Hz @ 1.0 g (peak); 18 Hz to 57 Hz @ 0.06
M160, M201, M202, M231, and
inches D.A.; 57 Hz to 500 Hz @ 10 g (peak).
M233.
ACCURACY SPD-100 Only
One rpm resolution; within 0.5% (0.1% American Bureau of Shipping:
typical at room ambient) under all combined type approval for use in classed
environmental conditions. vessels.
OUTLINE AND CONNECTION DRAWING

Dimensions in inches (mm)

• Signal-powered unit shown.

• Lighted unit has two additional terminals for input power.

HOW TO ORDER
I. Specify model required:
a. Gate time range: 0.26 to 5.70 III. Specify magnetic pickup, if required.
seconds. IV. For factory calibration: Advise the gate
• SPD-100: standard model time required or the number to be
• SPD-100L: internally lighted displayed at a given signal frequency.
b. Gate time range: 0.13 to 2.85 Or, just indicate the number of gear
seconds. teeth or discontinuities per revolution.
• SPD-108: standard model [Determine if the gear or shaft is
• SPD-108L: internally lighted rotating at the speed of interest or if
II. For internally lighted model select 12 or some step-up or step-down ratio must
24 Vdc version. be considered.]
 Reliable Measurement, Control, and
Diagnostics Equipment
Dynalco Controls specializes in products for harsh and hazardous
applications.
Areas include oil and gas production and pipelines; stationary engines;
and construction, agricultural, petrochemical, and marine equipment.
The extensive product line includes inductive and CD ignitions, engine
and compressor analysis products and service, engine controls, magnetic
and active pickups, speed and temperature monitors and transmitters,
and signal-powered meters and tachometers.

SPD-100, SPD-100L, SPD-108, and SPD-100L are trademarks of Dynalco Controls.

DYNALCO CONTROLS RESERVES THE RIGHT TO CHANGE THESE SPECIFICATIONS WITHOUT NOTICE.
FOR COMPLETE SPECIFICATION INFORMATION, CONTACT A DYNALCO REPRESENTATIVE.
Chapter 8
Accessories

NOTES

8-4 ch8.04/20/02
724-527-2811 http://www.elliott-turbo.com/
 CHAPTER NINE
SERVICE/PARTS/SALES

INTRODUCTION

This chapter contains information pertaining to spare parts, service assistance, service
parts and Elliott training programs. The Spare Parts List specifically for the purchased
unit is contained in Appendix A. A list of Elliott Sales and Service locations is contained
in Appendix B. Appendix C, ”Technical Manual Comment Sheet“ has been provided for
comments and/or questions regarding the technical manual and/or equipment.
Appendix D provides detailed information and scheduled dates for Elliott training
programs. Appendix E, if applicable, provides figures with number designations
pertaining to normal maintenance and capital parts.

SPARE PARTS

At the time your equipment is purchased, Elliott offers to furnish a spare parts package.
This package contains parts that may be damaged during shipment, installation, or initial
startup and includes journal bearings, thrust bearings, shaft seals, interstage seals,
balance piston seal (if required), and the necessary O-rings for these assemblies. These
parts are the minimum recommended to have on hand before startup.

Maintenance Parts List

A drawing with a recommended list of maintenance parts is provided in Appendix A.

The quantities shown on the Maintenance Parts List are for one particular machine.
Where duplicate machines are involved, or parts are interchangeable with other
machines, an inventory reduction may be considered. In making such an evaluation,
consideration should be given to the consequences of a catastrophic plant malfunction
including water or power loss.

The Maintenance Parts List included in this chapter shows the location of parts, provides
part numbers, descriptions, and may contain cross-reference figures that can be used for
ordering normal spare and replacement parts. Stocking these parts enable prompt
equipment maintenance or emergency repairs that could otherwise cause lengthy
shutdowns. Spare and replacement parts supplied by Elliott may be changed to parts of
equal or greater quality from those originally supplied on the unit.

CAUTION
Replacement parts should be purchased from Elliott
Company. Many vendor parts have been modified
and/or calibrated by Elliott Company to ensure
compatibility with the design. Parts purchased
directly from vendors may not properly function and
could damage other components.

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Chapter 9
Service/Parts/Sales

Ordering
When ordering parts, or when contacting Elliott Company concerning parts, always give the
following information:

1. Equipment model number and serial number/shop order number (shown on equipment
nameplate and on the technical manual record sheet).

2. Provide the Elliott Internal Part Number (titled “Catalog Number” on the Spare Parts List)
from the Spare Parts List provided and/or shop order number.

3. Part name or description and quantity required.

4. Name and address of purchaser.

5. Complete shipping address and shipping instructions.

6. Specify payment terms.

7. For instrumentation or lubrication system parts, furnish manufacturer’s name, name of

component, nameplate information, plus any other identifying information listed on the
Instrument Data Sheets (if available) or in furnished vendor’s instruction material.

Storage
Spare parts usually represent a substantial investment. To protect this investment, the
following must be observed.

1. Inspect the parts and coat any unprotected machined surfaces with a rust preventative.

2. Tag or mark the parts so they can be easily located and identified.

3. Store the parts in a clean, dry place.

4. Store small parts neatly on shelves or in bins to prevent damage. Store large parts on
skids, in crates, or on vertical racks.

5. Inspect the parts frequently. Clean and recoat parts with a rust preventative, if
necessary.

6. Periodically check the shelf life expiration dates on parts such as O-rings. The boxes
will be marked accordingly with an expiration date if applicable.

7. Store spare rotor assemblies (if supplied) by suspending them in a vertical position to
use minimum floor space, or store them in their shipping crates. Vertical storage is
recommended for all multistage compressor rotors (M, MB and Axial). Vertical
storage maintains axisymmetric conditions on the rotor and eliminates concerns of
rotor sag. It also minimizes risks of non-axisymmetric thermal and corrosion effects.
If the rotor cannot be stored vertically, the rotor should be rotated 90° to 120° every 1
to 3 months. Care should be taken when rotating the rotor to ensure it is not
supported on the journal or probe regions (to avoid damage to those surfaces).
Supports for the rotor should be inboard of the journal surfaces. If the rotor in

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 Chapter 9
Service/Parts/Sales

question is in the compressor casing, turning should be performed with the lube oil
system activated. Prior to installation of a horizontally stored rotor, it may be
advisable to turn the rotor for approximately 8 hours to minimize possibilities of a
temporary bow. Depending upon the size of the rotor, this can be performed on a
lathe or balancing machine. Support requirements for shipping purposes may be
more stringent, depending upon the relative length of the rotor. If the original
shipping container is not available, Elliott Company should be consulted. If indoor
space is not available, store the rotor by suspending vertically in a cylindrical tank
filled with oil. Cover the tank and install a drain valve at the bottom to drain any
accumulated condensate.

Returning Parts to the Factory

Should it become necessary to return parts to the factory, contact the nearest Elliott
Company Office. This is necessary to provide proper material accountability.

FIELD SERVICE ASSISTANCE

Your local Elliott Service Office is trained and authorized to meet your service needs.
Service is locally available for installation, start-up, operation and maintenance
requirements. Service contracts and parts are available locally through your Elliott
Service Office. Field Service Representatives are available to oversee the installation
and start-up or any phase of maintenance of Elliott equipment. Also, Field Service
Engineers are available to conduct Performance Analysis and other related equipment
evaluations. (Refer to the Elliott Sales and Service locations in Appendix B of this
chapter.)

CUSTOMER TRAINING

Specialized training programs are available for your operators and maintenance
personnel. The training is geared to the specific Elliott Company equipment that you
use. Provided in this chapter is a list of training programs offered through Elliott
Company for the year this technical manual was issued. For assistance in organizing a
training program or inquiring about currently scheduled training programs, contact the
nearest Elliott Company Office.

TECHNICAL MANUAL COMMENT SHEET

We have made every effort to provide a technical manual that reflects your equipment.
Should you require additional information, which cannot be found in your manual,
complete the Technical Manual Comment Sheet located at the end of this chapter.
When completing the sheet, provide as much detail as possible and reference part
numbers, page numbers, drawing numbers, etc., to which the comment is directed.
Comments regarding the technical manual can also be directed to Elliott Company’s
Technical Manual Department’s email address at [email protected].

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Chapter 9
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NOTES

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QTY UOM PART NAME PART NUMBER ITEM NO. QTY UOM PART NAME PART NUMBER ITEM NO.
1 each SENTINEL VALVE (75 PSIG) P67B31 5 1 each SET SCREW 1/2-13 3/4 LG. P23K137 450
2 each PKG CASE ASSY EY0427-7 6 3 each SLEEVE SEAL 693952-4 455
2 each BEARING LINER, TOP 412223-2 10 1 each COLLAR 1014519-1 460
2 each BEARING LINER, BOTTOM 412223-3 15 1 each SET SCREW #10-24 1/4 LG. P23A30 461
1 each BUCKET HOLDER ASSEMBLY 1000892-10 30 1 each WORM (6.1667/1) 681536-1 467
1 each BUCKET SHIELD ASSEMBLY 1044798-20 34 1 each ROLL PIN .264 1-1/4 LG. P36T346 468
6 each SPACER (B/O)(SERV) 645997-1 35 1 each VALVE TRIP ASSEM 680894-9 500
6 each CAP SCREW 1/2-13 3-1/2 LG. P23T3206 40 1 each STEAM STRAINER 633805-21 505
8 each CARBON RING ASSEMBLY 634159-54 45 1 each SPRING 645953-1 510
1 each GOVERNOR UG-12.8 P4045D160002I 50 1 each SPRING SEAT 696575-1 515
1 each NOZZLE RING F602328-100 60 1 each CONNECTION 682499-1 520
1 each MAGNETIC PICKUP 436023-9 86 2 each BLOCK 646639-2 525
1 each ARMOR CABLE ASSEMBLY 48* LG P8405B550-048 87 1 each BUSHING 692071-1 530
1 each TACHOMETER, DYNALCO SPD100 P82M471 90 1 each STRAIGHT DOWEL PIN 1/2 2.00 LG. P36P238 535
1 each GROUNDING BRUSH P80A975 91 1 each SPRING SEAT 646660-1 540
28 EACH CAP SCREW 5/8-11 1 LG. P23T3226 102 1 each SPRING 693447-1 545
24 each INTERNAL TOOTH LOCKWASHER 5/8 P25R26 115 1 each SPRING 693448-1 550
6 each INTERNAL TOOTH LOCKWASHER 1/2 P25R24 125 1 each FOLLOWER 646107-1 555
24 each CAP SCREW 3/4-10 1-3/4 LG. P23T3259 130 1 each GLAND (YR) 646203-1 565
1 each MACHINE SCREW 1/4-20 5/8 LG. P20A177 131 1 each GOVERNOR VALVE ASSEMBLY 1045246-10 575
2 each BUSHING P286A240 132 1 each GOVERNOR VALVE SEAT 1045272-10 580
1 each KNIFE EDGE, LATCH 436004-1 133 1 each BUSHING, GOVERNOR VALVE STEM 649735-1 585
24 each INTERNAL TOOTH LOCKWASHER 3/4 P25R28 135 2 each BUSHING 682498-1 590
1 each HANDVALVE ASSEMBLY 664832-28 180 1 each KNIFE EDGE, TAPERED 436003-1 595
1 each FOLLOWER 695793-1 185 1 each PIN 691999-1 600
2 each PACKING P725Z050 190 1 each BUSHING 696574-1 605
1 each SPRING 692334-1 200 1 each SET SCREW 1/4-20 1/2 LG. P23A54 610
1 each T&T VALVE GASKET 646126-4 215 1 each COPALTIT 1#QTLIQ-SHELFLIF12/CS X412-120 800
1 each PLUNGER 693346-2 220 1 each TITESEAL MED#1 (12# PER CASE)+ X467-110 802
1 each PLUG 693347-2 221 1 each 1/2 PINT - MILL-ROSE BLUE MONSTER NICKET ANTI-SEIZEX6521-100
SEALANT 803
1 each WASHER (100 PCE MIN) 693348-1 225 1 each LOCKTITE 567 SEALANT 50ML X6724-100 804
1 each SPRING, TRIP PLUNGER 693338-1 230 1 each TEMPTITE 3/16''D(SHELFLIFE 6MIN X416-103 806
1 each RETAIN RING P27B27 235 1 each 1/16''TEMPTITE IIGSKT QT.CN S/L X416-133 807
1 each SHOULDER STUD (YR) 646505-4 240 1 each FEL PRO C-5 X415-115 808
1 each RING, RETAINING P27B35 245 1 each GREASE X6500-001 809
1 each WORM WHEEL (6.1667/1) 681539-1 255 1 each SILASTIC RTV732-20(3 OZ TUBES) X427-100 810
1 each COTTER PIN 1/8 1-1/4 LG. P36A57 256 X EA MAINTENANCE PARTS LIST F602328MPL-GR1 GR1
2 each SHIM DY0479-1 260
2 each SHIM DY0479-2 261
2 each SHIM (YR) P835F135 262
1 each GASKET, END COVER P480B235 265
1 each CONNECTION 696106-1 310
1 each PIN, CONNECTION 646771-4 315
1 each SET SCREW 1/4-20 3/8 LG. P23A52 324
6 each SET SCREW 1/4-20 1/4 LG. P23A50 325
1 each PIN, LINKAGE 692818-1 326
2 each BEARING 692784-2 327
1 each BRG ROD END P1562R331 353
1 each BRG ROD END 1/4''-28F P1562R311 354
2 each SHIM (YR) 692787-3 356
6 each SHIM (YR) 692787-2 357
1 each SHIM 692787-1 358
2 each SHOULDER SCREW #10-24 1/2 LG. P23W508 360
1 each LINK DY0476-1 366
1 each COMPLETE ROTATING ASSEMBLY F602328-RA 399
1 each ROTOR ASSEM (DYR) 666945-203-F602328 400
1 each KEY, COUPLING 436018-3 401
1 each OVERSPEED TRIP PIN ASSEMBLY 672397-GR3 405
1 each EMER.GOV.WEIGHT (SERV)(B/O) 645573-1 406
1 each SPRING 645584-1 407
1 each PLUG 693386-1 408
2 each WASHER (SERV) (.010 THICK) 643320-3 409 MAINTENANCE PARTS LIST
2 each WASHER (SERV) (.005 THICK) 643320-4 410 This Drawing and all information shown thereon
3 each WASHER (.030 THICK) 643320-2 411 is the exclusive property of Elliott Company and
1 each SPACER 696402-1 412 is provided subject to the express condition that
1 each TRIP BODY 1019150-1 425
the drawing is not reproduced in whole or in part,
1 each THRUST BEARING ASSEMBLY 672171-18 440
1 each RETAINING RING P27D27 445 or used for the benefit of anyone other than Elliott

CONTINUE ON TOP RIGHT Company and no information shown in this

drawing may be disclosed or used in any way. 2006 ELLIOTT COMPANY
SHEET BM 1 OF 1 PLM System Generated Bom

F602328MPL Rev: 0
 APPENDIX B
SALES AND SERVICE LOCATIONS
1/17/2017

Elliott Group has sales, service, and engineering facilities throughout the world. Whatever your
application or service need, an experienced Elliott field engineer or sales representative is
available to assist you. Just call, write, or fax to one of the following Elliott locations, or send an
email to [email protected].

HEADQUARTERS ELLIOTT COMPANY

901 North Fourth Street, Jeannette, PA 15644-1473
Phone: 724-527-2811 Fax: 724-600-8442

UNITED STATES ELLIOTT COMPANY

California Los Angeles (Sales)

2500 Via Cabrillo Marina, Suite 110
San Pedro, CA 90731-7224
Phone: 310-833-5891 Fax: 310-833-5974

San Francisco (Service)

2339 Courage Drive
Fairfield, CA 94533-6718
Phone: 707-746-5933 Fax: 707-746-5937

Florida Jacksonville (Service)

10485 Busch Drive North
Jacksonville, FL 32218-5601
Phone: 904-757-7600 Fax: 904-757-7604

Indiana Chicago (Service)

1301 N. Indiana Avenue
Crown Point, IN 46307-2739
Phone: 219-661-9701 Fax: 219-661-9707

Louisiana Baton Rouge (Service)

58035 Industrial Blvd.
Plaquemine, LA 70764-5256
Phone: 225-687-1717 Fax: 225-687-1555

New Orleans (Service)

5901 Hefferson Highway
Harahan, LA 70123-5116
Phone: 504-733-2108 Fax: 504-733-8693

© Elliott Company ISO 9001 CERTIFIED PRINTED IN THE U.S.A

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 APPENDIX B
SALES AND SERVICE LOCATIONS
1/17/2017

Pennsylvania Jeannette (Sales & Service)

901 North Fourth Street
Jeannette, PA 15644-1473
Phone: 724-527-2811 Fax: 724-600-8442

Pittsburgh (Service)
Donora Industrial Park
1250 Scott Street Extension
Donora, PA 15033-2249
Phone: 724-379-5440 Fax: 724-379-5535

Elliott Packaging Solutions (Auxiliary Sales & Service)

236 Finley Road, Suite 47
Belle Vernon, PA 15102
Phone: 724-929-1200 Fax: 724-929-1299
After Hours: 724-929-1254

Texas Houston (Sales)

10940 W. Sam Houston Pkwy. N., Suite 150
Houston, TX 77064-5768
Phone: 281-517-7100 Fax: 281-955-5072

Houston (Service)
2001 W. Sam Houston Pkwy. N.
Houston, TX 77043-2421
Phone: 713-984-3800 Fax: 713-984-3905

CANADA ELLIOTT TURBOMACHINERY CANADA, INC.

Burlington (Service)
955 Maple Avenue
Burlington, ON L7S 2J4
Canada
Phone: 905-333-4101 Fax: 905-333-3863

Edmonton (Service)
2024 – 87th Avenue
Edmonton, AB T6P 1L4
Canada
Phone: 780-449-3080 Fax: 780-449-3081

© Elliott Company ISO 9001 CERTIFIED PRINTED IN THE U.S.A

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 APPENDIX B
SALES AND SERVICE LOCATIONS
1/17/2017

LATIN AMERICA
BRAZIL ELLIOTT EBARA SERVICOS PARA EQUIPAMENTOS
ROTATIVOS LTDA.

Piracicaba (Service)
Rua Abelardo Benedicto Liborio
105 Distrito Industrial Uninorte
Piracicaba 13413-075
SP, Brazil
Phone: 55-19-3421-0414 Fax: 55-19-3421-0414

Rio De Janeiro (Sales)

Praia Do Flamengo 66 Bloco B 1416
Rio De Jairo 22210-903
RJ, Brazil
Phone: 55-21-2225-3134 Fax: 55-21-2225-2957

GUATEMALA ELLIOTT TURBOCHARGER-GUATEMALA, S.A.

MIXCO (Service)
4 Av. 4-44 Zona 8
San Cristobal, Sector A-5
Mixco, Guatemala, S.A.
Phone: 502-2427-9696 Fax: 502-2427-9608

EUROPE, MIDDLE EAST

& AFRICA
UNITED KINGDOM ELLIOTT TURBOMACHINERY LIMITED

Silchester (Service)
Unit 11 Easter Park
Benyon Road, Silchester
Reading RG7 2PQ, England
Phone: 44-1189-701122 Fax: 44-1189-701333

Staines Upon Thames (Sales)

Elizabeth House, 56-60 London Road
Staines Upon Thames
Surrey, TW18 4BQ
England
Phone: 44-1784-227100 Fax: 44-1784-227133

© Elliott Company ISO 9001 CERTIFIED PRINTED IN THE U.S.A

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 APPENDIX B
SALES AND SERVICE LOCATIONS
1/17/2017

SWITZERLAND ELLIOTT TURBOMACHINERY S.A.

Lachen (Field Service)

Feldstrasse 2, CH 8853
Post Fach 249
Lachen, Switzerland
Phone: 41-55-451-8000 Fax: 41-55-451-8099

ITALY ELLIOTT TURBOMACHINERY LIMITED

Florence (Sales)
Viale Belfiore 10
50144, Florence, Italy
Phone: 39-055-324-1137 Fax: 39-055-324-1137

ELLIOTT TURBOMACHINERY S.A.

La Spezia (Service)
Zona Industriale N. 1
54011 Frazione Albiano Magra
Aulla (MS), Italy
Phone: 39-0187-41311 Fax: 39-0187-413000

RUSSIA ELLIOTT TURBOMACHINERY LIMITED

Moscow (Sales & Service)

11 Bolshaya Tulskaya Str.
Moscow 115191, Russia
Phone: 7-495-734-7876 Fax: 7-495-967-6799

UNITED ARAB EMIRATES ELLIOTT TURBOMACHINERY LIMITED

Abu Dhabi (Sales, Field Service)

Khalidiyah Street, Das Tower (Seha Tower)
Mezzanine Floor Office M1
Abu Dhabi, United Arab Emirates
Phone: 971-26-987-999 Fax: 971-26-772-150

© Elliott Company ISO 9001 CERTIFIED PRINTED IN THE U.S.A

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 APPENDIX B
SALES AND SERVICE LOCATIONS
1/17/2017

BAHRAIN ELLIOTT EBARA MIDDLE EAST W.L.L.

Bahrain (Service)
Office No. 52, Building No. 47
Dream Building No. 2
Road 2701, Block No. 327
Adliya Area
Kingdom of Bahrain
Phone: 973-1729-3829 Fax: 973-1729-3809

SAUDI ARABIA ELLIOTT GAS SERVICES

Al Jubail (Service)
Unit No. 2, PO Box 5797
Al Jubail 35522-7662
Kingdom of Saudi Arabia
Phone: 966-13-344-8900 Fax: 966-13-344-8902

ASIA PACIFIC

JAPAN ELLIOTT EBARA TURBOMACHINERY CORPORATION

Sodegaura (Sales & Service)

20-1 Nakasode
Sodegaura-Shi
Chiba-Ken, 299-0296
Japan
Phone: 81-4-3860-6111 Fax: 81-4-3860-6070

CHINA ELLIOTT COMPANY BEIJING REPRESENTATIVE OFFICE

Beijing (Sales)
Suite 1706, Tower B
Beijing Global Trade Center
36 North Third Ring Road East
Dongcheng District
Beijing, China 100013
Phone: 86-10-5825-7488 Fax: 86-10-5825-7489

© Elliott Company ISO 9001 CERTIFIED PRINTED IN THE U.S.A

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 APPENDIX B
SALES AND SERVICE LOCATIONS
1/17/2017

CHINA, cont’d ELLIOTT TURBOMACHINERY SERVICES

Tianjin (Service)
No. 260, Huang Hai Road, TEDA
Tianjin, China 300457
86-22-5985-6688
Phone: 86-22-5985-6688 Fax: 86-22-5985-9719

TAIWAN ELLIOTT EBARA SERVICE, TAIWAN CO., LTD.

Taichung (Service)
1, Road 42, Industrial Zone
Taichung T407
Taiwan, R.O.C.
Phone: 886-4-2359-4202 Fax: 886-4-2359-5510

SINGAPORE ELLIOTT EBARA, SINGAPORE PTE, LTD.

Singapore (Sales & Service)

1A International Business Park
#07-01
Singapore 609933
Phone: 65-6563-6776 Fax: 65-6563-1387

INDIA ELLIOTT EBARA TURBOMACHINERY INDIA PVT. LTD.

Bangalore (Service)
Plot No. 12/3, Abbanakuppe
Bidadi Industrial Area, Bidadi Post
Bengaluru – 562109, India
Phone: 91-80-3062-5000 Fax: 91-80-3062-5005

KOREA ELLIOTT KOREA CO., LTD.

Seoul (Sales)
Hyunseok Tower 3rd Fl.50
Seolleung – RO 93 – GIL
GANGNAM – GU
Seoul, Korea 135-513
Phone: 82-70-4362-1150 Fax: 82-70-8230-2030

© Elliott Company ISO 9001 CERTIFIED PRINTED IN THE U.S.A

http://www.elliott-turbo.com 724-527-2811
 APPENDIX C

TECHNICAL MANUAL COMMENT SHEET

If you have any questions, comments and/or suggestions concerning this technical
manual, or if you require additional information on the installation, maintenance or
operation of your Elliott equipment, complete the information below. Mail or fax this form
to the address below. Be sure to include Elliott Shop Order number and required
information. Required information is designated by an asterisk *.

ELLIOTT COMPANY
901 NORTH FOURTH STREET
JEANNETTE, PA 15644-1473 USA
TECHNICAL MANUAL DEPARTMENT 62-27

TELEPHONE: 724-527-2811
FAX: 724-600-8318

Questions, comments and suggestions can be emailed to:

[email protected]

*Elliott Equipment Serial Number/Shop Order Number ________________________

Questions, Comments, Suggestions:

Please send additional information covering the following areas:

Contact Information

Name __________________________________ Title _________________________

Email Address _________________________________________________________

*Company _______________________________ Department ___________________

Address ______________________________________________________________

*City ___________________________________ *State/Province _________________

*Country _______________________________ _ Postal Code ___________________

Telephone ______________________________ Fax __________________________

ch09.7/32008 9-10
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 2017 TURBOMACHINERY TRAINING
ELLIOTT YR TURBINE
Length of Course: 3 days Dates: April 4-6, 2017
Class size: 8 Min – 12 Max October 3-5, 2017
Price: $ 1,500 per person
Who Should Attend:
This course is designed for operations, maintenance, engineering, and supervisory personnel responsible for the Elliott YR turbine.
This course is balanced between classroom lectures and hands-on workshops.

Objectives:
Upon successful completion of this course, the student will be able to:
- Identify All the Major YR Components,
- Understand the YR Components’ Functions,
- Explain how Mechanical & Electronic Turbine Governors operate,
- Understand Mechanical & Electronic Overspeed Trip Systems,
- Disassemble a YR Turbine (with actual AYR Turbine),
- Assemble a YR Turbine (with actual AYR Turbine),
- Start-up & Shutdown of a YR Turbine, and
- Define Preventative Maintenance Procedures including Troubleshooting.

Course Overview:
YR Components & Function
Steam Turbine Governors & Servo Motors
Disassembly/Assembly of an AYR Turbine (including Workshops)
Start-Up & Operation
Safety Precautions
Proper Maintenance & Troubleshooting

ELLIOTT MULTI-STAGE MULTI-VALVE STEAM TURBINE

Length of Course: 3 days Dates: April 24-26, 2017
Class size: 8 Min – 18 Max October 16-18, 2017
Price: $ 1,700 per person*
Who Should Attend: *if attend with Centrifugal Compressor: $ 2,800 for both
This course is designed for operations, maintenance, engineers, and supervisory personnel responsible for Elliott MSMV Steam
Turbines.

Objectives:
Upon successful completion of this course, the student will be able to:
- Understand Steam Turbine Theory & the Basic Thermodynamics of Steam Turbines,
- Identify All the Major Steam Turbine Components,
- Understand the Turbine Components’ Functions,
- Explain how Mechanical & Electronic Steam Turbine Governors operate,
- Understand the Function & Operation of Steam Turbine Servo Motors,
- Understand Mechanical & Electronic Overspeed Trip Systems, and
- Operate & Maintain an Elliott Steam Turbine (including Troubleshooting).

Course Overview:
Steam Turbine Theory & Basic Thermodynamics
Steam Turbine Components and Function
Steam Turbine Governors & Servo Motors
Rotor Balancing
Operation & Troubleshooting
Preventative Maintenance

Elliott Technical Training 2017

 ELLIOTT CENTRIFUGAL COMPRESSOR
Length of Course: 3 days Dates: April 26-28, 2017
Class size: 8 Min – 18 Max October 18-20, 2017
Price: $ 1,700 per person*
*if attend with MSMV Steam Turbine: $ 2,800 for both
Who Should Attend:
This course is designed for operations, maintenance, engineers, and supervisory personnel responsible for Elliott Process
Compressors.

Objectives:
Upon successful completion of this course, the student will be able to:
- Identify All the Major Compressor Components,
- Understand the Compressor Components’ Functions,
- Understand Basic Compressor Aerodynamics,
- Interpret Compressor Performance Curves,
- Explain how Compressor Controllers operate,
- Operate & Maintain an Elliott Compressor, and
- Understand Rotor Balancing.

Course Overview:
Compressor Components & Function
Basic Compressor Aerodynamics
Compressor Controllers including Anti-Surge Control
Operation, Maintenance, & Troubleshooting
Rotor Balancing
Compressor Disassembly/Assembly (lecture only)

ELLIOTT LUBE & SEAL SYSTEM

Length of Course: 2 days Dates: May 1-2, 2017

Class size: 8 Min – 18 Max October 23-24, 2017
Price: $ 1,000 per person Location: The 2nd part of day 2 is in Belle Vernon, PA
(40 minutes from Elliott in Jeannette, PA)
Who Should Attend:
This course is designed for operations, maintenance, engineering, and supervisory personnel responsible for Elliott Lube & Seal
Systems. It is recommended for anyone attending the Process Compressor or MSMV Turbine Course.

Objectives:
Upon successful completion of this course, the student will be able to:
- Identify All the Major Lube/Seal System Components and Buffer Gas Systems,
- Understand the Lube/Seal System Components’ Functions,
- Understand the Properties of Turbomachinery Lubricants,
- Define Basic Instrumentation,
- Explain the principle Steps required for Lube System Commissioning, and
- Operate & Maintain an Elliott Lube System.

Course Overview:
Lubricating Oil Properties Review
Oil System Overview
Buffer Gas System Overview
Basic Instrumentation
Start-Up & Operation
Maintenance & Troubleshooting
Plant Tour of our Lube Manufacturing Facility

Elliott Technical Training 2017

 CUSTOMIZED ON-SITE PROGRAMS

When possible, Elliott recommends that training take place at Elliott – away from normal business and phone interruptions.
However, when distance makes travel prohibitive, when staff availability is a problem, or when it is best that training be carried out
at site (or using your own system configuration and equipment), Elliott will draw from its technical resources to prepare and present
a course to meet your specific needs.

For a quote for customized on-site training, please call the Technical Training Department or send the following information by email
to [email protected].

1. Elliott Shop Order Number(s)

2. Desired Training Location
3. Number of Attendees
4. Attendees Job Status (engineer, operator, maintenance,…)
5. Desired date(s)
6. Agenda Requirements

Please check out our website for additional training programs, locations nearest you,
and our “free” maintenance tip webinars:

http://www.elliott-turbo.com/Training

Elliott Technical Training 2017

 COURSE INFORMATION

ENROLLMENT

To register for a course, you can register online at: https://www.surveymonkey.com/r/2017_Elliott

SEMINAR FEE

The prices indicated cover course tuition, training manual, lunch & refreshments during class, and attendance certificate.

Travel and living expenses are the responsibility of each student. Elliott assumes no liability for any fees that may be incurred due
to the cancellation of any classes. We recommend that you book fully refundable air tickets or wait until the program is confirmed
before booking your reservations.

PAYMENT

Payment for all factory courses is to be made prior to the class. We accept company checks (payable to Elliott Company) or credit
card (Visa or MasterCard).

COURSE LOCATION AND HOURS

All factory-training programs will be conducted at Elliott’s headquarters in Jeannette, Pennsylvania USA, unless otherwise noted.
The classes are held from 8:00 am to 3:30 pm daily.

ACCOMMODATIONS

A block of rooms has been set-aside at a local hotel in Greensburg, PA. Reservation information will be provided when class is
confirmed.

TRANSPORTATION

If you fly into Pittsburgh International Airport, it will take you approximately two hours to arrive at your hotel. Return flights should
be scheduled for 7:30 pm or later on the last day of class.

CANCELLATIONS AND REFUNDS

If you must cancel, please notify the Elliott Technical Training Dept as soon as possible. Cancellations less than fifteen (15) days in
advance of program are subject to one-half of the tuition fee. With prior notification, substitutions can be made.

There are no refunds for “No Shows”. Elliott reserves the right to cancel or reschedule any class. If Elliott cancels, a full refund for
tuition will be made.

MORE INFORMATION

Please contact the Technical Training Department at (724) 600-8521 or [email protected].

Elliott Technical Training 2017

 TRAINING REGISTRATION FORM 2017
(Please type or print.)

Please send completed registration form to: The Technical Training Department
901 North Fourth Street
Jeannette, PA 15644
Tel: (724) 600-8521
Fax: (724) 600-8018
E-Mail: [email protected]

Course Title/Date: Date:

Company: Contact:
Bill to Address:
City: State:
Country: Zip Code:
Phone: Fax:

Please list your Elliott Shop Order No(s):

STUDENT TITLE
PHONE FAX
EMAIL ADDRESS

STUDENT TITLE
PHONE FAX
EMAIL ADDRESS

STUDENT TITLE
PHONE FAX
EMAIL ADDRESS

STUDENT TITLE
PHONE FAX
EMAIL ADDRESS

TOTAL TUITION:

Method of Payment: Company Check or Credit Card

Check No. Amount:

Charge*: MasterCard Visa American Express

*Please call 724-600-8521 to provide credit card name, number, & expiration date.

Elliott Technical Training 2017

 Chapter 10
Technical Drawings

INTRODUCTION

This chapter contains engineered drawings specific for the purchased equipment. The
drawing numbers on the bill of materials or parts lists may have a suffix number, or group
number identifying the applicable assembly on the drawing. Be sure to use the suffix
listed when making reference to a drawing.

If this manual is in an electronic format (CD-ROM), scroll down for a list of Technical
Drawings.

NOMENCLATURE AND USE OF ASSEMBLY DRAWINGS

Beginning in 2004, both the drawing numbering convention and Bill of Materials on
assembly drawings changed.

The following description will help you understand the format of Elliott drawings created
since 2004:

1. The title block in the lower right-hand corner identifies the drawing by name and
number. Additional descriptive information may also be included.

2. A separate Bill of Materials is attached to each assembly drawing.

a. The “Position” number corresponds to the part identification number located

adjacent to the appropriate item on the drawing.

b. The “Item Number” column will list either a part number with a letter ‘P’ prefix,
or a drawing number that may include a dash (-) suffix number. These
numbers are part or catalog numbers used for ordering spare or replacement
parts.

c. “Quantity” column numbers specify the quantities of items used on that drawing.

NOTE:
Drawing and Bill of Materials revision numbers are not
related and may differ.

For drawings created prior to 2004:

1. The title block in the lower right-hand corner identifies the drawing by name and
number. It may also contain additional information describing the drawing. The
drawing number is a six-digit number or a six-position alpha numeric drawing number.

2. The numbers in the quantity column specify the quantities of items used on that
drawing.

3. The part name column lists the item nomenclature.

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Chapter 10
Technical Drawings

4. The part number column will list either a part number with a letter ‘P’ prefix, or a six
position drawing number and may include a dash (-) suffix number. These numbers
are part or catalog numbers used for ordering spare or replacement parts.

5. The drawing may also have a column or section listing group numbers (GROUP 1, 2,
etc. or -GR. 1, 2, etc.). These group numbers define lists of related parts used for
specific variations of parts arrangements and/or assemblies.

10-2 chap10.7/15/2008
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 Chapter 10
Technical Drawings

Form 188-B (05/14/02)

TECHNICAL DRAWINGS
F602328

DRAWING REVISION
TITLE
NUMBER NUMBER
3014696 General Arrangement 0
3014697 Wiring Diagram 1

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 8 7 6 5 4 3 2 1
3014696 REVISION HISTORY
GENERAL NOTES REV CHANGE DESCRIPTION ZONE
INSTALLATION NOTES
PURCHASER'S CONNECTIONS (LEAKOFF & DRAIN) THE FOLLOWING ITEMS NOT FURNISHED BY ELLIOTT COMPANY ARE
1. TURBINE COMPLETE WITH DRIVEN EQUIPMENT SHOULD BE SUPPORTED ON A
H REQUIRED TO COMPLETE INSTALLATION OF THE TURBINE: INLET, EXHAUST, DRAIN AND WATER PIPING, H
SYMBOL DESCRIPTION SIZE / RATING REMARKS RIGID AND SUBSTANTIAL FOUNDATION.
GASKETS, FITTINGS, MISCELLANEOUS VALVES AND GAUGES. ALSO REFER TO THE FOLLOWING:
L3 LEAKOFF FROM SHAFT PACKING CASES 1" MALE NPT CONNECT TO OPEN DRAIN 2. AN ATMOSPHERIC RELIEF VALVE, CAPABLE OF PASSING 75,500 LBM/HR
THE FOLLOWING ITEMS ARE FURNISHED BY ELLIOTT COMPANY
[34,246 KG/HR], MUST BE INSTALLED BY THE PURCHASER BETWEEN THE
L4 TRIP VALVE STEM LEAKOFF 3/4" NPT CONNECT TO OPEN DRAIN TURBINE EXHAUST FLANGE AND THE FIRST SHUT OFF OR ISOLATION VALVE,
BOLTING HARDWARE FOR INLET CONNECTION
L5 GOVERNOR VALVE STEM LEAKOFF 1/2" NPT CONNECT TO OPEN DRAIN AS PRESCRIBED IN SECTION 8.7 OF NEMA SM23-1991. THIS VALVE SHOULD BE
TURBINE MOUNTING BOLTS, NUTS, WASHERS, DOWELS
SET TO BEGIN TO OPEN AT 75 PSIG [5.2 BARG] WITH FULL RELIEF AT NO
M TURBINE CASING DRAIN 3/4" NPT CONNECT THRU SUITABLE VALVE TO OPEN DRAIN SHIMS
GREATER THAN 10 PERCENT ABOVE THE SET PRESSURE.
M4 BELOW SEAT DRAIN (STEAM CHEST) 3/4" NPT CONNECT THRU SUITABLE VALVE TO OPEN DRAIN AUTO START UNITS REQUIRE STEAM TRAPS FOR TURBINE DRAINS M4 & M5.
3. A STEAM TRAP SHOULD BE INSTALLED IN THE LOW POINT OF THE EXHAUST
FOR TURBINES WITH NON-CONDENSING EXHAUST THIS APPLIES TO THE M
M5 ABOVE SEAT DRAIN (STEAM CHEST) 3/4" NPT CONNECT THRU SUITABLE VALVE TO OPEN DRAIN LINE TO PREVENT ACCUMULATION OF WATER IN THE TURBINE CASING. WHEN
CONNECTION ALSO.
USED FOR STAND-BY SERVICE, AN ADDITIONAL STEAM TRAP IS REQUIRED IN
S1 NOZZLE RING PRESSURE GAUGE CONNECTION (PLUGGED) 3/4" NPT CONNECT TO RING PRESSURE GAUGE THE INLET LINE.
STEAM TRAPS ARE NOT FURNISHED BY ELLIOTT COMPANY
G G
4. DOWEL HOLES ARE TO BE REAMED AND DOWELS FITTED AFTER FINAL COUPLING
BOLTS IN INLET AND EXHAUST CONNECTIONS TO STRADDLE CENTERLINE AS SHOWN.
ALIGNMENT.
PURCHASER'S CONNECTIONS (OIL PIPING) ALL FLANGE CONNECTIONS CONFORM TO ASME B16.1 OR B16.5 UNLESS OTHERWISE SPECIFIED.
5. TURBINE BLANKET TYPE INSULATION IS NOT FURNISHED.
SYMBOL DESCRIPTION SIZE / RATING REMARKS TURBINE BEARINGS:
6. THIS TURBINE IS NOT CAPABLE OF SUSTAINED REVERSE (OPPOSITE DIRECTION
PRESSURE LUBED
G1 LUBE OIL SUPPLY (STEAM END) 1/2" NPT 1 GPM [3.8 LPM] AT 7-9 PSIG [.48-.62 BARG] FROM INTENDED) ROTATION. REVERSE ROTATION OF MORE THAN 5 REVOLUTIONS
MAY CAUSE DAMAGE TO THE TURBINE OR RELATED AUXILIARIES. IT IS THE CUSTOMER'S
ALL DIMENSIONS ABOVE THE DIMENSION LINES ARE IN INCHES,
G2 LUBE OIL SUPPLY (EXHAUST END) 1/2" NPT 1 GPM [3.8 LPM] AT 7-9 PSIG [.48-.62 BARG] RESPONSIBILITY TO PREVENT ANY OCCURRENCE OF REVERSE ROTATION.
BELOW THE DIMENSION LINES ARE IN MILLIMETERS.

G7 LUBE OIL SUPPLY (GOVERNOR) 1/2" NPT .5 GPM [1.9 LPM] AT 7-9 PSIG [.48-.62 BARG] 7. ALL DRILLED HOLES THRU 1.00" [25.4 mm] DIAMETER ARE SIZED .125" [3.2 mm]
ALL PIPING DIMENSIONS +/- 1.00" [25.4 mm].
LARGER THAN THE BOLT OR STUD SIZE REQUIRED. ALL DRILLED HOLES LARGER
ALL OTHER DIMENSIONS +/- .12" [3.1 mm] UNLESS OTHERWISE SPECIFIED.
H1 LUBE OIL DRAIN (STEAM END) 1" MALE NPT THAN 1.00" [25.4 mm] DIAMETER ARE SIZED .188" [4.8 mm] LARGER THAN THE BOLT
F IF VENT IS DESIRED, USE ONE OF THE TWO 1/4" NPT HOLES PROVIDED FOR OR STUD SIZE REQUIRED. F
H2 LUBE OIL DRAIN (EXHAUST END) 1" MALE NPT OIL RING INSPECTION. HOLES LOCATED ON TOP OF BEARING HOUSINGS.
8. VERTICAL COMPONENT POSITIONING SCREWS ARE FURNISHED BY ELLIOTT COMPANY.
H5 LUBE OIL DRAIN (GOVERNOR) 3/4' NPT THE NOMINAL CONNECTION SIZE INDICATED SHOULD BE MAINTAINED AS
A MINIMUM THROUGHOUT DOWNSTREAM PIPING. 9. DURING INITIAL INSTALLATION, IT MAY BE NECESSARY TO TEMPORARILY SUPPORT THE
INLET CONNECTION TO ALLOW FOR PROPER ALIGNMENT. WHEN NEEDED, THE SUPPORT
ALL NPT CONNECTIONS ARE FEMALE UNLESS OTHERWISE SPECIFIED. SETUP AND DEVICE IS THE RESPONSIBILITY OF THE CUSTOMER AND IS NOT SUPPLIED
BY ELLIOTT COMPANY. IF AN INSULATING BLANKET IS FURNISHED, ALLOW FOR
PURCHASER'S CONNECTIONS (ELECTRICAL) CONNECTING PIPING MUST HAVE SUFFICIENT FLEXIBILITY TO ALLOW UNRESTRICTED 2.00" [50.8 mm] OF CLEARANCE BENEATH THE TURBINE CASING.
DIMENSIONAL GROWTH OF THE STEAM TURBINE AS THE CASING HEATS OR COOLS.
SYMBOL DESCRIPTION SIZE / RATING REMARKS RESTRICTION OF THERMAL GROWTH MAY CAUSE MISALIGNMENT AS THE TURBINE AND 10. SENTINEL VALVE SET AT 75 PSIG [5.2 BARG].
PIPING HEAT AND COOL.
C4 UG-12.8 GOVERNOR MOTOR SPEED CHANGER
PIPING TO BE SUPPORTED AS NEEDED TO REDUCE VIBRATION STRESSES TO A
E MINIMUM. PIPE SUPPORTS ARE THE RESPONSIBILTY OF THE PURCHASER. E

IN DETAILED VIEWS, SOME GEOMETRY MAY BE REMOVED FOR CLARITY.

CONDUIT HEADS FOR SOME INSTRUMENTATION MAY BE ROTATED TO AVOID

INTERFERENCE WITH OTHER INSTRUMENTATION.
ALIGNMENT DATA:
OIL SYSTEM TOTAL HEAT LOSS: 6,350 BTU/HR [1,859 W] DATA IS EXPRESSED IN INCHES, BASED ON DESIGN OPERATING CONDITIONS
AND USES THE COORDINATE SYSTEM. SHOWN AS .
ALL OIL DRAIN PIPING TO MAINTAIN A MINIMUM SLOPE OF 1/2" PER FOOT.
AXIS INLET EXHAUST SHAFT AT SHAFT AT
FLANGE CONNECTIONS FOR DRAINS MAY BE AT A DOWNWARD ANGLE DUE TO SLOPE.
OF FLANGE FLANGE EXHAUST GOVERNOR
PRESSURE LUBE SYSTEM INSTALLATION NOTES: MOVEMENT END BRG. END BRG.
(NORM / NO-LOAD) (NORM / NO-LOAD) (NORM / NO-LOAD) (NORM / NO-LOAD)
1. FOR PRESSURE LUBED SYSTEMS, LOCATION OF OIL RESERVOIR MUST ALLOW FOR PROPER
D DRAINAGE OF THE OIL. THE MINIMUM VERTICAL ELEVATION FROM THE CENTERLINE OF X (in) 0.0759 / 0.0901 0.0114 / 0.0203 N/A N/A D
THE TURBINE TO THE OIL LEVEL WITHIN THE RESERVOIR MUST BE 10.00" [254 mm] Y (in) -0.0201 / -0.0201 -0.0092 / -0.0213 0.0079 / 0.0079 0.0079 / 0.0079
WITH A MAXIMUM OF 84.00" [2134 mm]. ALL OIL DRAIN PIPING MUST SLOPE TOWARD Z (in) -0.0898 / -0.0898 0.0380 / 0.0649 N/A N/A
THE RESERVOIR AT A MINIMUM OF 1/2" PER FOOT. ELEVATIONS OUTSIDE OF THESE X (mm) 1.9279 / 2.2885 0.2896 / 0.5156 N/A N/A
PARAMETERS MUST BE REVIEWED BY ELLIOTT COMPANY. Y (mm) -0.5105 / -0.5105 -0.2337 / -0.5410 0.2007 / 0.2007 0.2007 / 0.2007
Z (mm) -2.2809 / -2.2809 0.9652 / 1.6485 N/A N/A

ALL FORCES AND MOMENTS EXERTED BY STEAM PIPING CONNECTED TO THE

TURBINE MUST NOT EXCEED LIMITS SPECIFIED BY PART 8 OF NEMA STANDARD VERTICAL
SM23-1991.
PURCHASER'S IDENTIFICATION
Inlet 6 Exhaust 12 Limits are to be 1.00 times NEMA Standards
Y+
C RIGHT ANGLE C
STEAM PIPING MUST BE CONFIGURED SO AS NOT TO IMPOSE UNDUE STRAIN TO TURBINE
ON THE TURBINE. THE MAXIMUM ALLOWABLE FORCES AND MOMENTS ARE
SHAFT
DEFINED IN SECTION 8.4.6 OF NEMA SM23-1991 AND ARE AS FOLLOWS:
(0,0,0)
THE TOTAL RESULTANT FORCE (FR) AND TOTAL RESULTANT MOMENT (MR) TURBINE SHAFT
IMPOSED ON THE TURBINE AT ANY CONNECTION SHOULD NOT EXCEED THE GOVERNOR END OF
FOLLOWING: TURBINE
X+ (PARALLEL TO
AT TURBINE INLET, 3 FR+ MR <= 3000 TURBINE SHAFT) PURCHASER: PT OMETRACO ARYA SAMANTA
FR MAX = 1000 lbf 4448 N WHEN MR = 0 PURCHASER'S ORDER NO.: C.325/CIE-EC/I/2017
MR MAX = 3000 lb-ft 4067 N-m WHEN FR = 0
USER: RSPI POM
AT TURBINE EXHAUST, 3 FR+ MR <= 4667 Z+ S.O.: F602328 G.O.: F16045P SERIAL: F602328
FR MAX = 1556 lbf 6919 N WHEN MR = 0
B MR MAX = 4667 lb-ft 6327 N-m WHEN FR = 0 X CERTIFIED FOR CONSTRUCTION: MAJOR CONNECTIONS & FOOTPRINT B
VERTICAL X CERTIFIED FOR CONSTRUCTION: ALL CONNECTIONS
IN ADDITION TO THE ABOVE LIMITS, THE COMBINED RESULTANTS OF FORCES
(FC) AND MOMENTS (MC) OF THE INLET AND EXHAUST CONNECTIONS, CERTIFIED FOR CONTRUCTION: FINAL AS BUILT
RESOLVED AT THE CENTERLINE OF THE EXHAUST CONNECTION SHOULD NOT
EXCEED THE FOLLOWING THIS DRAWING SUPERCEDES
Y+ DWG. NO.
2FC + MC <= 2618 RIGHT ANGLE DRAFTER: Z.OPLINGER
TH IS D RA W ING AN D ALL IN FO RM AT ION
FC MAX = 1309 lbf 5823 N WHEN MC = 0 TO TURBINE CHECKER: J.SNODERLY SH OW N TH ER EON IS T HE EX CLU SIVE
MC MAX = 2618 lb-ft 3550 N-m WHEN FC = 0 FY SHAFT MODELER: Z.OPLINGER PR OPER TY O F ELLIOTT CO M PANY A ND IS
PR OVID ED S UBJEC T T O T HE EXP RESS
PROJ. ENG.: J.GREENE C ON DIT ION TH AT T HE D RAW IN G IS N OT TO BE
(0,0,0) MY PROD. ENG.: N/A
R EPR ODU C ED IN W HO LE OR IN PAR T, O R
DYR WEIGHTS FURTHER, THE COMPONENTS OF THESE RESULTANTS SHOULD NOT EXCEED THE U SED F OR TH E BEN EFIT O F AN YON E OT HER

FOLLOWING: TURBINE SHAFT DATE: 2/27/2017 TH AN ELLIOTT CO MPA NY AN D NO

IN FOR M ATIO N SH OW N IN T HIS D R AW ING MAY
FX GOVERNOR END OF BE D ISCLO SED O R U SED IN AN Y W AY C 2017 ELLIOTT COMPANY
APPROX. MASS LBS kg
TURBINE
NET 2300 1045
FX
FY
=
=
524
1309
lbf
lbf
2329
5823
N
N
MX
MY
=
=
2618
1309
lb-ft
lb-ft
3550
1775
N-m
N-m X+ (PARALLEL TO GENERAL ARRANGEMENT
A MZ MX DYRUG TURBINE A
FZ = 1047 lbf 4658 N MZ = 1309 lb-ft 1775 N-m TURBINE SHAFT)
SHIPPING 3680 1669
THE ABOVE LIMITS ARE ABSOLUTE VALUES AND SIGN/ORIENTATION ARE DEFINED SIMILAR TO SIZE PROJECT: REV
ROTOR 355 161
APPROX. CENTER OF GRAVITY (TURBINE ONLY) BY THE FOLLOWING: FZ H F602328 3014696 0
CASING (TOP HALF) 375 170 SCALE: NTS GENERATED BY: INVENTOR SHEET 1 OF 5
8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
3014696

H H

SHAFT 5.74
EXTENSION [145.8]
SHAFT END TO SPEED 4.68
G PICK-UP BRACKET [118.9] G
(WHEN FURNISHED)
KEYWAY 3.96
LENGTH [100.6]
4.00 6.94 15.19 1.38
MAX. HUB 3.59 [101.6] [176.2] [385.8] [35.1]
LENGTH [91.1]
.87 2.00 2.50
[22.1] [50.8] [63.5]
1.00 .50
[25.4] [12.7]

2.9325 +- .0000
.0005
.32 1H, 9/32 [7.1]
[8.1] PILOT HOLE
F [74.4855 +- 0.0000
0.0127] REAM & DOWEL AT ASSEMBLY F

2H, 1/2-13
FOR JACKSCREWS

SHAFT END DETAIL

14.50
10.50 [368.3]
E [266.7] E
3.207 +- .000
.004 24.00 22.24 C/L TURBINE 16.50
[564.9]
[81.458 +- 0.000
0.102]
[609.6] [419.1]

2H, 1/2-13 5.25

.750 +- .000
.002
FOR [133.4]
7.26
JACKSCREWS
8.25
[19.050 +- 0.000
0.051]
[184.4]
[209.6]
11.12
[282.4]

D D

4.00 6H, 3/4 [19]

[101.5] 1-3/8 [35] SF, NS
SHAFT KEY DETAIL
(ENLARGED 2X)

.56 X .75 X 3.96 KEY .88 2H, 13/32 [10.3]

[22.4] 5.74
[14.2] [19.1] [100.6] [145.8] PILOT HOLE
FURNISHED BY ELLIOTT CO. REAM & DOWEL AT ASSEMBLY

C NOTES: C
PLAN VIEW OF CONTACT SURFACES
1. ELLIOTT CO. PREFERS USING
COUPLING MANUFACTURE'S
STANDARDS FOR SPACER & HUB
LENGTHS.

2. ELLIOTT CO. RECOMMENDS HUB

KEYWAY & INTERFERENCE FIT TO
BE IN ACCORDANCE WITH AGMA
9002 OR API 671.
ELLIOTT CO. RESERVES THE RIGHT
TO NOT INSTALL ANY HUB FOUND IN
CONTRAST TO THESE STANDARDS.
B 3. MAX. COUPLING B
HALF-WEIGHT
= 35 LBS [15.9 Kg]

IF MAX. COUPLING WEIGHT IS

EXCEEDED, ELLIOTT CO.
ENGINEERING APPROVAL IS NEEDED. DRAFTER: Z.OPLINGER
TH IS D RA W ING AN D ALL IN FO RM AT ION
CHECKER: J.SNODERLY SH OW N TH ER EON IS T HE EX CLU SIVE
PR OPER TY O F ELLIOTT CO M PANY A ND IS
DATE: 2/27/2017 PR OVID ED S UBJEC T T O T HE EXP RESS
C ON DIT ION TH AT T HE D RAW IN G IS N OT TO BE
R EPR ODU C ED IN W HO LE OR IN PAR T, O R
U SED F OR TH E BEN EFIT O F AN YON E OT HER
TH AN ELLIOTT CO MPA NY AN D NO
IN FOR M ATIO N SH OW N IN T HIS D R AW ING MAY
BE D ISCLO SED O R U SED IN AN Y W AY C 2017 ELLIOTT COMPANY

GENERAL ARRANGEMENT
A DYRUG TURBINE A

SIZE PROJECT: REV

H F602328 3014696 0
SCALE: NTS GENERATED BY: INVENTOR SHEET 2 OF 5
8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
3014696

H H

G G
DISMANTLING HEIGHT
CASING (TOP HALF)

A SENTINEL
VALVE
TACHOMETER
CONNECTED TO
MAG PICK-UP BY LIFTING LUG
ELLIOTT CO. CAUTION: TO BE USED
F FOR LIFTING COVER ONLY! F
C4

S1

L4
E E

UPPER 3.62
HANDVALVE [91.9]
56.37 (NOT SUPPLIED)
[1431.8] STUD
PROJECTION 6" STEAM INLET, CL 600 R.F.
12 STUDS, 1"-8
ON 11.50 [292.1] B.C.
14.00 [355.6] O.D. FLANGE
8.50 [215.9] R.F., .25 [6.4] THK.
C/L UNIT

39.57 12 EXHAUST, CL 150 R.F.

D [1005.1] 12 HOLES, 1.00 [25.4] D
ON 17.00 [431.8] B.C.
19.00 [482.6] O.D. FLANGE
15.00 [381] R.F.,
.06 [1.5] THICK
C/L STEAM INLET

(22.00
[558.8])
21.24
[539.6]
16.94
[430.3]
13.50
C [342.9] C
L3
M4 M5
8.50
G1 6.75 [215.9]
[171.5]

A LOWER 2.00
HANDVALVE 1.11 H1
[28.2] [50.8]
(SEE SHEET 4) (NOT SUPPLIED)
C.O.G.
19.62 27.24 3.24
[498.3] [691.9] [82.3]
B B
22.24 SPACE REQ'D
[564.9] FOR REMOVING
STEAM STRAINER

DRAFTER: Z.OPLINGER
TH IS D RA W ING AN D ALL IN FO RM AT ION
CHECKER: J.SNODERLY SH OW N TH ER EON IS T HE EX CLU SIVE
PR OPER TY O F ELLIOTT CO M PANY A ND IS
DATE: 2/27/2017 PR OVID ED S UBJEC T T O T HE EXP RESS
C ON DIT ION TH AT T HE D RAW IN G IS N OT TO BE
R EPR ODU C ED IN W HO LE OR IN PAR T, O R
U SED F OR TH E BEN EFIT O F AN YON E OT HER
TH AN ELLIOTT CO MPA NY AN D NO
IN FOR M ATIO N SH OW N IN T HIS D R AW ING MAY
BE D ISCLO SED O R U SED IN AN Y W AY C 2017 ELLIOTT COMPANY

GENERAL ARRANGEMENT
A DYRUG TURBINE A

SIZE PROJECT: REV

H F602328 3014696 0
SCALE: NTS GENERATED BY: INVENTOR SHEET 3 OF 5
8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
3014696

H H

(SEE SHEET 5)

B B
G G

7.44 13.56
[189.0] [344.4]

C4
SENTINEL
VALVE

F F

G1
E E
G2

C/L TURBINE

40.88
5.12 [1038.2]
[130.0]
C.O.G.

D D

C/L EXHAUST
22.00
[558.8] 20.38 20.63
[517.7] 18.38 [523.9]
[466.7]
H2
14.35
12.72 12.00 [364.4]
[323.1] M
[304.8] H1 L5
7.56
H5 & G7 [192.0]
C 3.74 C
[95.0]

.13 1.00 .88

[3.2] [25.4] 3.19 [22.4]
2.00 ALLOW [81.0]
[50.8] FOR C.O.G.
ALLOW THIS SHIMS
SPACE FOR 16.94 21.68
PIPING [430.3] [550.7]

51.01 7.00
B [1295.8] [177.8] B
ALLOW THIS SPACE FOR
REMOVING GOVERNOR
VIEW A-A AND GOVERNOR VALVE

C C DRAFTER: Z.OPLINGER
TH IS D RA W ING AN D ALL IN FO RM AT ION
(SEE SHEET 5) CHECKER: J.SNODERLY SH OW N TH ER EON IS T HE EX CLU SIVE
PR OPER TY O F ELLIOTT CO M PANY A ND IS
DATE: 2/27/2017 PR OVID ED S UBJEC T T O T HE EXP RESS
C ON DIT ION TH AT T HE D RAW IN G IS N OT TO BE
R EPR ODU C ED IN W HO LE OR IN PAR T, O R
U SED F OR TH E BEN EFIT O F AN YON E OT HER
TH AN ELLIOTT CO MPA NY AN D NO
IN FOR M ATIO N SH OW N IN T HIS D R AW ING MAY
BE D ISCLO SED O R U SED IN AN Y W AY C 2017 ELLIOTT COMPANY

GENERAL ARRANGEMENT
A DYRUG TURBINE A

SIZE PROJECT: REV

H F602328 3014696 0
SCALE: NTS GENERATED BY: INVENTOR SHEET 4 OF 5
8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
3014696

H H

35.57
L4 [903.5]

27.63 27.94
[701.8] [709.8]
1.14
G
26.96 [29.1] (10.94
[277.8])
G
[684.8]

24.43
[620.6]

L3

S1 H5
F F

H1

21.00 20.88 M
[533.4] [530.2] 2.63 G7 2.70
[66.9] [68.6]

E 9.12 E
[231.6] C/L TURBINE
.88
[22.2]
C/L TURBINE
10.50
[266.7] 11.74
[298.2]
5.75 2.00 5.75 H2
[146.0] C4 [50.8] [146.0]

22.74
D [577.6] D

L5

G2
G1
M4

L3
1.18
C [30.0] C

M5
32.60
3.49 [828.1]
[88.6]

(10.94
[277.8])
39.16
[994.7]
24.51
[622.4]
VIEW C-C
35.74
B [907.8] B

VIEW B-B

DRAFTER: Z.OPLINGER
TH IS D RA W ING AN D ALL IN FO RM AT ION
CHECKER: J.SNODERLY SH OW N TH ER EON IS T HE EX CLU SIVE
PR OPER TY O F ELLIOTT CO M PANY A ND IS
DATE: 2/27/2017 PR OVID ED S UBJEC T T O T HE EXP RESS
C ON DIT ION TH AT T HE D RAW IN G IS N OT TO BE
R EPR ODU C ED IN W HO LE OR IN PAR T, O R
U SED F OR TH E BEN EFIT O F AN YON E OT HER
TH AN ELLIOTT CO MPA NY AN D NO
IN FOR M ATIO N SH OW N IN T HIS D R AW ING MAY
BE D ISCLO SED O R U SED IN AN Y W AY C 2017 ELLIOTT COMPANY

GENERAL ARRANGEMENT
A DYRUG TURBINE A

SIZE PROJECT: REV

H F602328 3014696 0
SCALE: NTS GENERATED BY: INVENTOR SHEET 5 OF 5
8 7 6 5 4 3 2 1
Chapter 10
Technical Drawings

NOTES

10-4 chap10.7/15/2008
724-527-2811 http://www.elliott-turbo.com/