APPLICATION #1: THERMAL GROWTH STUDY
OBJECTIVE
To measure the cold (shutdown) to
hot (operating) changes in the shaft alignment of a rotating
machinery train. This data can be used to produce a target for
the mechanical alignment or can be used with an existing set of
mechanical alignment data to show a present hot shaft alignment.
The same data acquisition techniques can also be applied to
reciprocating engines and compressors, as a troubleshooting tool.
DESCRIPTION
Dowel pins or tooling balls are
installed directly into the unit being surveyed, on or near the
bearing housings, for use as machinery data points. benchmark
plates with dowel pins pre-installed and spot-faced are permanently
positioned on or near the machine foundation for use as reference
points. Cold and hot optical surveys are then taken in the
order required.
 Horizontal data is normally taken
on both sides of the machine train using an optical transit that is
set up to plunge a precise, plumb vertical plane defined by optical
tooling scales extended from the benchmarks. Tooling scales in
their respective holders are extended from each machine data point
to coincide with the optical line of sight. Vertical data is
taken using a precision sight level set up at various locations
around the machine. The level establishes an accurate
horizontal plane that is referenced to various benchmarks located
around the train. Tooling scales in their respective holders
are extended vertically from each machine data point to coincide
with the line of sight. All data is tied into one common
elevation in the final data reduction.
APPLICATION #2:
RECIPROCATING MACHINERY BORE ALIGNMENT
OBJECTIVE
To measure and achieve proper
alignment of the main bearing saddles or of the compressor cylinders
to their crosshead guides. Other applications include leveling
sole plates prior to grouting, leveling engine frames and
crankcases, and cold to hot thermal growth studies. These are
described on other application notes.
DESCRIPTION
Main bearing saddle alignment. An
optical instrument is positioned to read a line of sight through
optical targets located in the center of the two end bearing
saddles. The optical targets are centered to their respective
bores using a dial indicator that rotates on the target holder's
centering head. Readings are taken in the remaining saddle
bores using a third optical target. Data is taken on both halves of
each saddle where applicable. This data is usually used in
conjunction with elevation readings before an adjustment is made.
Compressor cylinder to crosshead
guides alignment. An optical instrument is positioned to read
a line of sight through a pair of optical targets centered at each
end of the crosshead guides bore. Displacement from this line
of sight is then measured at the two optical targets centered in
each end of the compressor cylinder liner. Adjustments in the
alignment can be immediately verified using the optical tooling.
APPLICATION #3: EXTRUSION
MACHINERY BORE ALIGNMENT
OBJECTIVE
To measure and achieve proper
alignment of an extrusion bore system or a mixing chamber bore
system. This data can be used during a new installation or
during a machinery overhaul.
DESCRIPTION
 Extrusion bore system alignment:
An optical instrument is positioned to read a line of sight through
optical targets centered into each end of the drive gear system.
The optical targets in the gear spindle are centered to the axis of
rotation of the spindle. Readings are then taken at each
flange intersection in the liner of the extrusion barrel components
using an optical target located at each station. The optical
targets are fixed into the liner and are centered using a dial
indicator that rotates on the centering head if the target holder.
If realignment is necessary, the adjustments can be verified
immediately with the optical tooling.
Mixer bore alignment: An
optical instrument is positioned to read a line of sight through a
pair of optical targets located at each end of the drive system, on
one side of the chamber. Readings are then taken at the water
end section using one optical target located in the respective bore.
The optical targets are centered to their respective bores using a
dial indicator that rotates on the target holder's centering head.
the procedure is repeated for the opposite chamber in the mixer.
The water end frame is then adjusted into alignment while being
observed and verified with the optical tooling.
APPLICATION #4: CENTRIFUGAL
MACHINERY BORE ALIGNMENT
OBJECTIVE
To measure and achieve proper
alignment of the internal components of a centrifugal machinery train.
This can be a steam turbine generator set in a utility or a steam
turbine driven process compressor train in a petrochemical facility.
the optical tooling technology is a similar for these applications.
The advantage of using optical tooling technology is similar for these
applications. The advantage of using optical tooling over a
piano wire or a mandrel is the speed of the measurements and the
ability to make changes in the alignment of the internal components
(diaphragms, packing glands, etc.) while other work is progressing.
DESCRIPTION
 An optical instrument is
positioned to read a line of sight through optical targets centered
into each end of the pre-determined set points. These set
points are normally established by the Original Equipment
Manufacturer. Optical targets are then centered in each bore
or half bore, i.e. cylinders (casings, shells), diaphragms, packing
glands, bearings, etc., and measured to the line of sight.
Realignment, where necessary, can be immediately verified with the
optical tooling.
APPLICATION #5: COUPLING
ALIGNMENT MEASUREMENTS
OBJECTIVE
To measure and achieve proper
alignment of a shaft system in a rotating equipment train. This
applies to machinery ranging from small, one coupling, motor driven
pump trains to the large, multiple component, gas turbine driven
generator sets.
DESCRIPTION
A laser alignment measurement system
is employed to obtain the shaft alignment data. The laser system is
mounted to read across a coupling, with or without the spool piece or
transmission unit in place. Mechanical alignment data is obtained by
rotating the shafts as near to one complete revolution as possible.
The laser system will calculate any shim changes necessary, allowing
for cold coupling offsets. It will also measure soft feet and
monitor the vertical and horizontal repositioning of the machinery as
it takes place. Graphical representations of the alignment are
furnished with the data.
R E ALIGN will also convert any data
to Reverse indicator Reading and/or Rim and Face formats if desired.
APPLICATION #6: ELEVATIONS,
LATERAL AND AXIAL MACHINERY PLACEMENT
OBJECTIVE
To measure and establish proper
elevation and/or levelness of machinery, usually prior to and during a
foundation repair. This application may include lateral and
axial measurements. This technology is used to establish the
x-y-z coordinates of centrifugal, reciprocating and extrusion
equipment, along with their support pads such as sole plates, skids or
rails and/or equipment foundation bolts.
DESCRIPTION
Elevations: An optical paragon
level is positioned to read on a precise horizontal plane, referenced
to gravity, at a pre-determined elevation. Readings are taken at
locations on the machinery prior to removal that can be repeated
during its re-installation. A set of data may be taken on the
machinery support pads and/or the foundation bolts after the equipment
is removed but prior to chipping them out. During the
re-installation, the elevations are monitored while being jacked to
the desired heights.
Horizontal/Axial: A jig
transit is set up to plunge on a vertical plane that is set-up either
parallel for the horizontal data or perpendicular for the axial data,
to the center of the machinery. The optical line of sight must be set
up so it can be repeated during the reinstallation phase of the
project. During the reinstallation portion the machinery is
jacked into place and verified using the optical tooling to monitor
the position.
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