SOP: COUPLING & ALIGNMENT
SOP-MECH-002 REV 1.3

COUPLING & ALIGNMENT

Zero-Stress Coupling Logic & Foundation Settlement

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FOUNDATION SETTLEMENT RISK

Since 2014, the powerhouse foundation has likely shifted. For a 1.3 MW unit spinning at 750/1000 RPM, the margin for error is microscopic.

A vertical shift of only 0.10mm creates a permanent bending force (Cyclic Loading) that will eventually shear the shaft or melt a bearing.

TYPE A: OFFSET

Parallel mismatch: Generator centerline is higher/lower than turbine centerline.

TYPE B: ANGULAR

Gap/Zazor mismatch: Coupling faces are not parallel (open at top or side).

RIM & FACE PROCEDURE

  1. Mount dial indicators to read Rim (Radial) and Face (Axial).
  2. Rotate both shafts together in 90° increments (12:00, 3:00, 6:00, 9:00).
  3. Record Total Indicator Reading (TIR). Pass threshold: ≤ 0.05 mm.

COUPLING BOLT INTEGRITY

CHEMICAL LOCKING:

Vibration is constant. Mechanical washers are insufficient. Apply Loctite 243 (Blue) to threads during final torquing.

SYMPTOM AWARENESS:

A low-frequency "Growl" or "Hum" coming from the coupling guard indicates misalignment.