ROTATING MACHINERY SERVICES, INC.

VOLUME 6, ISSUE 3

July - September 2010

RMS
The Finish Line
Phone 484-821-0702 Fax 484-821-0710 [Link]

What’s Inside
39TH TURBOMACHINERY SYMPOSIUM
GEORGE R. BROWN CONVENTION CENTER Rule of Thumb 2
HOUSTON, TEXAS
OCT. 4 - 7, 2010
Preparing for “The Real 2
World”

Steam Turbine Over 3

Speed Trip
Rotating Machinery Services, Inc. will be attending and
exhibiting at the 39th Turbomachinery Symposium,
held at the George Brown Convention Center in RMS Adding Tools of 4
Houston, Texas on October 4 - 7. the Trade, Part 2

2010 has been a busy and productive year for Rotating

Spreader Tool for 4
Machinery Services, Inc. There is much to share with our customers, suppliers and friends.
Assembly/Disassembly
We have many new projects in the works, acquired more advanced equipment, added more of a Centrifugal
technical expertise and our expansion has been completed!! Compressor

Please stop by our booth to say hello and let us fill you in on what’s new!
Shipboard Turbocharger
RCFA 4

Identifying Interferences
API 687 ROTOR REPAIR SEMINAR on the Interference
Diagram
5

Rotating Machinery Services, Inc.

Bethlehem, PA Dresser-Rand GT61
NOVEMBER 1 - 5, 2010 Power Turbine 6
Component Restoration
Rotating Machinery Services, Inc. will host the API 687 Rotor Repair Course at our Bethle-
hem, PA office on November 1-5, 2010. The course will be taught by Cliff Cook. The API
Rotor Repair Course based on API standard 687, covers the minimum requirements for RMS “The Solution” -
Expander Emergency
the inspection and repair of rotating equipment rotors, bearings and couplings used in the 6
Turnaround
petroleum, chemical and gas industry services.

RMS Engineer Tony Rubino contributed to the writing of the API 687 standard. For more RMS Power Solutions
Capabilities 7
information or to register, please visit the API website at: [Link]/[Link]

The Marriott Courtyard at 2220 Emrick Boulevard, Bethlehem PA (610-625-9500) located

2 blocks from our Office is offering a special rate of $99.00 per night for the API Confer- RMS Welcomes 8
ence. Please mention API 687 Conference / Rotating Machinery Services, Inc. when making
your hotel reservations. If you have any questions about the conference, you can contact
Booths
Matthew Cunningham, API Events Manager at 202-682-8158 or Kathy54Ehasz, & 756RMS Event
Coordinator at 484-821-0702.
 RMS Page 2 ROTATING MACHINERY SERVICES, INC.

RULE OF THUMB - TURBOMACHINERY By Neal Wikert

H2S Service:
Alloy Steel / 410 SS / 17-4PH: All three materials are acceptable at different strength levels. Low
alloy steels like 4330 could be used to HRC 22 max (UTS app. 113 ksi max), 410 stainless steel
can be used up to HRC 25 (UTS app. 126 ksi) and 17-4PH can be used up to 33 HRC (UTS app.
140 ksi). These limits are outlined in NACE MR0175. Corrosion resistance is in the same order.
17-4PH is the material of choice if there is any chance of H2S reacting to form H2SO4, or any other corrosive byprod-
uct, in a particular stage(s).
Impeller manufacturing notes:
Double Temper weld procedure for H2S service:
1600F normalize w/ oil quench
First temper: 1225F +/-15 F
Second Temper: 1175 to 1200F
Impeller Repair Notes:
Impeller Bore Repair
API687: Welding and thermal spraying are the only accepted methods. Chrome or nickel plating is strictly for-
bidden due to the difference in thermal growth coefficients. Thermal spray coatings have recommended fin-
ished thickness limits as follows:
7-25 mils for high velocity fuel processes and
3-10 mils for combustion processes
Vibration - Common Causes:
Unbalance – Most common cause of vibration. Frequency is 1 per running speed.
Bent Shaft – Predominantly 1 per running speed, sometimes 2 times. It is accompanied by a high axial vibration compo-
nent.
Bearings, Sleeve – Excessive clearance will result in vibration with a frequency of 1 times running speed.
Misalignment – Will result in a vibration with a frequency that can be 1, 2, or 3 times running speed. It is accompanied
by a high axial vibration and may be as high as 1.5 times the vertical or horizontal readings.
Oil Whip – May occur in lightly loaded sleeve bearings. The frequency of vibration is sub synchronous (below running
speed)
Looseness – Mechanical looseness will result in a vibration with a frequency 2 times the running speed.

PREPARING TO TRANSITION FROM TEXT BOOKS TO “The Real World”

By John Smolko

For most students, college is a mixture of social life, homework and exams. How much emphasis is
placed on each of these components can vary greatly from student to student. From my perspective,
another component should be added that will help the student transition from the college mindset to the
work force. Preparing for life after school was a critical part of my college career. I had the opportunity
to participate in a co-op program that gave me an insight into what “The Real World” was all about be-
fore I graduated.

By working full-time during my academic career, I gained valuable experience that built my resume and
prepared me to go straight from graduation into the work force. I also believe the best starting point for
a recent graduate is with a company like RMS that is willing to dedicate valuable time and expertise in
order to train an entry level employee. After all, success begins with preparation, no matter if you’re
preparing for an exam or a turbomachinery overhaul.
Volume 6, Issue 3 Page 3 RMS

STEAM TURBINE OVER SPEED TRIP By Sydney Gross

When we talk about over speed with respect to turbine rotors we refer to a limit in rpm beyond which the rotor is not
guaranteed for continuous operation. This speed is the MCS, maximum continuous speed or MCOS, maximum continuous
operating speed. Trip speed is a point which, if reached, the machinery protection system will commence shutting the turbine
down.

API defines MCOS as 105% of the highest specified design speed of the turbine and the trip speed as 110% of MCOS. The
idea is that the turbine should operate around rated speed but not beyond MCOS, hence the 5% margin. However, speed
excursions do occur and are limited only by the governing system’s ability to control them. Therefore there is a 10% speed
margin above the MCOS which accommodates the governor system reaction.

Additionally, since there is a lag from the time the trip system senses trip speed and when the trip valve is shut and energy to
the turbine is isolated, the rotor will achieve a higher speed than trip speed. Therefore, API requires that new rotors be de-
signed for momentary operation up to 110% of trip speed.

In order to achieve trip speed shut down, the trip system has to sense turbine speed and initiate trip valve closing. Trip valves
are commonly shut with a heavy spring and are latched open mechanically by system oil pressure. Loss of oil pressure initi-
ated by an oil dump valve then results in valve closing. In a mechanical system, the dump valve is activated directly by me-
chanical input from a shaft knockout plunger or other centrifugally displaced mechanism. When a high enough rpm is reached
the mechanism displaces enough to strike a lever that activates the dump valve. The electronic system senses shaft speed
through non-contacting magnetic pick-up sensors. The input goes to the electronic over speed control unit, which initiates
the dump valve actuation.

Development of electronic trip systems over the past several years has established their reliability and speed such that they
are preferred by most users and manufacturers. Many older turbines have been successfully retrofitted with electronic sys-
tems and the mechanical system is either kept as redundant or discarded. One of the primary benefits of the electronic sys-
tem is that it can be set and tested without actually over-speeding the turbine which is inherently dangerous. This is accom-
plished by way of a signal generator providing the speed input to the control unit rather than the shaft.
 Page 4
RMS Page 4 ROTATING MACHINERY SERVICES, INC. RMS

RMS ADDING TO OUR TOOLS OF THE TRADE, Part 2 By Barry Ruch

In continuance to last issue’s article, with the purchase of the Coordinate Measuring Machine behind us, new developments
of improvement are in the works. RMS is now laying out a floor plan to construct a climate controlled inspection room.
This room will be located in the Shop Area and will be approximately 24’ x 40’. Along with the CMM, it will house all in-
spection tools, including two granite inspection tables, 4’ x 6’ and 5 1/2’ x 8’ and ensure not only a clean environment but
also a constant temperature, which will further increase the accuracy of dimensional results of parts being reverse engi-
neered.

Our years of experience in dimensional inspection have shown that extreme hot or cold conditions in which parts may be
inspected can influence part geometry sizes.

SPREADER TOOL FOR ASSEMBLY/DISASSEMBLY OF A CENTRIFUGAL

COMPRESSOR By John Smolko

RMS was recently contracted to design and manufacture a set of diaphragm

mounting studs for a model RF2BB-30 centrifugal compressor. An on-site visit
was planned in order to examine the existing studs during a planned disassem-
bly. During re-assembly of the compressor, it was discovered that the retain-
ing ring, which locates the shear ring in a groove in the compressor casing,
was difficult to install. In order for the retaining ring to be properly installed,
the shear ring should be ex-
panded from its relaxed shape
to allow easy bolting of the retaining ring
segments to the diaphragm. RMS used state-of-the-art 3D mod-
eling software to design a spreader tool that will be used to aide in future
assemblies and disassemblies of the ring. The design of the tool was based
on a turn-buckle that will be bolted to the existing holes in the shear ring
and used to either expand the ring during assembly or shrink the ring during
disassembly.

SHIPBOARD TURBOCHARGER RCFA By Tony Rubino, PE

RMS recently completed a root cause failure analysis for a marine diesel engine turbocharger. The units were experiencing
catastrophic failures in the turbochargers’ compressor section including loss of blading, extensive bearing damage, shaft fail-
ure, and subsequent oil contamination of the after cooler. Due to the
catastrophic nature of the failures, reconstruction of the failure sce-
nario was impossible due to the secondary damage to the failed com-
ponents. Preliminary analysis highlighted early detection parameters to
allow damaged turbochargers to be removed from service prior to
catastrophic failure. Forensic disassembly of damaged (but not failed)
turbochargers provided the evidence to relate the root cause to bear-
ing lubrication failure during rapid throttle movements. The short term
approach was to limit the rate of throttle movement. A bearing redes-
ign was recommended as a long term solution.
 Volume 6, Issue 3 Page 5 RMS

IDENTIFYING INTERFERENCES ON THE INTERFERENCE DIAGRAM

By William Sullivan, PE

In this installment of articles on the interference diagram we will see how interferences are identified. To do this we will look
at a situation that often arises as part of a turbomachinery re-rate.

Figure 1 Steam Turbine

Bladed Disk (51 Blades)
Figure 1 is an interference diagram for a steam turbine stage with 51 blades.
Interference Diagram The “reflection” line on the right side of the diagram is 51 / 2 = 25.5 nodal di-
9,000
Original Conditions ameters. The minimum speed of 5,535 rpm “reflects” at 5,535 * 25.5 / 60 =
Mtl: Alloy Steel
A/F Temp: 800 F
2,352 Hz. The maximum speed of 6,565 rpm reflects at 2,790 Hz. There are
8,000 5% separation margins included
with the speed lines (one just Figure 2 Steam Turbine
Bladed Disk (51 Blades)
7,000
64 = 2 X Vanes
below the minimum speed and Interference Diagram

one just above the maximum Rerate Conditions

9,000
6,000
speed). This turbine stage has 32 Mtl: Alloy Steel
A/F Temp: 850 F
5,000
vanes just upstream of the rotat- 8,000
Frequency, Hz

6,565 RPM ing blades.

4,000 7,000
Using the procedure presented
3,000
5,535 RPM
in the last newsletter, we locate 6,000

32 Vanes the 32 vanes at 19 nodal diame- 64 = 2 X Vanes

ters. We then place a vertical

Frequency, Hz
2,000 5,000
6,565 RPM
line on the diagram at 19 nodal
1,000 4,000
diameters extending from the
0
minimum speed margin line to 3,000
5,535 RPM

0 3 6 9 12 15 18 21 24 the maximum speed margin line. 32 Vanes

Nodal Diameter Family
We do the same for twice the 2,000

number of vanes.
1,000

There are no interferences on the “Original Condition” interference diagram = Interference

(Figure 1). 0
0 3 6 9 12 15 18 21 24
Nodal Diameter Family
The rerate consisted of increasing the airfoil height and increasing the inlet tem-
perature to increase the power output of the turbine. The combination of in-
Figure 3 Steam Turbine
creasing the airfoil length and increasing the airfoil temperature caused the disk
Bladed Disk (51 Blades)
Interference Diagram and blade natural frequencies to decrease. Figure 2 is the interference diagram
9,000
Rerate Conditions for the rerate conditions. There now are two interferences, highlighted on the
Mtl: Alloy Steel
A/F Temp: 850 F
diagram by bright green circles. One interference is the third blade mode at 19
8,000
nodal diameters with the 32 vanes. The other interference is the fifth blade
mode at 13 nodal diameters with 2 X the vanes.
7,000
Generally, we want to avoid interferences on lower order blade modes, par-
6,000 ticularly the first two bending modes and the first torsional mode. Therefore,
60 = 2 X Vanes to eliminate the interference with the third mode, we will reduce the vane
5,000 count to 30. The interference diagram with 30 vanes is shown in Figure 3. The
Frequency, Hz

6,565 RPM
interference with the third blade mode is eliminated but there is still an inter-
4,000 ference with the fifth mode at 9 nodal diameters and twice the number of
5,535 RPM
vanes.
3,000
30 Vanes Higher order modes are more difficult to excite than lower order modes and
2,000 the stimulus at twice the vane frequency is substantially less than the stimulus at
the vane frequency. There is also evidence form the position of the ninth nodal
1,000 diameter point of the fifth mode that there is limited blade movement (more
= Interference about that in the next newsletter). Therefore, the remaining interference
0
0 3 6 9 12 15 18 21 24
probably poses little risk to the reliability of the turbine and the changes re-
Nodal Diameter Family quired to remove the interference would most likely compromise the perform-
ance of the turbine.
 Page 6
RMS Page 6 ROTATING MACHINERY SERVICES, INC. RMS

DRESSER-RAND GT61 POWER TURBINE COMPONENT

RESTORATION By Robert Klova, PE

RMS recently completed a major component overhaul of a 1970’s vintage

GT61 power turbine for a North American gas pipeline company. The pro-
ject involved the restoration and repair of the two stage-rotor and all high-
temperature nickel-alloy stationary components. A new upgraded Incoloy
901 rotor disk was designed and manufactured by RMS to replace the original
A286 second stage disk. Components from the customer’s inventory of used
spares, along with parts from the currently operating turbine, were inspected
to determine the most suitable components for repair.
To define the work scope, RMS performed dimensional and NDT inspections
of all components. A detailed CAD layout of the turbine was created to in-
sure that proper fit-up and clearances would be maintained during the rebuild,
given that components from several sources were used. High-temperature
casings were weld repaired, straightened, re-heat treated and remachined.
Stators were weld repaired and remachined to re-establish proper axial clearances to the rotor. All new high-temperature
fasteners were supplied. A significant portion of the repair work was performed on a rapid-turnaround basis on components
removed after shutting down the operating turbine.
The customer expects to be able to operate the repaired power turbine until eventual retirement, using the components
manufactured and overhauled by RMS.

RMS “THE SOLUTION” - EXPANDER EMERGENCY TURNAROUND

By Mike Amato
A major domestic refinery experienced a failure of their FCC expander resulting in the shutdown of the power recovery
train. RMS was contracted to repair and rebuild the unit on an emergency basis. RMS responded to the emergency rebuild
with 24-7 support from engineering services, manufacturing and field services to provide the refurbished rotor, bearing and
seal assembly. During the initial inspection of the spare replacement rotor, RMS engi-
neering determined the rotor disc was not suitable for service and would require a new
rebladed disc. The rotor rebuild and refurbishment of the bearing and seal assembly,
along with a rebuild of the exhaust casing to add stiffeners to
eliminate casing cracking during operation were completed at
the RMS manufacturing facility. In addition, a new coupling
guard was fabricated and machined. Field service was provided
to reassemble the expander and rework the intermediate cas-
ing and exhaust transition piece. RMS completed the entire
scope within the customer's turnaround schedule.

RMS POWER SOLUTIONS By Paul Poley

The RMS Power shop operation is continuing to strengthen and grow in 2010. We have recently added a 20” engine lathe to
our list of machining support equipment. Also adding to the support equipment is our new 40,000 pound capacity balance ma-
chine currently being installed, and a used CMM that will be commissioned and calibrated soon.

We have also added to our manpower, by increasing our staff to six full time people. Adding a Quality Control Specialist has
proven to be helpful in moving material into the projects with expediency. Additionally, we have added a rotor assembly and
balance person; this will allow us to support the rotor assembly and balance machine operation around the clock, as needed,
to support turnaround work. Our shipping department has a new face as well. Our new “shipping administrator” has proven
to be very effective and helpful as we remain committed to serving our customers with excellent service.
Volume 6, Issue 3 Page 7 RMS
 Rotating Machinery PRSRT STD
RMS
Services, Inc. US POSTAGE PAID
EASTON, PA
PERMIT NO. 65
2760 Baglyos Circle
Bethlehem, PA 18020
RETURN SERVICE REQUESTED
Phone: 484-821-0702 / Fax: 484-821-0710
[Link]

EXCELLENT
ENGINEERING

PRODUCT LINES:

AXIAL COMPRESSORS •
CENTRIFUGAL COMPRESSORS •
EXPANDERS • GAS TURBINES •
POWER TURBINES •
STEAM TURBINES

RMS WELCOMES...
Glenn Gaddis
Manager of Projects
Over 36 years of experience in the Turbo Machinery business. Thirteen years as Gas Turbine Project Engineer
for off-shore gas transmission installations and gas pipelines in Mexico, Iran, and Prudhoe Bay, Alaska among
others nationwide. Sr. Project Manager for a complete line of turbomachinery from Motors, Gas Turbines,
Steam Turbines, Expanders, Axial and Centrifugal Compressors, and supporting Lube and Seal Oil Systems.
Managed the manufacturing of large new equipment packages for both international and domestic oil refineries
as well as upgrades and rerates of Turbomachinery. Director of Project Management at CONMEC Inc. with a
staff of Project Managers and technical writer for state of the art instruction manuals.

Caleb Guhlin
Shipping Administrator
Caleb comes to us all the way from San Marcos, Texas, where he graduated from Texas State University with
a Bachelor of Arts in Literature. Prior to college, Caleb served in the United States Marine Corps where he
was responsible for the serviceability, maintenance and logistics for Nuclear Biological and Defense equipment
for high turnover and frequently deploying units.

Carl Hess
Rotor Assembler / Balancing Technician
Carl has over 30 years experience in the Turbo Machinery field. He will be responsible for the rotor assem-
bly and balancing projects. He previously worked at CONMEC and Ingersoll-Rand.