Instalation, Leveling and Alignment

Question 1

Machine units that do not share a common baseplate and require alignment to
other units should not be mounted directly onto a foundation. They are set and
fastened to.
A) Bedplates C) Foundation plates
B) Soleplates D) Grout

Answer 1

B: Soleplates

Question 2

Machine units must be installed in a particular order to ensure satisfactory
operation of the equipment. Select the proper order below.
A) Primary equipment, prime mover, transmission unit.
B) Prime mover, primary equipment, transmission unit.
C) Primary equipment, transmission unit, prime mover.
D) Prime mover, transmission unit, primary equipment.

Answer 2

C Primary equipment, Transmission unit, Prime mover

Question 3

Which one of the following steps is not important when installing machines?
A) Leveling C) Alignment
B) Torquing D) Testing

Answer 3

B Torquing

Question 4

If attachments to machine units (piping, ducts, etc.) cause misalignment from
the specified tolerances, the attachments should be.
A) Connected with flexible hose C) Installed with baffles
B) Adjusted to eliminate forces D) Isolated from vibration

Answer 4

B; adjusted to eliminate forces

Question 5

Various methods are employed to mount and secure machines in place. The
method used must support the machine without distorting it as well as…
A) Eliminate soft foot C) Avoid grout pockets
B) Absorb eddy currents D) Absorb vibration

Answer 5

D: Absorb Vibrations

Question 6

In modern manufacturing facilities, mobility of equipment is very important.
How is this accomplished when installing machines?
A) Self-leveling mounts C) Vibration isolators
B) Adjustable foundations D) Adjustable mounts

Answer 6

D: Adjustable mounts

Question 7

To prevent the amplification of internal stresses which cause misalignment and
wear of machine elements as well as absorbing vibration these devices are
installed.
A) Self-leveling mounts C) Vibration isolators
B) Adjustable foundations D) Adjustable mounts

Answer 7

C: Vibration Isolators

Question 8

This procedure in foundation work eliminates concern about foundation
shrinkage as well as providing space for shimming to elevation.
A) Pouring to minus elevation C) Pouring with additives
B) Pouring grout with concrete D) Pre-installing anchor bolts

Answer 8

A: Pouring to a minus elevation

Question 9

The primary purpose of this component is to secure machine units to the
baseplate, soleplates, or structural steel foundation.
A) Anchor bolt C) Hold-down bolt
B) Hold-down screw D) All of the above

Answer 9

C: Hold down bolt

Question 10

Straight anchor bolts without deformed ends should be set into the foundation
concrete to a depth of.
A) 4 times their diameter C) 10 times their diameter
B) 8 times their diameter D) 25 times their diameter

Answer 10

D: 25 times the Diameter

Question 11

When anchor bolts have deformed ends, the length of the bent leg should be?
A) 4 times their diameter C) 10 times their diameter
B) 8 times their diameter D) 25 times their diameter

Answer 11

A: 4 times the diameter

Question 12

This type of anchor bolt is preferred to fixed anchor bolts as they allow the bolt
to be moved slightly in case of an error in hole layout.
A) Tube anchor bolt C) Grout anchor bolt
B) Flexible anchor bolt D) Canned anchor bolt

Answer 12

A: Tube anchor bolt

Question 13

Some hold-down bolts are subject to severe vibration and are liable to break at
the thread section. What type of anchor bolt is used in these cases?
A) Extra thick anchor bolts C) Pipe anchor bolts
B) Tube anchor bolts D) Boxed anchor bolts

Answer 13

D: Boxed anchor bolt

Question 14

Where anchor bolts need to be installed in existing concrete this style of anchor
bolt is most often used.
A) Resin anchor bolt C) Mechanical expansion anchor
B) Hydraulic expansion anchor D) Cementitious anchor

Answer 14

C: Mechanical expansion anchor

Question 15

This component assists in locating, setting and holding anchor bolts in place
while the cement cures.
A) Baseplate C) Soleplate
B) Bedplate D) Template

Answer 15

D: Template

Question 16

These lines are established on the machine base or baseplate for both the length
and the width of the machine base and are used to establish the exact position of
the machine.
A) Bench lines C) Permanent lines
B) Center lines D) Foundation lines

Answer 16

B: Center Lines

Question 17

These lines are used to establish a machine’s elevation and horizontal position.
A) Benchmarks C) Center lines
B) Foundation lines D) Piano lines

Answer 17

A: Benchmarks

Question 18

This component placed under each leveling screw or bolt prevents the end from
digging into the foundation and stops the machine from moving out of position
(walking) when it is tightened down?
A) Leveling washers C) Leveling isolators
B) Leveling wedges D) Leveling shims

Answer 18

A: Leveling washers

Question 19

This component supports the weight of the machine that is set directly to the
floor and not grouted in place. It screws into threaded holes provided in the
machine base.
A) Anchor bolt C) Leveling bolt
B) Hold-down bolt D) Leveling screw

Answer 19

D: Leveling screw

Question 20

This component is often used to raise machine units so that shims may be
inserted or removed when aligning and leveling units vertically.
A) Jacking screws C) Leveling screws
B) Leveling bolts D) Elevator bolts

Answer 20

A: Jacking screws

Question 21

Flat metal plates that provide a permanent firm adjustable support at points
where weight will be concentrated (anchor bolt locations) are known as !!!
A) Wedges C) Leveling washers
B) Shims D) Bench plates

Answer 21

B: Shims

Question 22

A structural filler that is the critical connection that links the bed or soleplate to
the concrete foundation is known as !!!!
A) Resin C) Grout
B) Epoxy D) Concrete

Answer 22

C: Grout

Question 23

The major advantage that polymeric structural filler has over other types is.
A) Moisture resistant C) Corrosion resistant
B) Vibration resistant D) All of the above

Answer 23

D: All of the above

Question 24

During the installation of transmission, primary and prime mover units it is
sometimes necessary to ensure permanent alignment. This is accomplished by
using???
A) Epoxy resins C) Rigid couplings
B) Grout D) Taper dowel pins

Answer 24

D: Taper doewl Pins

Question 25

Why is concrete mix not used to grout anchor bolts in machine foundations? A) It is too rough when cured C) It cures too slowly B) It can’t withstand compression D) It shrinks when cured

Answer 25

D: It shrinks when it cures

Question 26

Normal cement concrete reaches 100% of its compressive strength within how many days? A) 28 days C) 10 days B) 17 days D) 3 days

Answer 26

A: 28 Days

Question 27

Normal cement concrete reaches its desired working strength in how many days? A) 28 days C) 7 days B) 18 days D) 3 days

Answer 27

C: 7 Days

Question 28

Air-entrained concrete should be used where the hardened concrete will be subjected to…. A) Vibration C) Excessive moisture B) Freezing & thawing D) Shock loading

Answer 28

B: Freezing and thawing

Question 29

What type of concrete is easier to pour and place and requires less working to assume the shape of the form? A) Wet consistency C) Stiff consistency B) Dry consistency D) Medium consistency

Answer 29

A: Wet consistency

Question 30

The foundation of a machine which is subjected to critical alignment is poured with the concrete level at a minus elevation. What is that minus elevation? A) ½” to ¾” C) 7/8” to 1 9/16” B) ¾” to 1 ½” D) 1” to 1 5/8”

Answer 30

B: 3/4" to 1 1/2" 19mm - 38mm

Question 31

What type of misalignment is always corrected first? A) Horizontal parallel (offset) misalignment B) Horizontal angular misalignment C) Vertical parallel (offset) misalignment D) Vertical angular misalignment

Answer 31

D: Vertical angular misalignment

Question 32

If during normal operation the driven machine expands due to thermal conductivity, the drive unit must first be aligned in what manner? A) Within normal limits C) Higher than the driven unit B) Lower than the driven unit D) In the horizontal plane

Answer 32

C: Higher than the driven unit

Question 33

The condition within machinery that causes reduced bearing life, coupling damage, high vibration levels and reduced seal life is referred to as? A) Resonance C) Critical speed B) Soft foot D) Misalignment

Answer 33

D: Misalignment

Question 34

These items (usually placed in packs) are placed under the mounting feet of the drive unit to align it in the vertical plane? A) Wedges C) Feeler gages B) Shims D) Pack gages

Answer 34

B: Shims

Question 35

The devices used to push the equipment from side to side on the horizontal plane to correct alignment are called? A) Jacking bolts C) Leveling screws B) Alignment screws D) Elevator bolts

Answer 35

B: Alignment screws

Question 36

Sometimes machining errors cause coupling runout. When the coupling bore is machined at an angle to its axis it is called? A) Angular runout C) Eccentric runout B) Wobble D) Total runout

Answer 36

A: Angular runout

Question 37

The misalignment condition that occurs in the vertical plane can be identified by measuring the gap between the coupling faces, and is identified as. A) Offset misalignment C) Parallel misalignment B) Angular misalignment D) Face misalignment

Answer 37

B: Angular misalignment

Question 38

The misalignment condition that occurs in the vertical plane can be identified by measuring the gap at the top of the coupling with a straight edge and feeler gage. A) Rim misalignment C) Parallel misalignment B) Angular misalignment D) Face misalignment

Answer 38

C: Parallel misalignment

Question 39

To successfully align the shafts in a misalignment condition it must be corrected in two planes, what are they? A) Angular & offset C) Parallel & offset B) Horizontal & vertical D) Vertical & Parallel

Answer 39

B: Horizontal & Vertical

Question 40

This misalignment condition occurs when the centerlines of the two shafts are not parallel. A) Parallel misalignment C) Offset misalignment B) Angular misalignment D) Vertical misalignment

Answer 40

B: Angular Misalignment

Question 41

This misalignment condition occurs when the centerlines of the two shafts are parallel but not in line. A) Horizontal misalignment C) Offset misalignment B) Angular misalignment D) Vertical misalignment

Answer 41

C: offset misalignment

Question 42

Vertical offset misalignment is corrected with equal amounts of shims under what locations of the drive unit? A) All four feet C) Left side only B) Front feet only D) Back feet only

Answer 42

A: All four feet

Question 43

Vertical angular misalignment is corrected with equal amounts of shims under what locations of the drive unit? A) All four feet C) Left side only B) Back or front D) Right side only

Answer 43

B: Back or front

Question 44

In most situations when you approach a machine, weather it is the alignment of the primary unit, transmission unit, or the drive unit the type of misalignment condition you will encounter is. A) Parallel misalignment C) Offset misalignment B) Angular misalignment D) Combination misalignment

Answer 44

D: Combination misalignment

Question 45

When all the supporting feet of a machine do not equally support the weight of the machine, the condition is called? A) Parallel misalignment C) Softfoot B) Angular misalignment D) Combination misalignment

Answer 45

C: Soft foot

Question 46

When using a steam turbine as a prime mover, and considering the fact that it encounters considerable thermal growth during operation, where would you set the shaft in relation to the primary unit? A) Lower C) Higher B) Parallel D) Dynamically parallel

Answer 46

A: Lower

Question 47

It is generally accepted that this type of machinery alignment check produces unreliable results and therefore is not used very often. A) Hot check C) Ambient check B) Cold check D) NSF check

Answer 47

A: Hotcheck

Question 48

Choosing the coupling alignment procedure for a particular situation depends on a number of factors. Which one of the following is NOT a consideration? A) Speed of the equipment C) Available tools B) Ambient temperature D) Alignment specifications

Answer 48

B: Ambient temperatures

Question 49

To lessen the springing effect caused by shims being stacked, always use the least number of shims to give the correct stack thickness. What is the maximum number to be used. A) Three C) Five B) Four D) Six

Answer 49

B: Four but least amount as possible

Question 50

When reading a dial indicator the difference in reading from top to bottom is known as. A) Face reading C) Total indicator reading B) Total rim reading D) Rim reading

Answer 50

C: total indicator reading

Question 51

Dial indicator readings taken on the face of the coupling by rotating through 180 deg. indicate what type of misalignment? A) Angular C) Parallel B) Combination D) Offset

Answer 51

A: Angular

Question 52

Dial indicator readings taken on the rim of the coupling by rotating through 180 deg. indicate what type of misalignment? A) Angular C) Parallel B) Combination D) Axial

Answer 52

C; parallel

Question 53

The component on the dial indicator that must be zeroed out before any readings can be taken is called. A) Face C) Plunger B) Bezel D) Indicator

Answer 53

B: Bezel

Question 54

While taking dial indicator readings to determine the amount of misalignment, it is critical that the coupling halves be rotated in what manner? A) Clockwise C) Independently B) Counter-clockwise D) Together

Answer 54

D: Together

Question 55

What misalignment condition should be corrected first. A) Angular misalignment C) Parallel misalignment B) Offset misalignment D) Softfoot

Answer 55

A: Angular

Question 56

Most prime movers run at relatively low rim speeds. Couplings must be aligned very carefully if they are running at or above ________ SFM. A) 1,000 C) 3,600 B) 1,600 D) 5,000

Answer 56

C: 3,600

Question 57

While taking readings with a dial indicator or feeler gages to determine if there is any misalignment present, the prime mover hold down bolts must be. A) Tight C) Doesn’t matter B) Loose D) Removed

Answer 57

A: Tight

Question 58

What type of shim is NOT recommended for making minor adjustments to correct misalignment conditions? A) Solid shims C) Strip shims B) Slotted shims D) Brass shims

Answer 58

C: Strip shims

Question 59

When reading a dial indicator for shaft misalignment, the dial reading is + .014”. The actual total (rim) misalignment present is? A) + .007” C) + .028” B) + .014” D) - .007”

Answer 59

A: +.007"

Question 60

When angular softfoot is present in machinery it is usually corrected by using what type of shim? A) Brass shim C) Stainless steel shim B) Laminated shim D) Cedar shim

Answer 60

B: Laminated Shim

Question 61

The weight of dials, clamps, brackets and other accessories may cause bending of supporting attachments while taking readings with the indicators. This is called. A) Indicator sag C) Bracket bend B) Indicator error D) Attachment sag

Answer 61

A: Indicator sag

Question 62

The corrections in dial settings for the problem mentioned in the question above only apply when you are taking what type of readings. A) Rim readings C) Combination readings B) Face readings D) Palm readings

Answer 62

A: rim readings

Question 63

To correct for the amount of deflection in the dial indicator setup when the weight of the dial and attachments creates bending in the brackets which affects the readings, how is the dial indicator set to compensate for this? A) Position @ 12 o’clock C) Position @ 6 o’clock bezel to + equal to sag bezel to + equal to sag B) Position @ 12 o’clock D) Position @ 9 o’clock bezel to - equal to sag bezel to + equal to sag

Answer 63

A: Position @ 12 oclock Bezal + bar sag

Question 64

Setting a dial indicator to a fixed base and the plunger on the coupling half then rotating the coupling through a full 360 deg. sweep will help determine. A) Angular misalignment C) Offset misalignment B) Runout D) Softfoot

Answer 64

B: Runout

Question 65

During the alignment routine there are two very important procedures to follow in order to get consistent readings on the dial indicator. A) Softfoot & torque C) Runout & softfoot B) Torque & sequence D) Sag & sequence

Answer 65

B: torque and sequence

Question 66

Rim and face alignment is used where the alignment specifications are more critical than in rough alignment. This method can be used if there is no…. A) Softfoot C) Eccentricity B) End float D) Sag

Answer 66

B: End float

Question 67

When setting up dial indicators, one of the advantages of this method is that it is geometrically accurate when used on large diameter couplings with short spans. A) Cross dialing C) Face dialing B) Rim & face dialing D) Rim dialing

Answer 67

B: Rim and Face alignment

Question 68

When setting up dial indicators, the indicator plunger should be set up to read the face of which coupling half? A) Primary unit C) Drive B) Prime mover D) None of the above

Answer 68

A: Primary unit

Question 69

When taking readings on a coupling, sometimes space limitation requires the use of an attachment to enable face readings to be taken. What is the attachment? A) Spacer C) Face attachment B) Wiggler D) Edger

Answer 69

B: Wiggler

Question 70

When taking a rim reading the dial indicates a (+) result. To correct the misalignment you would? A) Insert shims C) Check for runout B) Remove shims D) None of the above

Answer 70

B: Remove shims

Question 71

When aligning couplings with this method, high degrees of accuracy can be obtained without the concern of dial indicator bracket sag. A) Feeler gage C) Rim & face B) Reverse dial D) Laser

Answer 71

D: Laser

Question 72

To ensure that shaft alignment is maintained when the machine is in operation it is advisable to secure the position of both machine units with. A) Jacking screws C) Leveling screws B) Doweling D) Vise grips

Answer 72

B: Dowling

Question 73

Calculate the following misalignment conditions to determine the correct shim pack to insert. Coupling Diameter 10” Total Indicator Reading on the coupling rim, + .018” Coupling face & front hold down bolt 8” Coupling face & back hold down bolt 16” A) .005” shim pack C) .009” shim pack B) .006” shim pack D) .018” shim pack

Answer 73

C: .009" shim pack

Question 74

A pump heats up under operating conditions. How will you align the unit? Ambient temperature 75 deg. Pump operating temperature 280 deg. Coefficient of expansion for steel .000006” Shaft center height 18” A) Pump @ - .012” C) Motor @ - .018” B) Pump @ + .022” D) Motor @ + .022”

Answer 74

D: Motor at +.022" 205 x 18 x .000006 = .022

Question 75

Determine the shim pack required under the front and back feet in the following misalignment situation. Coupling diameter 8” Feeler calculation (gap difference) .037” Coupling face & front hold down bolt 10” Coupling face & back hold down bolt 22” A) Front .046”, back .101” C) Front .055”, back .104” B) Front .034”, back .133” D) Front .062”, back .022”

Answer 75

A) Front .046”, back .101”

Question 76

What class of laser is used in shaft alignment equipment? A) Class I C) Class III B) Class II D) Class IIII

Answer 76

A: Class 1

Question 77

On a single reflected beam laser unit, where would you mount the laser/detector unit? A) On the stationary machine C) On either machine B) On the prime mover D) On the intermediate machine

Answer 77

A: On the stationary machine

Question 78

What part of the laser system performs misalignment calculations? A) Laser transmitter C) Laser/detector B) Control unit D) Prism

Answer 78

B: Control unit

Question 79

How do you ensure consistent and correct readings at the clock locations? A) Use a shaft clock chart C) Use a shaft precision level B) Use an inclinometer D) Use a shaft clock graph

Answer 79

B: Use an inclinometer

Question 80

Why should laser alignment systems be shielded from strong heat sources? A) Extreme heat can cause laser head distortion B) The prism becomes unstable at high temperatures C) The beam wanders in elevated temperatures D) The control unit becomes unstable in heat

Answer 80

C: The beam wanders in elevated temperatures

Question 81

What instrument has the ability to measure angles down to minutes or even seconds, depending on the accuracy of the instrument? A) Theodolite C) Optical square B) Tilting level D) Optical level

Answer 81

A: Theodolite

Question 82

What instrument is normally used for precision leveling the tilting level? A) The auto-collimator C) The plum bob B) The coincidence level D) The optical micrometer

Answer 82

B: A coincidence level

Question 83

Why misalign a set of machines at the coupling when performing an alignment? A) To be within coupling specifications B) To account for coupling wear C) To offset for thermal growth D) To correct for seasonal foundation movements

Answer 83

C: to offset for thermal growth

Question 84

What is the value of the information collected when you perform a hot alignment check? A) Determines machine foundation integrity B) Indicates soft foot conditions C) Reveals improper coupling spacing D) Reveals relative shaft positions

Answer 84

D: reveals relative shaft positions

Question 85

When shafts are not aligned with each other in the vertical and horizontal planes when running, what is the most common result or symptom? A) Bearings develop rotational oil whirl B) Bearings wear until they align themselves C) Machine vibration levels increase D) Shaft alignment measurements change

Answer 85

C: machine vibration levels increase

Question 86

After locking out a breaker at the M.C.C. and placing the information tag on the lockout device, what should you do at the machine before commencing with a coupling alignment? A) Check to make sure that all tools are available B) Remove the coupling guard C) Secure the entire work area D) Try the local command station

Answer 86

D: try the local command station

Question 87

When aligning an electric motor to a hydraulic pump the system including the accumulators should be bled off and then isolated because. A) An increase in temperature could cause the pressure safety to open B) High-pressure trapped oil could backflow through the pump C) Other components in the system might be energized D) No system pressure is required

Answer 87

B: High pressure oil could back flow through the pump

Question 88

A high-accuracy, short distance laser has an accuracy of: A) 1 inch in 30 feet C) 0.001 inch in 10 meters B) 0.010 inch in 100 feet D) 0.0001 inch in 30 feet

Answer 88

C: .001" in ten meters

Question 89

What is the purpose of a millwright racking out a breaker within the local M.C.C. before performing an alignment? A) To prevent machine shaft rotational drift B) To prevent machine shaft rotation C) To prevent accidental starts/stops D) To prevent breaker contact arcing

Answer 89

C: To prevent accidental start/stops

Question 90

Lasers can cause serious eye injury due to: A) Direct viewing C) Indirect viewing B) Amplification through targets D) Flashes caused by dust particles

Answer 90

A: Direct viewing