Your tension is too tight. To adjust your tension, thread your machine and sew a test piece. It should be perfectly even within the test piece. If the threads are not centered, adjust your tension wheel and re sew until the threads align. See your owner's manual for instructions.
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It is a standard construction measurement. Most homes have studs at 16 inch intervals.
2.5 inch bsp thread o.D
This generally has to do with the way that fabric is physically manufactured. The picks, or fill thread, is pulled through the "shed" created by the spread apart warp yarns (pick yarns). It is much easier to keep the warp yarns that are running parallel to the fabric roll production direction close and tight than it would be to get each fill thread that is inserted into the shed to be tight.
Depending on the classification it can be simply the size across the flats on the head. Alternatively it can be the diameter of the threaded part of the bolt, this can also be subdivided into the type of thread. (Called the pitch, called teeth per inch, or other linear unit). This determines how fine or coarse the thread is. There are also other classifications for specialized work in various industries.
Mechanically by a fixed reference. One turn of the barrel equals 25 thousandths of an inch- sometimes called 25 mills ( do not confuse with milimeters) therfore it can be read-off by an experienced operator.