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Millwright Manual > Chapter 22 - Installation And Levelling > Flashcards

Chapter 22 - Installation And Levelling Flashcards

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1
Q

Why is proper installation, levelling, and alignment vital to satisfactory machine operation?

A
  • following the proper steps alleviates many maintenance problems and extends the life of the equipment
  • studies have traced 70% of mechanical breakdowns to misalignment
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2
Q

How are machines maintained in alignment during operation?

A
  • proper installation onto baseplate / bedplates when driver-driven units share a common mounting
  • machines not sharing a common mounting can be installed on soleplates / sub-bedplates, which are set into and anchored to the foundations
  • independent machines are mounted directly onto a floor or foundation
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3
Q

Define the following:

- primary equipment

A
  • the first unit of machinery set into place
  • examples - pumps, conveyors, compressors, refiners
  • most cases, referred to as the driven unit
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4
Q

Define the following:

- prime movers

A
  • convert potential energy input of varying kinds into a mechanical form to drive other machine units
  • referred to as drives or drivers
  • examples - electric motors, steam turbines, and combustion engines
  • usually the last machine unit to be aligned
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5
Q

Define the following:

- transmission units

A
  • transmit mechanical energy from a prime-mover to a driven machine
  • usually increases the torque and reduces the speed
  • examples - gearboxes, differentials, VSD’s
  • for alignment purposes, may be referred to as a driven or a drive unit
  • a transmission unit for multiple-units is usually regarded as the primary unit and it installed first
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6
Q

Define the following:

- foundation

A
  • main support on which a machine rests
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7
Q

Define the following:

- dowel

A
  • straight or tapered (1/4”/ft) pin preferably with jacking (removal) nuts
  • used to ensure permanent location and alignment of the machine to its base
  • two dowels are usually used in each unit and located at diagonally opposite corners
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8
Q

Define the following:

- bench marks

A
  • points of reasonably permanent character
  • established by a surveyor to known elevations
  • used as reference points in surveying and by millwrights for levelling machinery to elevation
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9
Q

Define the following:

- datum points

A
  • known points from which any reckoning (measuring) or scale starts
  • necessary to correlate measurements used to determine elevations and horizontal positions for different locations
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10
Q

Define the following:

- datum plane (level)

A
  • horizontal plane from which heights, and depths are measured
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11
Q

Define the following:

- piano wire

A
  • wire with very high tensile strength
  • may be drawn extremely taut, giving a straight true line that does not stretch, loosen, or sag
  • used as reference or control lines in three dimensions for machinery layout and installation
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12
Q

What operating principles of rotating machinery should the installer understand?

A
  • machine function
  • fitting procedures
  • mounting
  • machine mechanisms
  • lubrication
  • bearings
  • transmission
  • alignment
  • seals
  • rigging procedures
  • guards
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13
Q

During installation of a multi-unit machinery set, which unit is usually set into place first?

A
  • primary equipment is the first unit of machinery set into place
  • followed by the transmission unit (sometimes primary unit)
  • last to be installed is the drive unit
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14
Q

What maintenance procedures should followed after receiving, and prior to, installation of on-site machinery?

A
  • upon arrival at the site, inspect the equipment to ensure that it is in good condition. Report any damage or defects. Also check packing slips for deficiencies
  • check the manufacturer’s recommendations and owner’s requirements as to storage, locations, recommended lubricants to protect against rust, etc.
  • fill bearing housings, gear reducers and any other oil-lubricated parts of the equipment with oil. Usually a light flushing oil containing a rust inhibitor is used
  • examine equipment with openings, such as pumps, fans, refiners, compressors. Remove any foreign matter and seal the openings covers to prevent contamination
  • unless otherwise specified, rotate the shafts of large units of rotating equipment at least once a month. Do this whether the equipment is in storage or on its permanent mounts.
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15
Q

What procedures should be followed during rigging and handling of machines?

A

1 - plan the move from the storage area to the final place of installation. This ensures that no unforeseen problems arise during the move.
2 - review the lifting specifications, such as, equipment weight, location of lifting lugs or special lifting considerations
3 - protect all machined surfaces from damage that can be caused by rigging equipment and attachments
4 - lift the load so that it is balanced and oriented in the required installation position

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16
Q

What installation procedures must be followed for warranty requirements?

A
  • manufacturer’s specifications provide information about:
    • installation
    • alignment
    • testing
    • calibration
    • lubrication
    • start-up
    • test-running
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17
Q

How are the machine and base prepared, prior to placing the machine on the base?

A

1 - before it is placed, inspect and make needed modifications to the equipment (this should be done prior to transporting the equipment to its prescribed location)
2 - review mounting method to be used for the machinery. Determine if it is the be mounted to the foundation, direct to the floor, or on an adjustable mounting
3 - lay out the machine’s position in relation to existing equipment (or blueprint) by establishing centrelines and reference lines
4 - prepare the mounting surface. This includes installing anchor bolts for baseplate, soleplate installation, levelling and grouting

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18
Q

What course of action is to be taken after the machine is moved into place?

A

1 - rig the machinery and set it in place

2 - fit the couplings, sheaves, sprockets and other field mounted equipment to each unit

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19
Q

What are the requirements for setting the primary unit?

A

1 - check the bearing clearances and remove locking devices on the primary unit
2 - position, level, and set to elevation the primary equipment

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20
Q

What are the requirements for setting the transmission and prime mover units?

A

Transmission
1 - check the bearing clearances and remove locking devices on the transmission unit
2 - rough align the transmission unit to the primary unit

Prime mover
1 - check the bearing clearances and remove locking devices on the prime mover unit
2 - rough-align the drive unit to the transmission unit or primary unit

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21
Q

What are the requirements for connecting piping and other attachments to the machines?

A

1 - connect all piping chutes and other attachments and check their alignment for stresses etc. so that no strain is placed on the machine
2 - disconnect from the equipment all the piping chutes etc. Adjust the piping etc. fro any misalignment between them and the equipment
3 - precision align to the tolerances specified in the manufacturer’s specifications
4 - if attachments cause misalignment from the specified tolerances, the attachments should be adjusted to eliminate these forces; sprockets and sheaves should be in line and parallel to one and another

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22
Q

What steps are involved in lubricating, powering, and testing the machines?

A

1 - remove flushing oil from equipment. Install the lubricant according to the specifications supplied by the engineer or vendor
2 - complete the installation of the power source for the prime mover (electricity, steam, etc.). Install other electrical and instrumentation interfaces
3 - test run the prime mover. This includes such steps as checking the direction of rotation doing a load test
4 - connect all drives to the primary equipment
5 - lubricate coupling, chains, and other drive components where necessary
6 - install all equipment guards and platforms (work stations) in accordance with design standards and to WBC requirements

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23
Q

How are the stages of installation and testing recorded?

A
  • recommended that equipment tags be used
  • as each stage of the installation is completed, that section of the tag is filled in
  • it may be necessary to report directly to your supervisor the completion of each step and file equipment reports to be checked by the engineer
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24
Q

What are the requirements for mounting and securing machinery?

A
  • must support the machine without distorting it
  • absorb vibrations
  • secure the machine at its correct location and level
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25
What methods are used to mount machines?
- mounted directly to concrete pads or floors - set on concrete pads or floors using special mountings - mounted on structural steel supports or steel floors - on soleplates - on a baseplate when mounting on structural steel: - use a base plate - make the thickness of the base equal to or greater than the thickness of the unit feet - extend it under the entire unit as shown - bolt unit and base plate securely to steel supports
26
Describe the following: | - adjustable machinery unit
- machinery is mounted on devices called machinery mounts or machinery levellers - anchor bolts are not generally required with this type of mount - the levelling features incorporate double wedges that enable a machine to be levelled to precise limits in a minimum amount of time When using this type of mount: - ensure that it is clean and greased so that it does not jam - always use mountings that are designed to carry the load of the machine
27
Describe the following: | - self-levelling pads
- used where the floor is not flat, smooth, or level | - incorporate a rocker in the design to compensate for the misalignment
28
Describe the following: | - vibration isolators
- prevent machine vibrations from being transmitted to adjacent equipment - prevent the amplification of internal stresses which cause misalignment and wear of machine elements various devices used: - simple felt pads between baseplate and floor - plain spring mount - shock-dampeners
29
What are the requirements of a foundation?
- be solid and rigid - footings must be firm and large enough to carry the distributed weight safely - should rest on a firm grounding such as rock, hard clay, well-compacted sand or gravel - if ground is less firm, weight should be distributed over a larger area - if soil is wet or soft, pilings may be needed, or vertical supports
30
How are foundations built to achieve their requirements?
- constructed of solid or reinforced concrete
31
What does a millwright check on a foundation?
- positions of anchor bolts should be checked against the locations of the anchor bolt holes in the machine (as built) - should errors be found, they must be recorded and the necessary modifications made to the baseplate (or soleplate) and/or foundation anchor bolts
32
Why is a machine foundation usually constructed lower than the bottom of the baseplate or soleplate?
- minus elevation by 19mm to 38mm - 38 mm is a practical thickness for shimming and grouting - eliminates concern about foundation shrinkage - provides space for shimming to elevation - provides space for grouting the baseplate or soleplate
33
How is vibration controlled?
- use large, well designed foundations Foundation may also be isolated from the surrounding floor by means of: - dead air apaces - vibration insulators (felt, cork, insulation, etc)
34
What are the purposes of anchor bolts and hold-down bolts?
Anchor bolts - used to firmly secure the machine baseplate or soleplates to a concrete foundation - also used to fasten machines directly to concrete floors - commercially available anchor bolts referred to as cinch anchors Hold-down bolts - used to secure machine units to the baseplate, soleplates, or structural steel foundations
35
What factors affect the design of fixed anchor bolts?
- type of machine - foundation design - thickness and quality of concrete - types of loads to be applied to the anchor and machine
36
What designs ensure that anchor bolts are firmly held in place by the concrete?
- the buried end may be deformed by bending it into an L-shape - it may be bolted or welded to a plate washer or a length of angle iron - straight buried depth = no less than 25 X diameter - bent buried depth= 4 X diameter
37
What are the purposes of pipe and boxed anchor bolts?
Pipe (tube) anchor bolts - allow the bolt the be moved slightly either in the machine base or in the template holding the bolts within the concrete form - after levelling and alignment are complete, during grouting, the pipes are filled with grout. This prevents fluids from being trapped in the pipe and rusting the anchor bolts, weakening them Boxed anchor bolts - used where bolts subject to severe vibration - the pipe acts as a sleeve around the bolt - the box provides clearance so that the bolt can be replaced - mainly used on large mill machinery
38
Describe the types of anchor bolts used for installation with existing concrete
- mechanical expansion anchors: 1 - stud-type expansion anchor - drill hole - hammer in bolt - tighten nut 3-4 complete turns to set wedges 2 - drop-in anchor - drill hole depth to length of anchor - clean hole - insert anchor into hole - expand anchor with hand setting tool and hammer until collar rests on anchor shoulder 3 - chemical adhesive anchors (epoxy resin, hardener, and filler in glass tube) - drill hole to required depth of cartridge - clean hole with compressed air and brush - insert cartridge - thread a nut on the HAS rod. place a washer and thread another nut sandwiching the washer in between, leave top of nut flush with top of rod - insert square drive shaft into the drill - drive the HAS rod into the embedment mark
39
What care should be taken when setting anchor bolts in position?
- each anchor bolt is in its correct location - bolts sit straight, not at an angle. Crooked anchor bolts interfere with positioning, levelling, and placement of the baseplate - anchor bolts protrude above the foundation or floor to allow room for: - - thickness of baseplate, etc. - - shimming the baseplate to elevation and level - - grout - - washers - - one or two nuts
40
What are the advantages of using a template for positioning anchor bolts?
- can support a large number of anchor bolts being set into the foundation at the same time - location is accurately maintained while cement or grout sets - can be secured in the vertical position - can be reused where a number of foundations have the same anchor bolt pattern - can be used to align the core drill for drilling holes in floors and foundations for grouting and setting cinch anchors
41
Describe how anchor and cinch bolt locations are determined on existing foundations and floors
- Three methods: 1 - lay out the position of the bolt holes working from dimensions on the drawings 2a - position the equipment and mark the locations of the anchor bolts on the floor 2b - core oversized holes into the floor at the approximate bolt locations 2c - grout the anchor bolts to secure them 3a - drill the holes as specified for the cinch anchors 3b - set the anchors as specified for the cinch anchors
42
To what torque are anchor bolts tightened?
- normally torqued to approx. 2/3 of their yield strength | - or to vendor's specifications
43
What is meant by the term, building tie-in?
- the relationship of equipment to the structure of the building - Tie-in is usually dictated by the required position of a major piece of equipment
44
What are the main reference lines for installation of mechanical systems?
- a machine centreline - lines parallel to the machine centreline - lines at right-angles or square to the machine centreline
45
What rules should be observed when establishing proper reference lines?
1 - keep the number of lines to a minimum. Errors increase with more lines 2 - select an area on the front and back of the baseplates, or in the aisle where a single parallel line can be scribed from one end of the machine to the other. Also establish a line square (90*) to the first reference line so as to establish two important references to the machine 3 - keep the layout as large as practical. The larger the layout the less chance of small acceptable errors being magnified when projecting lines 4 - keep reference lines out in the open whenever possible. Lines square to the centreline of the machine should also be out in the open. They should NOT be under any machine supporting members or components 5 - it is important to establish permanent reference points to facilitate all future rebuilds of large complex machines. These points are usually the intersections of working lines and centrelines. One method of preserving these reference points is through the use of brass plugs or holes filled with and epoxy grout mixture. These plugs are scribed and the intersections of the lines prick-punched to preserve the reference point
46
What is the purpose of a centreline?
- used to establish the exact position of machinery | - established on the machine base or baseplate for both the length and the width of the machine base
47
How are centrelines constructed?
- constructed using mechanical or optical methods employing one (or combination) of the following: - - reference points - - benchmarks - - datums - - centrelines of existing machines
48
Describe the purpose of datums and benchmarks
- used to establish a machine's elevation and horizontal position
49
How are datums used in the manufacture of the machines?
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50
How are permanent reference points established on base plates and in floors?
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51
Describe how reference lines are established
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52
What are reference lines used for?
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53
How are references lines made square to each other?
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54
How is piano wire kept taut?
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55
What precautions should be followed when working with piano wire?
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56
What are the advantages of optical layout methods versus mechanical layout methods?
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57
What are the capabilities of a theodolite?
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58
What is involved in setting up a theodolite?
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59
What should be done to improve the accuracy and the efficiency of a theodolite?
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60
What are the purposes of lasers in the layout and alignment of machines?
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61
Describe the procedure for setting base plates and sole plates
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62
Describe the following: | - levelling screws
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63
Describe the following: | - jacking screws and bolts
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64
Describe the following: | - shims and wedges
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65
What are the reasons for setting and levelling machines?
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66
Why is it important to prevent twisting of the baseplate or soleplate?
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67
Why are soleplates of machine transmission and drive units installed 3 to 5 mm lower?
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68
How is baseplate elevation established?
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69
Describe the procedure for levelling a baseplate using a precision level
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70
What thickness of shims would be required to level a baseplate, if? ``` L1 = 4’ L2= 1’ T = 0.010” ```
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71
Describe the procedure for levelling a baseplate using both a precision and a tilting level
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72
Describe the procedure for levelling a baseplate using a laser transmitter and detector system
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73
List the other uses for lasers
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74
What precautions should be taken while using a laser?
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75
What are the purposes of grout?
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76
Describe these two types of grout: cementitious and polymeric
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77
How is grout selected for an application?
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78
What safety precautions should be taken when working with grout?
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79
How is the foundation prepared for grouting?
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80
Describe the grouting procedure
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81
Describe how voids are prevented during grouting
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82
Describe how voids in the grout are detected and repaired
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83
How is permanent alignment of machines ensured?
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84
When are guards installed and to what standard must thy comply?
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85
Describe the procedure to test run a machine
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Millwright Manual (24 decks)

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