Rotor Repair API RECOMMENDED PRACTICE 687 FIRST EDITION, SEPTEMBER 2001 REAFFIRMED, MARCH 2015 Rotor Repair Downstream Segment API RECOMMENDED PRACTICE 687 FIRST EDITION, SEPTEMBER 2001 REAFFIRMED, MARCH 2015 SPECIAL NOTES API publications necessarily address problems of a general nature With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed API is not undertaking to meet the duties of employers, manufacturers, or suppliers to warn and properly train and equip their employees, and others exposed, concerning health and safety risks and precautions, nor undertaking their obligations under local, state, or federal laws Information concerning safety and health risks and proper precautions with respect to particular materials and conditions should be obtained from the employer, the manufacturer or supplier of that material, or the material safety data sheet Nothing contained in any API publication is to be construed as granting any right, 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developmental process and is designated as an API standard Questions concerning the interpretation of the content of this standard or comments and questions concerning the procedures under which this standard was developed should be directed in writing to the standardization manager, American Petroleum Institute, 1220 L Street, N.W., Washington, D.C 20005 Requests for permission to reproduce or translate all or any part of the material published herein should also be addressed to the general manager API standards are published to facilitate the broad availability of proven, sound engineering and operating practices These standards are not intended to obviate the need for applying sound engineering judgment regarding when and where these standards should be utilized The formulation and publication of API standards is not intended in any way to inhibit anyone from using any other practices Any manufacturer marking equipment or materials in conformance with the marking requirements of an API standard is solely responsible for complying with all the applicable requirements of that standard API does not represent, warrant, or guarantee that such products in fact conform to the applicable API standard All rights reserved No part of this work may be reproduced, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher Contact the Publisher, API Publishing Services, 1220 L Street, N.W., Washington, D.C 20005 Copyright © 2001 American Petroleum Institute FOREWORD API publications may be used by anyone desiring to so Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any federal, state, or municipal regulation with which this publication may conflict Suggested revisions are invited and should be submitted to the standardization manager, American Petroleum Institute, 1220 L Street, N.W., Washington, D.C 20005 iii CONTENTS CONTENTS CHAPTER Page CHAPTER ROTOR REPAIR 1-1 CHAPTER SPECIAL PURPOSE CENTRIFUGAL COMPRESSORS 2-1 CHAPTER SPECIAL PURPOSE AXIAL COMPRESSORS 3-1 CHAPTER SPECIAL PURPOSE STEAM TURBINES 4-1 CHAPTER SPECIAL PURPOSE GEARS 5-1 CHAPTER SPECIAL PURPOSE EXPANDERS 6-1 CHAPTER POSITIVE DISPLACEMENT ROTARY SCREW TYPE COMPRESSORS 7-1 v CHAPTER 1—ROTOR REPAIR Drawing Number Chap 1, 8.2.4.1 3.4.2c & d Chap 1, D.2.9 Chap 1, 10.2 Chap 1, 9.6 Wet Magnetic Particle Inspect (fluorescent, continuous method) Machine to Final Dimension and Profile Final Dimensional Inspection Balance Runout Inspect Chapter 1, D.2.2.3 Chapter 1, D.2.2.1 C C Undercut for Weld Preparation Chemical Analysis of Base Material Hardness Check Chapter 1, D.2.2.3 Chapter 1, 8.2.4.1 Chapter 1, D.2.3 Rough Dimensional Inspection of Undercut Area Wet Magnetic Particle Inspect (Fluorescent, continuous method) Weld Repair Chapter 1, D.2.2.1 3.4 Weld Restoration AXIAL ROTOR SEAL STRIP RESTORATION (1) Chap 1, D.2.3 API 687 Reference Paragraph Weld Repair Material Cert Chap 1, 8.2.4.1 Material Spec Wet Magnetic Particle Inspect (fluorescent, continuous method) Description/ Operation WPS, PQR ASTM E 709 Vendor Procedure Vendor Procedure Vendor Procedure ASTM E 709 WPS, PQR ASTM E 709 Reference Procedure Chapter 1, 8.2.4.4 Mfg Requirement Report Mfg Requirement Chap 1, 9.6 Chap 1, 10.2.11 Mfg Drawing Mfg Drawing Chap 1, 8.2.4.4 Chap 1, 8.2.4.4 Acceptance Criteria WPS, PQR (4) Certificate Report Certificate Certificate Report (2) Report Report Report Report Certificate WPS, PQR (4) Certificate Verifying W/O/* Document Point Sign Off Date 7-26 API RECOMMENDED PRACTICE 687 Drawing Number Chap 1, 9.6 Chap 1, 10.4 Chap 1, 10.4.3/ Chap 1, 10.4.4 4.5.1 4.5.1 4.5.1 Residual Unbalance/Sensitivity Check Residual Unbalance With Coupling Rotor Assembly—Final Dimensional Rotor Assembly—Final Indication Rotor Assembly—Gauss Level Mfg Drawing Mfg Drawing Mfg Drawing Chap 1, 10.3.5 Chap 1, App A Report Report Report Report Report Report Chap 1, 10.3.10 Residual Unbalance—Rotate U-Joint Drive Chap 1, 10.3.10 Report Chap 1, 10.3 Rotor Balance Chap 1, 10.3.9 Report Report Report (2) Report Report Report Report Certificate Verifying W/O/* Document Point Rotor Indication Mfg Requirement 4.3 ROTOR ASSEMBLY/LOW SPEED BALANCE Chap 1, 10.5.1 Chap 1, 9.6 Runout Inspect Chap 1, 10.2.11 Mfg Drawing Balance Machine Calibration Chap 1, 10.2 Balance Vendor Procedure Mfg Drawing Chapter 1, 8.2.4.4 Acceptance Criteria Mfg Drawing Chapter 1, D.2.9 Final Dimensional Inspection Vendor Procedure ASTM E 709 Reference Procedure Interference Fit Summary 3.4.2 c API 687 Reference Paragraph Machine to Final Dimension and Profile Material Cert Chapter 1, 8.2.4.1 Material Spec Wet Magnetic Particle Inspect (fluorescent, continuous method) Description/ Operation Sign Off Date ROTOR REPAIR, CHAPTER 7—POSITIVE DISPLACEMENT ROTARY SCREW TYPE COMPRESSORS 7-27 Reference Procedure O Observation W Witness / Hold Pt * Vendor To Confirm That Requirement Has Been Met Report: defines a vendor generated quality control inspection form/report that will satisfy industry standards or requirements outlined on purchase order Certificate of Compliance Chemical Analysis Mechanical Properties Heat Treat Charts Impact A C M H I H.T PT MT VT UT W/A N/A Heat Treatment Liquid Penetrant Inspection Magnetic Particle Inspection Visual Inspection Ultrasonic Inspection Will Advise Not Applicable INSPECTION POINT MATERIAL CERT Date LEGEND GENERAL Sign Off 4) All WPS, WQR, and PQR shall be available to purchaser for review and approval prior to any welding Report Verifying W/O/* Document Point 2) All verifying document reports shall reference procedure and state drawing acceptance criteria Mfg Drawing Acceptance Criteria 3) Due to the moderate cost of new rotors on flooded screw compressors, new rotors are normally recommended in lieu of weld repair NOTES: DESCRIPTION/OPERATION Chap 1, 11 API 687 Reference Paragraph Prep For Shipment Material Cert 4.5.1 Material Spec Weight of Assembled Rotor Description/ Operation 1) Repairs other than minor blending would normally not be done on cast iron rotors Drawing Number 7-28 API RECOMMENDED PRACTICE 687 APPENDIX D—INSPECTION FORMS FOR ASSEMBLY AND BALANCE 7-29 7-31 Figure 7.D-1—Rotor Assembly Dimensions ROTOR REPAIR, CHAPTER 7—POSITIVE DISPLACEMENT ROTARY SCREW TYPE COMPRESSORS APPENDIX E—AUDITORS CHECK LIST E.1 General This Appendix, along with Appendix H, Chapter 1, is a checklist to provide information for the owner and the vendor to aid in summarizing the scope of the rotor repair Repairs require clear owner/vendor communication and the assignment of responsibilities The format of this checklist provides a summary of the items required and the parties responsible Each item on this checklist has a circle or a square to indicate whether the owner or vendor, respectively, is responsible for obtaining the information or performing the task The owner must indicate, for each item, whether the item is to be witnessed, observed, or verified Typically, inspections, processes or tests may be witnessed or observed while verification is the review of the results of the inspections, processes, tests, or other documentation so as to insure that the requirements have been met 7-33 ROTOR REPAIR, CHAPTER 7—POSITIVE DISPLACEMENT ROTARY SCREW TYPE COMPRESSORS 7-35 AUDITORS CHECK LIST Customer: _ Job/Project Number: _ Owner Equipment Identification Number: _ OEM Equipment Serial Number: _ Rotor Identification Number: _ Repair Purchase Order Number: _ Vendor Job Number: _ Auditors Check List Note: Information to be supplied or completed by: O owner vendor Item O/ API 687 CH REF SECTION N/A SECTION 2—Rotor Disassembly and Inspection Phase II Interference Fits 2.2.1 Match Mark Timing Gears 2.2.2 Timing Gear Measurements 2.2.3 Lobe, Seal Strips 2.2.4/ 2.2.5 Clean Rotor 2.2.6/ 2.2.7 Shaft Dimensions 2.2.8a Spacers, Sleeves 2.2.8b Balance Piston 2.2.8c Thrust Collar 2.2.8d Key Clearances 2.2.8e Eliminate Weight(s) 2.2.9 Clean Timing Gears 2.2.10 NDE 2.2.11/ 2.2.12 Photographs 2.2.13 Balance Piston 2.2.14 Remove Timing Gears 2.2.15 Witnessed or Observed or Verified (W/O/V) Indicate Choice W O V Date Inspected or Verified By Status 7-36 API RECOMMENDED PRACTICE 687 Auditors Check List (Continued) Note: Information to be supplied or completed by: O owner vendor Item O/ API 687 CH REF Thrust Collar, Distance Ring 2.2.16 Lobe Seal Strip Dimensions 2.2.17/ 2.2.18 Rotor Profiles 2.2.19 Threaded Areas 2.2.20 Inspection Report 2.3 Review 2.4.1 Blue Contact Check 2.4.2 Job Scope 2.5.1 Witnessed or Observed or Verified (W/O/V) Indicate Choice SECTION 3—Rotor Repair and New Component Manufacture Pre-Lobe Profile Repair 3.2.2 Lobe Blending Repair 3.2.3 Lobe Plating Repair 3.2.4 Lobe Weld Repair 3.2.5 Seal Strip Repair 3.3.2 Replace Timing Gears 3.4.1 Distance Ring Thickness 3.4.2 Replace Balance Piston 3.4.3 Component Replacement 3.5 Dimensional Verification 4.2.1 Clean Rotor 4.2.2 Interference Fits 4.2.3 Keyway Verification 4.2.4 Install Sleeves 4.3.1 Install Timing Gears 4.3.2 Distance Ring Measurements 4.3.3 SECTION 4—Assembly and Balancing W O V Date Inspected or Verified By Status ROTOR REPAIR, CHAPTER 7—POSITIVE DISPLACEMENT ROTARY SCREW TYPE COMPRESSORS 7-37 Auditors Check List (Continued) Note: Information to be supplied or completed by: O owner vendor Item O/ API 687 CH REF Install Thrust Collar & Key 4.3.4 Rotor Runouts 4.3.5 Orient Match Marks 4.3.6 Component Balance 4.4.1 Balance Corrections 4.4.1.1/ 4.4.1.2 Balance Rotor 4.4.2 Final Inspection 4.5 Documentation 4.6 Witnessed or Observed or Verified (W/O/V) Indicate Choice W O V Date Inspected or Verified By Status 01/01 1220 L Street, NW 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