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PRECISION ALIGNMENT STARTS AT THE BASE
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AGENDA
• Precision Alignment • Fundamentals • Bearing installation • Machine installation • Jack bolts • Soft foot
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WHY PRECISION ALIGNMENT?
Up to
50% of damage to
rotating machinery is
directly related to
misalignment
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WHY PRECISION ALIGNMENT?
Not aligning shaft centerlines to precision tolerances has a substantial impact on:
• Seal failures • Bearing failures • Shaft failures • Coupling wear • Decreasing component life • Excessive energy consumption. • Excessive heat and vibration
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“Vibration analysis just tells you that you have an issue.
Alignment keeps your equipment running.”
—John Upchurch Reliability Manager
Holcim Inc. St. Genevieve Plant
BE PROACTIVE! ALIGN YOUR MACHINES!
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Point where misalignment was detected by vibration analysis
Realignment should have been planned & scheduled
Other components identified as failed
Air handlers fails catastrophically
Repair should have been scheduled and bearing replaced
Proactive Predictive Reactive Cost to align
$550.00 Cost to repair component and Cost to align
$2120.00
Cost to adjust and Cost to repair component and Cost to repair collateral damage and Cost of downtime Cost for emergency OT Cost of expediting parts
$15,345.00
Bearings damaged due to misalignment
Increased Reliability - Decreased Costs Decreased Reliability - Increased Costs
WHY ASSET CONDITION MAINTENANCE
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FUNDAMENTALS - Definition of shaft alignment
- Shaft preloads
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DEFINITION OF SHAFT ALIGNMENT
• Positioning two or more machines so that their rotational centerlines are collinear at the coupling point under operating conditions.
– “rotational centerline” – “collinear” – “coupling point” – “under operating conditions”
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The term shaft alignment also implies that the
bearings and shafts are free from preloads.
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WHAT CAN CAUSE THESE PRELOADS?
• Bearing not installed properly • Base not flat
–Manufacturing –Installation
• Pipe stress • Coupling strain
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Bearing installation - Failures
- Pre-installation - Conventional Methods
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• Lubrication Failure • Contamination • Improper Mounting • Misalignment • False Brinelling • Improper Storage and
Handling • Poor bearing design
• Fatigue (Spalling) • Overheating • Excessive Loads • Corrosion • Fit • Electrical Damage
(Fluting)
COMMON BEARING FAILURES
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ROLLER ELEMENT BEARING FAILURE PATTERNS
Pattern A = 4% Pattern B = 2% Pattern C = 5%
Pattern D = 7% Pattern E = 14% Pattern F = 68%
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PRE-INSTALLATION CHECKS
• Safety procedures • Remove old bearing • Clean-up of shaft: remove grease,
nicks, and burrs. • Do not unwrap bearing until ready
for installation • Ensure shaft diameter is within
tolerances • Check bearing clearances
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BEARING PREPARATION
• Do not remove factory lubricant
• Ensure that bearing is the exact replacement
• Ensure once again that shaft is clean
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CONVENTIONAL HEATING METHODS
• No Temperature control
• Risk of over heating
• Grease Leaks out of bearing
• Tension in material
Blow Torch
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CONVENTIONAL HEATING METHODS
• Slow Heating process
• Grease cooks out of bearing
• Dangerous (Hot oil)
• Environment unfriendly
Oil Bath
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CONVENTIONAL HEATING METHODS
• Risk of over heating
• Grease Leaks out of bearing
• Tension in material
Hot Plate
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CONVENTIONAL HEATING METHODS
• Slow heating process
• High energy consumption
• Grease leaks out of bearing
Oven
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SLEDGEHAMMER
![Page 22: PRECISION ALIGNMENT STARTS AT THE BASE · 2020. 8. 24. · • Precision Alignment • Fundamentals • Bearing installation • Machine installation • Jack bolts • Soft foot](https://reader031.vdocuments.mx/reader031/viewer/2022012003/60a544dfddb8a665bf501095/html5/thumbnails/22.jpg)
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A low frequency induction field affects the complete part. The part heats equally.
LOW FREQUENCY INDUCTION HEATING
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ADVANTAGES OF INDUCTION HEATING
• High speed • High efficiency • High cleanliness • High safety • Easy control • Consistent temperature control of bearing • Reporting
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Machine Installation - Effects
- Components - Baseplates
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MACHINERY INSTALLATION
• Machinery Installation is just not new equipment installs
• Machinery Installation includes: – Rebuilds – Replacements – Overhauls
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• Misalignment • Twisted or distorted
bases • Soft Foot • Unbalance • Static Stress • Dynamic Stress • Coupling/Shaft runout • Mechanical Looseness
• Downtime • Poor product quality • Lower Capacity • High operating costs
Mechanical Financial
EFFECTS OF POOR MACHINE INSTALLATION
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COMPONENTS OF PROPER INSTALLATION
• Foundation • Anchoring • Isolation • Rigid, level, and flat • Alignment
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BASEPLATE
• Bases or Mounting pads must be: – Rigid – Level – Flat – Coplanar – Parallel to the other machine bases
on the train
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PROCEDURE BASED INSTALLATION
• If performing machinery installation, the installations should follow a procedure.
• Procedures reduce the possibility of start-up and premature failures by ensuring repeatability and consistency of activities.
• Procedures should follow the 3T process. – Target – Tolerance – Test
Target
Tolerance
Out-of-spec
James Kovacevic HP Reliability Inc
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BEST PRACTICES
• Machine should be installed centered on the baseplate
• Equal number of shims under all feet prior to alignment
• Inspect base for: – Cracked concrete – Broken welds – Warped surfaces
• Define standards for acceptance
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Jack Bolt Installation - Jack Bolts
- Bolt Torque - Best practices
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WITHOUT JACKING BOLTS
Accurate? Safe?
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DEFINITION OF JACKBOLT
A bolt or screw attached to the base or foundation used to move or position the movable machine horizontally
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JACK BOLT INSTALLATION
Jack bolts should be installed so that they are:
–Parallel to the baseplate –Perpendicular to the foot surface –Aligned with the hold down bolt –Leaving enough space to add
and remove shims
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BOLT TORQUE
• Bolts experience torsion and tension • Over-torquing creates high bolt tension • Rusted bolts can be under-torqued due
to high friction – Torqued bolt may not be tight. – Lube bolts
• Most bolts are designed to be torqued at 75% of Proof Load
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BEST PRACTICES
• Properly sized hold-down bolts to allow movement of machine
• Make provisions for horizontal jacking
bolts
• Apply proper torque to hold down bolts
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SOFT FOOT - Definition
- Importance - Causes of soft foot
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Soft foot means the machine frame distorts
as the foot’s bolt is tightened or loosened. An
example is a condition where the machine feet do not make solid contact (at
least 80%) with the soleplate surface or
external forces are acting on the frame.
SOFT FOOT - DEFINITION
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IMPORTANCE
Soft foot needs to be detected and corrected to within .002″ because:
• Destroys bearings and seals.
• Causes internal shaft misalignment that could eventually result in shaft failure.
• Makes shaft (coupling) alignment difficult.
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CAUSES OF SOFT FOOT
• Bad bases
• Bad motor feet (uneven, bent)
• Bad shim pack (bent, dirty, too many shims)
• Dirt, rust under motor feet
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BEST PRACTICES
• All of the previous considerations apply for the other machines in the train.
• So what else can cause defects on the ‘Driven’ machine?
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PIPE STRESS
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PIPE STRESS
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PIPE STRESS
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PIPE STRESS
• Pipes should be well fitted and supported, and flexible when possible.
• Monitor or measure the change in misalignment as flange is being bolted.
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TAKEAWAYS
• Be proactive! • Picture the lines • Do proper installation • Minimize soft foot
condition
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THANK YOU! Carlos Bienes, BSME, CRL
[email protected] Applications Engineer
LUDECA, Inc. - Miami, FL