Best Practice

SABP-G-003 31 October, 2004

Special Purpose Steam Turbines
Dynamic Analysis Factory Acceptance Test
Document Responsibility: Consulting Services Dept.

Saudi Aramco DeskTop Standards

Table of Contents

1 Introduction.................................................... 2
2 References.................................................... 2
3 General.......................................................... 3
4 Definitions...................................................... 3
5 Vibration Detectors........................................ 5
6 Shop Verification of Unbalanced
Response Analysis.…………………...... 6
7 Tests Procedure............................................ 6
8 FAT Acceptance Criteria................................ 8

Previous Issue: New Next Planned Update: 1 November, 2009

Revised paragraphs are indicated in the right margin Page 1 of 9
Primary contact: Khaleel M. Al-Hussain on 873-0311

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SABP-G-003
Issue Date: 31 October, 2004 Special Purpose Steam Turbines
Next Planned Update: 1 November, 2009 Dynamic Analysis Factory Acceptance Test

1 Introduction

1.1 Purpose

The purpose of this Practice is to establish guidelines in reviewing the dynamic

analysis of special purpose steam turbines during Factory Acceptance Test
(FAT).

1.2 Scope

This Best Practice gives general guidelines for reviewing vibration

instrumentation requirements, test procedure and acceptance limits during the
Factory Acceptance Test and does not include performance test criteria.

1.3 Disclaimer

This Best Practice is being provided for the general guidance and benefit of
Saudi Aramco engineers attending special purpose steam turbines Factory
Acceptance Test (FAT). The use of this Best Practice during factory acceptance
test, however, does not relieve the manufacturer from his responsibility or duty
to confirm or to verify the accuracy of any information presented or from his
contractual liability to perform an accurate FAT that conforms to Mandatory
Saudi Aramco Engineering Requirements. The use of the information or
material contained herein will not guarantee that the resulting product satisfies
the applicable requirements of Saudi Aramco Standards. Saudi Aramco
assumes no responsibility or liability whatsoever for any reliance on the
information presented herein or for FAT performed by manufacturer in
accordance with this Best Practice document. Moreover, this Best practice is
intended only to provide guidelines for Saudi Aramco engineers attending the
Factory Acceptance Test and shall not be considered as a replacement for the
Mandatory Saudi Aramco Engineering Requirements. Saudi Aramco® is a
registered trademark of the Saudi Arabian Oil Company. Copyright, Saudi
Aramco, 2004.

1.4 Conflicts with Mandatory Standards

In the event of a conflict between this Best Practice and other Mandatory Saudi
Aramco Engineering Requirement, the Mandatory Saudi Aramco Engineering
Requirement shall govern.

2 References

This Best Practice is based on the below referenced standard:

2.1 Saudi Aramco References

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Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SABP-G-003
Issue Date: 31 October, 2004 Special Purpose Steam Turbines
Next Planned Update: 1 November, 2009 Dynamic Analysis Factory Acceptance Test

Saudi Aramco Engineering Standard

SAES-K-501 Steam Turbines (30 September, 2003)

Saudi Aramco Materials System Specifications

32-SAMSS-010 Special Purpose Steam Turbines
(30 September, 2003)
34-SAMSS-625 Machinery Protection Systems (30 June, 2002)

2.2 Industry Codes and Standards

American Petroleum Institute

API STD 612 Special Purpose Steam Turbines for Petroleum,
Chemical and Gas Industry Services, 4th
Edition
API STD 670 Machinery Protection Systems, 4th Edition

3 General

¾ This best practice gives general guidelines for the vibration instrumentation
requirements, test procedure and acceptable limits during special purpose steam
turbines factory acceptance test. The attendee should review the rotordynamic
analysis prior the test.

¾ At least 6 weeks before the first scheduled test, the vendor shall submit to the
purchaser, for review and comment, detailed procedures for all tests, including
acceptance criteria for all monitored parameters. (API STD 612/ P 4.3.1.2)

¾ A minimum of 14 days advance notice shall be provided for any observed or

witnessed testing. (32-SAMSS-010 / P 4.1.4).

¾ Provisions shall be made for ready access (not requiring removal of the case) for
field balancing between the bearings. The number and location of these points shall
be mutually agreed upon by the purchaser and the vendor. (API STD 612 / P
2.6.15).

4 Definitions

Acceptance Level: This is the vibration level (displacement, velocity, or acceleration)

at which a machine can run indefinitely without inducing vibration related maintenance.

Factory Acceptance Test (FAT): is a test conducted at a factory to ensure that the
turbine meets its required performance and mechanical integrity.

Page 3 of 9

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SABP-G-003
Issue Date: 31 October, 2004 Special Purpose Steam Turbines
Next Planned Update: 1 November, 2009 Dynamic Analysis Factory Acceptance Test

General purpose steam turbines: are those turbines used to drive equipment that are
spared or not critical to plant operation. General purpose steam turbines shall not be
used for applications requiring a rated power exceeding 2,250 kW (3,000 HP), a
maximum continuous speed exceeding 5,000 RPM or for steam conditions exceeding a
pressure of 4,800 kPa Gauge (700 psig) and a temperature exceeding 400°C (750°F).
(32-SAMSS-009 / P 1.1.1.1).

Special purpose turbines: are those turbines used to drive equipment that is usually
not spared, is relatively large in size (power), or is in critical service. This category is
not limited by steam conditions or turbine speed. Special purpose turbines shall be used
for all applications not covered by the above general purpose steam turbines. (API STD
612/ P 1.1.2.2 & SAES-K-501 / P4.2.1).

Hydrodynamic bearings: Bearings that use the principles of hydrodynamic

lubrication. Their surfaces are oriented so that relative motion forms an oil wedge to
support the load without journal-to-bearing contact (API STD 612 paragraph 1.4.8).

Maximum continuous speed (revolutions per minute): is the speed at least equal to
105% of rated operating speed (see API STD 612 Figure 5). (API STD 612 / P 1.4.14).

Mechanical running test: is a test of a steam turbine to demonstrate mechanical

integrity of the turbine package and functionality of the instrumentation. This test is
normally performed uncoupled and under no load. (API STD 612 / P 1.4.21).

Slow roll: is the speed recommended by the vendor (typically 400-500 revolutions per
minute) for warm-up and initial check of equipment integrity prior to full operation.
(API STD 612 / P 1.4.31).

The speed governor system: is the primary system necessary to match the turbine
speed to the application. The governor includes those elements which are directly
responsive to speed and which “position” or influence the action of other elements of
the governing system to maintain the operating speed within the specified limits. (API
STD 612 / P 1.4.32 & 3.4.3.1).

Trip speed (expressed in revolutions per minute): is the speed at which the
independent overspeed shutdown system operates to shut down a prime mover. Trip
speed shall be at least 115% of the maximum continuous speed (see API STD 612
Figure 5). (API STD 612 & 32-SAMSS-010 / P1.4.36).

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Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SABP-G-003
Issue Date: 31 October, 2004 Special Purpose Steam Turbines
Next Planned Update: 1 November, 2009 Dynamic Analysis Factory Acceptance Test

API STD 612 Figure 5 – Overspeed Trip Requirements

5 Vibration Detectors

Vibration detection equipment shall be provided as per the below Table-1:

Table-1: Required Vibration Instrumentation for Special Purpose Steam Turbine

Seismic Measurement
Machine Relative Measurement
Applicable Reading at the monitor
Train
Standard Radial Thrust Key Φ Velocity Acceleration
(RMS)

Special Purpose
32-SAMSS-010 X&Y Dual Yes
Steam Turbine

Vibration detectors shall be provided, installed and calibrated in accordance with

34-SAMSS-625.

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Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SABP-G-003
Issue Date: 31 October, 2004 Special Purpose Steam Turbines
Next Planned Update: 1 November, 2009 Dynamic Analysis Factory Acceptance Test

6 Shop Verification of Unbalanced Response Analysis

6.1 Shop verification of unbalanced response analysis shall be performed as part of

the mechanical running test and the results shall be used to verify the analytical
model (API STD 612 / P2.8.3.1). The method to conduct the shop verification
test is described in API STD 612 & 32-SAMSS-010 section 2.8.3.

6.2 The results of the verification test shall be compared with those from the
original analytical model. The vendor shall correct the model if it fails to meet
any of the following criteria (API STD 612 / P2.8.3.2.2):

a) The actual critical speeds shall not deviate from the predicted speeds by
more than ±5%.

b) The predicted amplification factors shall not deviate from the actual test-
stand values by more than ± 20%.

c) The actual response peak amplitudes, including those are critically

damped, shall be within ± 50% of the predicted amplitudes.

6.3 When the test data does not meat the requirements of API STD 612, paragraph
2.8.3., additional more stringent testing is requires as per API STD 612,
paragraph 2.8.3.4. The purpose of this additional testing is to determine on the
test stand that the machine will operate successfully.

7 Tests Procedure

7.1 The Vendor shall demonstrate the compatibility of the contract probes and his
test stand readout equipment. The contract axial position probes and oscillator -
demodulators shall be used during the shop test. (32-SAMSS-010 / P4.3.3.1.7).

7.2 Shop test facilities shall include instrumentation with the capability of
continuously monitoring and plotting revolutions per minute, peak-to-peak
displacement and phase angle. Presentation of vibration displacement and phase
marker shall also be by oscilloscope. (API STD 612 / P4.3.3.1.8).

7.3 When seismic test values are specified, vibration data (minimum and maximum
values) shall be recorded and located (clock angle) in a radial plane transverse to
each bearing centerline (if possible), using shop instrumentation during the test.
(API STD 612 / P4.3.3.1.10).

7.4 As a minimum, the FFT spectra range shall cover a frequency range from 0.25-8
times the maximum continuous speed but not more than 1500 hertz. (API STD
612 / P 4.3.3.3.2).

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Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SABP-G-003
Issue Date: 31 October, 2004 Special Purpose Steam Turbines
Next Planned Update: 1 November, 2009 Dynamic Analysis Factory Acceptance Test

7.5 Tape recordings shall be made of all real-time vibration data. (API STD 612 / P
4.3.3.3.5).

7.6 Plots showing synchronous vibration amplitude and phase angle versus speed
for deceleration shall be made before and after the 4-hour run. Plots shall be
made of both the filtered (one per revolution) and unfiltered vibration levels.
When specified, these data shall also be furnished in polar form. The speed
range covered by these plots shall be from the specified trip speed to 400
revolutions per minute. (API STD 612 / P 4.3.3.3.7).

7.7 Bearing housing overall velocity should be measured in in/sec (mm/sec) RMS
and shaft vibration in mils (µm) pk-pk.

7.8 The combined total electrical and mechanical runout is presented in Table-2 (for
more detail refer to API STD 612 & 32-SAMSS-010 – paragraph 2.6.2.2):

Table-2: Allowable Total Runout

Probes Location RPM Applicable Standard Allowable Total Runout (TR)

Radial ≤ 1800
32-SAMSS-010 • TR ≤ 9 µm pk-pk (0.35 mils pk-pk)
(Sec. 2.6.2.2 a)
> 1800
32-SAMSS-010 • TR ≤ 6 µm pk-pk (0.25 mils pk-pk)
(Sec. 2.6.2.2 a)
whichever is greater
API STD 612
Axial All • TR ≤ 0.25 x maximum allowed pk-pk vibration
(Sec. 2.6.2.2 b) amplitude
• TR ≤ 13 µm pk-pk (0.5 mils pk-pk)

Note: If the vendor can demonstrate that electrical or mechanical runout is present
and the total runout is within the limit specified in Table-2, then the runout may
be vectorially subtracted from the vibration signal measured during the factory.
(API STD 612 & 32-SAMSS-010 / P2.8.5.8)

7.9 Electrical and mechanical runout shall be determined and recorded by rolling the
rotor in V-blocks at the journal centerline while measuring runout with a non-
contacting vibration probe and a dial indicator at the centerline of the probe
location and one probe-tip diameter to either side. (API STD 612 / P 2.8.5.6).

7.10 Accurate records of electrical and mechanical runout, for the full 360 degrees at
each probe location, shall be included in the mechanical test report. (API STD
612 / P 2.8.5.7).

7.11 The mechanical running test shall verify that lateral critical speeds conform to
the requirements of API STD 612 paragraph 2.8.2 and 2.8.3. The first lateral
critical speeds shall be determined during the mechanical running test and

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Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SABP-G-003
Issue Date: 31 October, 2004 Special Purpose Steam Turbines
Next Planned Update: 1 November, 2009 Dynamic Analysis Factory Acceptance Test

stamped on the nameplate followed by the word test. (API STD 612 / P
4.3.3.3.3).

8 FAT Acceptance Criteria

During the mechanical running test, the mechanical operation of all equipment being
tested, including all casing joints and connections, and the operation of the test
instrumentation shall be satisfactory. The measured vibration shall not exceed the
limits in Table-3 and shall be recorded throughout the operating speed range. This table
content is a combination of API STD 612 4th edition and 32-SAMSS-010 exceptions.
The below steps 1 to 3 specify the FAT vibration values that need to be checked.

1. The overall vibration at the maximum continuous speed or at any other speed
within the specified operating speed range shall not exceed the overall limit
specified in Table-3.

2. The frequency spectrum at the maximum continuous speed and at other speeds
that may have been specified in the test agenda should be checked to identify the
highest amplitude (excluding the running speed) and ensure that it does not exceed
the maximum limit for discrete frequency amplitude specified in Table-3.

3. At any speed grater than the maximum continuous speed, up to and including the
trip speed of the driver, the vibration should not exceed 150% of the maximum
value recorded at the maximum continuous speed. (API STD 612/ P 2.8.5.5).

Table-3: Vibration Limits for Special Purpose Steam Turbines

Location of vibration Vibration On Inboard & Turbine Shaft

Measurement Outboard Bearing Housing (adjacent to bearing)
Item

whichever is less
Overall • Au ≤ (5.16X106 /N)05 µm pk-pk
(i) Maximum continuous Vu ≤ 2.5 mm/sec RMS * ((8000/N)05 mils pk-pk)
speed or at any other (0. 10 in./sec RMS)*
speed within the • Au ≤50 µm pk-pk
specified operating (2.0 mils pk-pk)
speed range Discrete Vf≤ 0.5 mm/sec RMS 20% of the above allowable
frequencies (0.02 in./sec RMS) overall limit
(other than N) (API STD 612 / P 4.3.3.3.2) Af ≤0.2 x Au
(API STD 612 / P 4.3.3.3.2)

(ii) Vibration limits at any speed greater

than the maximum continuous speed, 150 % of the recorded value at 150 % of the recorded value at
up to and including the trip speed maximum continues speed maximum continues speed

Page 8 of 9

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SABP-G-003
Issue Date: 31 October, 2004 Special Purpose Steam Turbines
Next Planned Update: 1 November, 2009 Dynamic Analysis Factory Acceptance Test

Notes:
(*) These specifications are from 32-SAMSS-010 – paragraph 2.8.5.5 not API STD 612.

Where:
Vu = unfiltered vibration velocity.
Au = unfiltered displacement determined by FFT.
Vf = discrete frequencies, non-synchronous, velocity.
Af = discrete frequencies, non-synchronous, displacement determined by FFT.
N = rotational speed (RPM).

Revision Summary
31 October, 2004 New Saudi Aramco Best Practice.

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