The Power Generation Industry: Focus on Safety By: Ariel Stein

As all good businesses know, safety should be the number one priority in the workplace. Whether it’s a mater of cleaning up spills around the machinery, providing your workers with protective gear, or taking the appropriate preventative measures towards potentially dangerous situations, every single bit is important for yourself, for your employees, and for your overall workplace.

The statistics

According the Bureau of Labor Statistics, eight occupations had more that 20,000 injuries and illnesses in 2008, as they have every year since 2003. These eight occupations make up at least thirty percent of all injuries and illnesses with days away from work in 2008. This includes laborers in freight, stock, and material movers, heavy and tractor trailer truck drivers, construction workers, and carpenters. In the private industry, four industry sectors accounted for three-fourths of injuries and illnesses with days away from work in 2008, with trade, transportation and utilities being the number one sector with thirty percent of the overall injuries.

What can we do to reduce the risk of injury for our employees?

One of the leading causes of accidents in the workplace is the simple slip-and-fall scenario. When the Terry McDonald, past chairman of the ANSI B11.11 Subcommittee on Safety Requirements for Construction, Care and Use of Gear Cutting Equipment, stated in an article in Gear Solutions magazine that, “while it’s a good thing that someone recognized the danger that a spill represents and tried to do something about, those same materials are often left in place for far too long, becoming something of a hazard in themselves. I realize that the agent takes a little time to work, but if you think about it, even though they’re definitely better than the oil they’re absorbing, those loose granules on the floor are still a “slip and fall” hazard.” “…By trying to save time in the short term, you’re running the risk of enabling an injury that could be devastating to both the employee- in terms of physical pain, and worse- the employer, who could be found responsible for not providing a safe workplace.”

One question you can ask yourself and your company is whether they have a “culture of safety”. Do they make sure that every employee in the company actually participates in a workplace safety program, or at least bring themselves into working in a safe manner? A majority of shops have been found to have at least one employee who really doesn’t care about how safe they operate, as long as they get the job done. They could come up with every reason in the book as to why they can’t or won’t operate in a safe manner, by moving the topic to efficiency instead. The employer can offer safety training or incentives all they want, but sometimes, what it really comes down to is the individual who might be affected by an injury- or cause one to others. Can they be convinced that the safety program will be to their benefit? Sometimes the employer is going to have to re-evaluate the way they run interviews, because if they hire someone who can’t take safety seriously, they are looking at not only a loss in efficiency, but possibly a serious lawsuit on their hands.

For more information on ACQUIP, INC. please visit our website at www.acquip.com.

2010…WE GET TO HIT THE RESET BUTTON! By: Storm Josefsberg

Common conversation topics at the end of every year are New Year’s resolutions. I thought I may share some of ours with you!
1. Time management.
There are so many things to do when you’re running a business, it’s easy to get overwhelmed and try to do too many tasks at once. Determine your return on time investment, and determine how to prioritize your tasks. Task prioritization is the key to effective time management!

2. Market regularly and consistently.
Too often the task of sales and marketing slips to the bottom of the to-do list in the presence of unexpected tasks. Attracting new customers is a daily priority. Take the time to create a marketing plan and follow through!

3. Make business planning a regular habit.
Planning is essential if you want to grow a successful business. Business planning lets you take a look at the big picture! Planning can also help you set new directions and goals. This can also help you to feel more focused and relaxed!

4. Learn something new every day.
Learning something new will add to your skills and add a new dimension to your business knowledge! Knowledge equals sales power. The more you educate yourself on your industry the more your customers and colleagues will depend on you and trust in you.

5. Join a new business organization.
There’s nothing like networking with other people in your industry to get new ideas, change old ones, and make new business contacts. Whether you use a networking group or an organization dedicated to educating your industry, this is a great way to revitalize your business!

6. Get involved in contributing something to your industry.
There are all kinds of ways to make a difference in your industry. Acting as a sounding board to your customers and colleagues will keep you in the inner circle of your industry. The more you give the more you get!

7. Put time for your team on your calendar.
Team work is essential for your company to work! Team building activities promote success and overall employee happiness. We all have to work together to be a true success. If you have a happy team you are sure to have satisfied customers.

8. Set goals.
Goals directly lead to success. Hold yourself accountable to the goals that you set. Although it is important to set goals that are achievable, you should set your standards high so you have something to reach for. They don’t call it a goal for nothing!

9. Assess how much your time is worth.
Is there a piece of equipment, a work process, or a delegated task in your company that is interfering with your success? Ask yourself how much your time worth is. It may be worth it, in more ways than one, to replace old equipment, change a work process, or teach someone a new task. Stop putting off getting what you need. It is not worth it!

10. Stop doing what is not working and change!
All products and services are not going to take you to the bank. All marketing methods aren’t going to work, and all vendors are not going to be right for your business. If something isn’t working for you stop doing it! Move on to bigger and better things!

HAVE A SUCCESSFUL YEAR, FROM ALL OF US AT ACQUIP, INC!

For more information on ACQUIP, INC. please visit our website at www.acquip.com.

Powering America…With Wind! By:Jessica Mantler

The environment remains a key factor in determining future energy generating decisions. The latest trends are pointing to wind generated power.

But What Exactly is Involved in Wind Energy Production?

Wind turbines transform the kinetic energy of the wind into energy that can be harnessed for our practical use. Some of these uses include providing electricity to your home and business and providing energy to make the grain that becomes the bread in your grocery store. In comparison to the image of a water wheel utilizing the strength of a river to run a farm, wind energy uses wind in much the same way.

Will This Change Be Profitable?

Over the last twenty years, the cost of electricity from utility-scale wind systems has decreased by an excess of 80%. This has made the cost of power generation using wind turbines competitive to that of coal and gas-fired power plants, at under five cents per kilowatt! There are three major determinants however that affect the cost of wind-generated electricity. These include the speed of the wind at the site, the cost of installing the turbines, and the size of the wind farm. • The higher the wind speed, the lower the cost of energy. • The lower the cost of constructing the turbines, the lower the cost of energy. • The larger the wind farm the lower cost of energy. A downside in the wind energy industry is that there is more risk involved due to the uncertainty of sufficient wind supply. What does this mean? It simply means that before you install a wind turbine, you must determine if there is adequate wind supply to fuel the turbine. Wind strength can have significant variation and should therefore be determined by an expert. On the positive side companies will receive a 1.5 cent per kilowatt hour production tax credit. There is also the renewable energy production incentive (REPI) consisting of a direct payment to a public utility installing a wind plant. Not to mention all the obvious benefits to the environment.

For more information on ACQUIP, INC. please visit our website at www.acquip.com.

Facing the Economic Crisis Head On. By Jessica Mantler

The economy has been in a state of crisis now for quite some time. Companies are implementing all efforts to reduce costs in reaction to the crisis including shutting down equipment, reducing spending and cutting employee hours.  The unemployment rate (released October 2, 2009) has increased from the start of the recession in 2007 at 558,000 to a staggering 15.7 million.  This indicates an unemployment rate of 10.2! The crisis has been described as “The perfect storm” because of the economic boom of the 1990’s with the lack of regulation in the housing market and amount of greed setting the American dream off track.

Some economists claim a recovery is soon to come, while others speculate that the crisis is just starting.  There is one thing however that we can count on; the economy will recover.  It is just a matter of when.

WHAT NOW?

“Change will not come if we wait for some other person or some other time. We are the ones we’ve been waiting for. We are the change that we seek.”

–        President Barak Obama

So what can we all be doing to counteract the economic condition?  How can we be “the change that we seek?”  By optimizing what we already have.  Many companies are finding ways to cut costs which is beneficial, but in the long run we must all find ways to find and advance our competitive advantage.  Whether your company is the leader in providing low prices for your industry or providing excellent service, you must know what that competitive advantage is and then be the absolute best.

These times elicit the ever prominent factor of corporate Darwinism, and only the strong will survive.  The recovery will come, but what companies will be left standing?  We must all refocus our efforts and shut out the competition.  Performance and customer service must be unsurpassable.  The research and development within your industry must be profound.  And the desire to beat out the competition in all aspects must be unquestionable.

Other factors to remember are planning and preparation.  A company that will survive this economy will be prepared for as many unique circumstances as possible.  They will do extensive research and planning before all endeavors.  They will also expand their knowledge about the competition, the client, and the company itself in order to facilitate understanding. Obtaining knowledge will provide confidence for your employees and the clients as well.

Yes, times are tough, but there is a light at the end of the tunnel, and we all can and should be prepared for it.

It’s Turbo-Show time! By Jessica Mantler

The 2009 Turbomachinery Symposium Exhibition this year was, once again, in beautiful Houston, Texas.  The turnout was outstanding for both the exhibitors as well as the attendees.  The amount of attendees increased from last year’s total by nearly 500!

At ACQUIP, INC. we too had a great experience seeing old friends and clients as well as having the good fortune of meeting other exceptional companies.  Like many other booths ACQUIP, INC.’s booth featured give-aways and a raffle.  The prize for the raffle was a brand-new iPod-shuffle, which was awarded to Thaddeus Berry with HPI, LLC.  Congratulations Thaddeus!

WHAT THERE WAS TO CHECK OUT THIS YEAR!

Throughout the exhibition there was a series of seven short courses twelve lectures and seven tutorials.  Some of these that we at ACQUIP, INC. found particularly interesting were the short courses on centrifugal compressors 101 and combined cycle and cogeneration power, as well as the lecture on mechanical and performance testing method of an integrated high-speed motor compressor.

Centrifugal compressors 101 had many on the edge of their seats with its detailed descriptions of the basics concerning centrifugal compressors.  One of the best features of this course was its focus on providing practical information and minimal theory.

The spokesmen for the “mechanical and performance testing method of an integrated high-speed motor compressor” lecture, did an outstanding job as well.  Their lecture described high speed integrated motor compressors that are levitated by magnetic bearings and proposed the guideline for a mechanical and performance factory acceptance test.  Great job guys!

The Turbo show also featured generous hospitality events after the exhibition closed for all the exhibitors.  It was a great way for the ACQUIP, INC. team to get to know some of the attendees in a more relaxed and fun setting, in addition to enjoying some great refreshments!

ONE LAST QUICK NOTE ON THIS YEARS SHOW!

We greatly appreciate all the exhibitors and guests for taking the time to meet the representatives of ACQUIP, INC., it was a pleasure getting to know each and every one of you!  See you next year!

For more information about ACQUIP, INC. , go to www.acquip.com

Laser Alignment Vs. Traditional Alignment By: Jessica Mantler

Laser alignment vs. tradition alignment methods

It is obvious that having your plant running efficiently and effectively is key to operational optimization.  We are all aware that having our machines properly aligned is integral to the foundation of plant maintenance.  What some may not be aware of however, is why laser alignment, over traditional alignment is the best alignment method.

What is the difference between traditional alignment methods and laser alignment?

Traditional alignment and laser alignment is the difference between using a slide rule and a calculator!

Simply put laser alignment is faster, more precise, and more easily recorded.  Laser alignment uses laser technology and software technology which makes this method less prone to human error.

For machine train laser alignment, an entire template of the machine is entered into the computer so it can be looked at as a whole rather than each coupling at a time.  In a best case scenario, train laser alignments can be instantly tried out in the computer before actually performing them and discovering that you are bolt bound.

Shaft laser alignment uses a reference line instead of a metal bar, therefore reducing the need to account for bar sag.  The information received on the computer is also stored and is therefore easy to obtain with future alignments

Laser alignment for internal diaphragms, is far superior to tight wire methods.  There is no interference with machine operations during the internal alignment process.  This saves time because work can continue on the turbine while the alignment is being performed.

When using alignment software technology the data collected is stored and results calculated in the computer so there is no need to take unnecessary time to graph out the shaft line and machine feet. Computer generated alignment reports are available instantly upon completing measurements and can be used again in the future as reference.

Over 50% of machine vibration is caused by misalignment.  Vibration is a major cause of unnecessary costs.  It results in premature bearings, seals and couplings failures as well as unplanned outages and downtime.  The importance of accurate alignment is clear. It is a procedure that should be done correctly the first time with as little error as possible; a task that is accomplished through laser alignment.

For more information about laser alignment services go to www.acquip.com.

Go Green By Jessica Mantler

WHO KNEW  “GOING GREEN” WAS SO EASY AND EFFICIENT?

Energy efficiency, waste reduction, greenhouse effect, alternative energy and climate change are all words that seem to be popping up everywhere. But what does ACQUIP,INC have to do with this latest movement toward going green?

ACQUIP,INC is is the undisputed industry expert in the field of precision alignment services.  ACQUIP,INC utilizes laser technology to keep all rotating equipment working efficiently.  So what does this have to do with going green, and why is it so important?  To be specific:

EVERYTHING!

By having precisely aligned rotating equipment the likelihood of emergency outages decreases, machine operation dependability increases, bearing life increases, and all around safety increases.  All of these things are advantageous because they save time and money!

These practices save time and money because an accurately aligned machine uses less energy and releases less greenhouse gases; and that is what “going green” is all about.  Saving energy is not only environmentally beneficial, it is also economically advantageous.

This Global trend of “going green” is not a fad either.  Environmental awareness and contribution is here to stay. Companies around the world are looking for ways to jump on the “go green” band wagon any way they can, unfortunately for many they are also dealing with financial instability and economic crisis.  Everyone is facing a question of how to be environmentally friendly without reducing profit.

The advantage to laser alignment is that it is already necessary for proper operations.  By simply making rotating equipment work efficiently with precision alignment, ACQUIP,INC is contributing to energy efficiency and waste reduction.  ACQUIP,INC is providing a service that is necessary for effective and efficient operation, while providing an effortless way to be a part of the effort to save our planet. Let’s work on ways we can all turn “going green” into GO GREEN!

For more information please go to www.acquip.com

Dynamic Movement (Thermal Growth) of Rotating Equipment, by Damian Josefsberg, ACQUIP, INC

Alignment to a machine’s running alignment position is essential for reliability and efficient machine operation. It is not enough to only consider a machine’s cold off-line running position for shaft alignment. A machines shaft alignment position will change through start up to its hot on-line running state. Certain machines will move more than others if they have extreme temperature changes and/or are connected to extensive piping. The two most common types of machines that fit into this category are boiler feed pumps and gas turbines. These machines must have their dynamic movement considered to calculate their cold alignment targets.

Dynamic movement occurs when shaft alignment circumstances change from a machine’s cold off-line state to hot on-line running conditions. Machine dynamic movement is made up of movement due to thermal growth and torque movement combined. The misalignment at the coupling represents the total change that occurs because of these two components. There is no reason to separate out the two components of dynamic change unless you plan on correcting the source of them. This will take a good amount of time and money. The best thing to do is correct for the change where it affects the machine, at the coupling. There are several different ways to determine dynamic movement.

 

The easiest way is not to measure it at all. Use a pre-existing alignment target. An alignment target can come from the coupling manufacturer, machine manufacturer, or an in-house specification. If there are no pre-existing alignment targets, the next easiest thing to do is to perform a theoretical calculation. This is not an exact calculation of dynamic movement at the coupling, but it is better than doing nothing. It is a theoretical calculation of how much the machine case will expand from cold to hot running conditions, paying no attention to torque movement. Multiply the machine case material constant, by the distance from the shim plane to the center of the shaft, by the difference in temperature from hot to cold. Do this for the drive end and non drive end of the machine separately. This is done because the temperature, when hot, from drive end to non drive end may vary enough to affect the angle at the coupling. The most time consuming, but most accurate way to way to generate an alignment target for your machine is to measure it. Measuring the dynamic movement of your machine is the only way to get the exact alignment target. The only other traditional method to determine dynamic movement is a hot alignment check. This is not a recommended method because it captures no torque movement and most of the thermal change has been lost by the time the hot misalignment readings have been recorded.

This best way to determine dynamic movement of a machine is to deploy a laser based real time monitoring system. This approach will ensure that all movement data is collected and the movement can be verified in several runs.

Figures one and two show a laser based monitoring system mounted to a motor – boiler feed pump machine.

Figure 1: Permalign Laser Monitor on Motor Side of Coupling

Figure 2: Permalign roof prism target mounted on boiler feed pump side of coupling

The monitor and targets are mounted to the bearing brackets, so the monitoring system will display the relative movement change across the coupling. The movement that the monitoring system records mimics the way that the shafts are moving relative to each other. Table one shows the Vertical offset of the machine over a period of three days.

Table 1: Vertical Offset and temperature of a motor to boiler pump machine.

This machine was located outside. You can see how much affect the temperature alone has on the machine throughout the day. The machine starts on 5/10/09 at 11:00 AM, even though the machine is running with a constant load the movement due to the environment does not go away. Conventional methods such as theoretical calculations or snapshot movement checks will not capture the incremental change in movement of the machine and may lead to incorrect conclusions.

 

This pump is supposed to have very little vertical movement because it is center mounted. The motor and the piping connected to the pump will still have an effect on the vertical alignment. Collecting this data allows you to make a decision for which conditions the machine will be aligned. This data is collected for the vertical offset, vertical angle, horizontal offset, and horizontal angle. All of the dynamic alignment change information is interpreted and converted into alignment targets. The alignment targets are used as the end state position of the machine for a cold alignment procedure.

 

Some laser alignment computers can accept the targets. If your alignment system does not have this capability or you are using dial indicators it is a good idea to graph out the desired final alignment position. You may have dynamic movement numbers that are generated from different sources so they will get displayed differently. That is why it is never a bad idea to graph out your alignment. It will cut down on mistakes and your total time to complete a shaft alignment. If you employ this process in all of your machines you will improve machine efficiency and increase machine up time.

Professional Leadership: Interview with Damian Josefsberg, President of ACQUIP, INC

1. What is the shape of the “perfect” leader and does he or she exist?

A perfect leader is someone who can motivate and get the best out of those around him. A perfect leader is an excellent delegator and can identify the right tasks for each member of an organization, in order to use that persons strengths and allow them to succeed. A perfect leader is a superb communicator; he is able to perfectly align the goals of a person in the organization with the outward mission of that organization. There really is no perfect leader because a leader is human. Any leader can never accomplish his mission 100% of the time and maximize his resources 100% of the time.

2. How can leaders maintain themselves to stay motivated?

That is a great question. It very difficult to stay motivated sometimes, especially in the face of an adverse economy or a mature product line. That is why it is always important to look for what is coming next. That may be coming up with new product lines for your current customers or diversifying into different regions or market segments. Always keeping things fresh and challenging is the key to staying motivated.

3. Does every manager need to be a leader?

Every manager doesn’t need to be good leader to be effective, but it doesn’t hurt. I have seen managers that are very good at the daily operations of a business, just delivering on commitments with the resources at hand. These managers don’t necessarily have a vision for the future they operate in the here and now. That is ok we need people like that also.

4. Are there people whose traits make them unfit to be a leader?

There are few rather obvious answers to this question. People who are lazy or apathetic can never be a good leader, but it is the less obvious traits that you have to watch out for. Some individuals are extremely motivated, which is great for leadership; however they are only out for personal achievement and that does not make for a good leader. A leader has to be driven for the success of the entire organization not just themselves.

5. In which way do you see that new technologies will affect leadership and leaders?

New technologies are great and they always embraced by leaders. Current technological trends make communication and dissemination of information increasingly rapid. This is great to help leaders deliver a clear vision and keep everyone operating towards the same goal.

6. What is the relationship between leaders and followers?

To be an effective leader you also have to be a good follower. You don’t start out as a leader in an organization you work towards it. A leader has to understand the wants and goals of those that they are leading. A leader is completely ineffective if no one wants to follow them.

7. Is there any trend that could be called “the new leader”? Or have things really not changed that much over the years?

Essentially things haven’t changed that much. The only difference now is that it is much easier for key personnel to move to different organizations. The new leader has to be cognizant of this when mentoring and dealing with talent within the organization, always providing opportunity and compensation for members of the organization that should be retained.

8. Does a leader need power? How can a leader avoid being corrupted by the power?

A leader has power. Without power in certain areas it is impossible to lead. If a leader is corrupted my power the market will correct for it. The leader will either be removed, the company will fail, or they will be prosecuted.

9. Some say leaders must divide their time in three parts: finances, quality, and relationships. What are your thoughts on this?

I think that is pretty accurate. An effective leader has to have their hand in all parts of the business. They may not be involved in the day to day operation of every part, but they certainly should know what is going on.

10. What’s the worst fault a leader can have?

Hubris, a leader must credit those around them for an organizations success. A leader must remain humble and not take themselves too seriously. After all, the organization is greater than they are.

11. As far as communication is a key point, how can a shy person be a leader?

A truly shy person would have a very difficult time being a true leader. With the advent of email and other non direct communication, a shy person can be an effective manager without confronting people verbally.

12. If so much success is credited to leadership, why do most say that are there so few real leaders in companies?

I think what people are referring to is that there are few people willing to make unpopular decisions. It is this courage to take risks that are lacking. This is driven by the earnings cycle. So much attention is paid to quarterly objectives that longer term goals are lost. If a leader makes a long term decision that positions the company in 5 years that person may not be around to see it if quarterly goals are not met.

13. The role of principles of leadership is so extensive that it seems impossible. Is a good leader a kind of superman or superwomen?

It may seem that a great leader is super human, but this is hardly the case. A great leader has a clear vision and a drive to get there. This may mean working long hours, sleeping less time, and covering a wide range of functions, but when the objective is obtained it is well worth it.

14. Is a military model of leadership adequate to any company, as far as it based most on authority and discipline?

This model only works for an organization that operates well established and unchanging product line and even then eventually the organization would be run down and taken over by competitors. It is important to nurture inspiration and always be looking for way to be done better. This is the key to the long term success of any organization.

15. What are your thoughts on an ideal percentage of leaders in a company? Can an “excess” of leaders turn into a problem?

You can never have enough leaders in an organization. Everyone can be a leader of there area. If every one is both a leader and a follower than you have created a nimble organization that can easily adapt to change and quickly implement best practices.

16. What is better for a company that does not have huge sums to invest in training? To try to build a company of leaders or concentrate on building a good team of efficient managers?

The best thing to do is to hire very smart people. They will always find the resources that they need to be effective at their jobs. You will always have the most successful organization, because at the end of the day your people are your product.

17. Can someone be a good leader, but not a good manager?

This is common in large organizations, where the leader is there for vision and motivation but not daily operations. This type of leader selects individuals for specific areas and then leaves them alone.

18. Is there any index of success for turning common managers into leaders?

It all depends on the manager if this person can select a direction for the organization and effectively convey it to others then they can lead them.

19. How do you keep people’s loyalty in a company?

By publicly recognizing them for there achievements and benefit to the organization. When people feel that they are needed and that they are contributing then they will be loyal.

20. One of the main trends in the new economy is people working with each other over long distances, connected to work by the internet. How can one be a leader with much less eye-to-eye contact?

This can be hard. It is important to stay in constant communication by way of phone and email and listening to concerns and suggestions. When there is eye-to-eye contact it is important to maximize this time by going over a wide range of business.

Soft Foot: What it is, How it Affects Machine Operation, and How it can be Corrected. By: Jason Seiler, ACQUIP, INC.

If you’ve ever sat in a dinner chair, or a bar stool, and noticed that when you shift your weight around the chair does not sit flat, but rather wobbles as you move, you’ve witnessed a soft foot problem. “Soft foot” is a condition that results when one or more feet of a machine do not sit in the same plane as, are angled differently from, or are different lengths than, the rest of the machine’s feet. Soft foot conditions can also be induced by forces applied to the machine by fixtures that are attached to it. Soft foot is a term used to describe conditions that manifest themselves as machine frame distortion. If a machine’s feet are anything but level and coplanar with one another, distortion of the machine’s frame will result when the hold down bolts are tightened on a machine’s feet. This distortion applies forces to the machine’s bearings, which in turn transmit these forces to the rotor. This causes the rotor to bend, and, therefore, to transmit tell-tale vibration signatures back through the machine frame to be recorded and interpreted by a vibration analyst or maintenance technician. Soft foot conditions come in many varieties including inside/outside angle bent foot, high/low foot, pipe strain (i.e. induced soft foot), and loose feet; they can be detected and corrected using various methods (vibration analysis, dial gauges, feeler gauges, laser alignment systems); and effectively dealing with soft foot can pay dividends in time and money saved when compared with more costly repairs. This article will summarize various types of soft foot, how to detect and correct them, and the benefits of doing so.

The name often given to the soft foot condition that results when one or more feet/legs of a machine are shorter (longer) than the others is “high (low) foot.” A difference in foot height of .002 to .003 inches might not seem severe enough to warrant further action, but these are the usual standards by which a high foot condition is diagnosed. The simple action of tightening the hold down bolt of a foot that is .002 inches (2 “mils” henceforth) shorter than its neighbors can distort the machine’s frame. Such distortion exerts forces on its rotor that distort the rotor, which causes the machine to damage itself during operation. Fortunately, this condition can be easily diagnosed and remedied.

One way to diagnose a high (or low) foot condition is to use dial gauges. Place the dial gauge against the top of a machine foot and as close to its center as possible (follow the normal procedures for using dial gauges to ensure that your measurements are valid and precise). Then, loosen the hold-down bolt on that foot until the foot stops moving upward, recording the distance this foot moved upward on a simple diagram (see Figure 1 below). This diagram will come in handy during the diagnosis stage.

Figure 1: Example of how to record soft foot measurements (all measurements in mils).

Tighten that hold-down bolt, and proceed to measure the movement of the rest of the feet in this same manner, recording your findings in the diagram you created. Some laser alignment systems also have modes that allow you to take foot height measurements using the laser system instead of dial gauges. It only takes a little more time to diagnose angle bent foot conditions. To do this, use feeler gauges to measure beneath each of the four corners of the feet in order to get a feel for the angle the foot makes with the base. Record these measurements in the same diagram (see Figure 3).

Figure 2: Diagram representative of an outside angle bent foot condition (all measurements in mils).

Notice how the outside measurements on foot 1 show it to be much higher off the base than

the part of the foot toward the inside of the machine.

 

This diagram happens to represent an outside angle bent foot at position 1. By analyzing diagrams like these (and with some practice under your belt) you will be able to diagnose and correct for high and low-foot conditions.

In order to correct high, low, and angled bent foot conditions, we need only to decide the amount of shim necessary to place beneath each foot, and where to place it. For example, the condition in Figure 1 should be diagnosed as a high foot at positions 1 and 3. To correct this, we would place 5 mils of shim beneath feet 1 and 3 because each foot raises approximately 10 mils when its hold down bolt is loosened, and we want to balance out this effect so that each foot doesn’t move at all. To correct the outside angle bent foot condition in Figure 2, we would create a step shim to place beneath the foot at position 1.

We mentioned earlier that induced soft foot conditions can be caused by pipe strain, which is the force that any fixture attached to the machine exerts on the machine. Figure 3 shows a diagram that indicates an induced soft foot due to pipe strain.

Figure 3: Example of a soft foot condition induced by pipe strain (all measurements in mils)

We can see that the feet all exhibit the same behavior when their respective hold down bolts are loosened – they angle upward (away from the base) and toward the upper right of the diagram. Before you place shim beneath machine feet to alleviate this stress, realize that this is not an option! Doing so would create a misalignment condition. To correct this problem it is usually required that the fixture attached to the machine be changed in some way to alleviate the force it is exerting on the machine.

Loose feet, which encompass problems such as unstable or cracked foundations, cracked feet, eroded grouting, and loose hold-down bolts, can also be a source of soft foot. Many machines sit on inadequate foundations, which is a major contributing factor to this type of soft foot. A machine foundation should consist of a poured slab of concrete that is 3 to 5 times heavier than the machine itself, followed by a base plate (sole plate) on top of that, and finally grouting between the base plate and machine to act as a dampener. When a foundation is not adequate for the machine it supports, the condition of the foundation can deteriorate in the form of cracks. A foundation that is not heavy enough for its machine may also provide it with an insufficient damping platform. A cracked machine foot can have many causes, including oxidation and stress. Obviously, no amount of shimming can correct a cracked machine foot – it must be repaired in order to correct this type if soft foot. Fortunately for the technician, these problems can often be diagnosed by inspection. Where the problem may not be so apparent, phase analysis (which will not be discussed in detail here) can also be a useful diagnostic tool.

Simply placing your finger on the gap between a machine foot and its base plate can shed light on a machine problem. In doing so (and with a little practice), you will be able to notice that the foot is vibrating away from the base plate. This is indicative of either a loose hold-down bolt or the erosion of grouting between the two surfaces. Following this “finger analysis” you may do a visual inspection to notice whether or not the grouting has actually eroded from between the foot and base plate, or if the vibration is more likely due to a loose hold-down bolt. A visual inspection can also tell whether or not the foundation is cracked. While visual inspection can tell you a lot about obvious problems, phase analysis is usually needed to detect less obvious ones.

A phase analysis reveals the relative motion between two measurement points. Phase measurements can be easily taken with two accelerometers linked to a dual-channel data collector, and also with a tachometer and an accelerometer (although this setup is more time consuming). Ideally, we would like to see the entire machine vibrating at low amplitude, and all measurement points vibrating in phase with one another. However, when there is a phase difference between two measurement points (usually a 90 to 180-degree difference) this can indicate a problem. Taking phase measurements on a machine foot, its hold down bolt, a nearby position on the base plate, and on the base itself is a useful way to determine where the problem lies. For example, if the measurements are relatively in phase (to within 30 degrees) between the hold down bolt and the machine foot, and between the base plate and the base, but about 180 degrees out of phase between the machine foot and the base plate, then the problem lies between the foot and base plate. This is by far not the only use for phase analysis; it can also be used to diagnose other machine faults such as unbalance, misalignment, and bent shafts.

Correcting loose feet can be as simple as tightening hold down bolts, or as complicated as replacing an entire machine base. However, the money-saving benefits of correcting all types of soft foot are well worth the effort. Eliminating soft foot conditions removes machine frame distortion, which prevents a machine’s bearings from distorting the shape of the machine rotor. This all leads to increased machine life and productivity, and reduced long-term maintenance costs and down-time.

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