Handbook of Shaft Alignment Part 17 pps

____ Yes Course title __________ Fee per student charge _____ (U.S. dollars) Fee per course charge _____ (U.S. dollars) ____ minimum number of attendees ____ maximum number of attendees ____ Yes Course title __________ Fee per student charge _____ (U.S. dollars) Fee per course charge _____ (U.S. dollars) ____ minimum number of attendees ____ maximum number of attendees 4. Do you provide classroom material for each student? If so, describe the training material (e.g., books, course notes, CD, etc.) that each student receives in the course. ____ No ____ Yes Course title __________ Course material __________ ____ Yes Course title __________ Course material __________ ____ Yes Course title __________ Course material __________ 5. Can the classroom material be purchased without attending the course? If so, what is the cost of the classroom material? _____ (U.S. dollars) 6. Do the attendees perform hands-on work on alignment training simulators in the course? If so, indicate the number of students per training simulator. ____ no training simulators used ____ 1 student per training simulator ____ 2 students per training simulator ____ 3 students per training simulator ____ 4–6 students per training simulator ____ 1 training simulator for entire class ____ 1 training simulator for instructor only ____ Others, describe __________ 7. Can a training simulator be purchased? If so, what is the cost of the training simulator? _____ (U.S. dollars) 8. Please indicate what topics are taught in your course(s) and whether it is covered in a lecture (LCTR), and=or a real life example or case history (XMPL), and=or if it is practiced with the hands-on training simulators (LAB): LCTR XMPL LAB Content ____ ____ ____ Symptoms of misaligned rotating machinery ____ ____ ____ Definition of shaft misalignment ____ ____ ____ Alignment tolerance guidelines Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_A001 Final Proof page 770 29.9.2006 7:46pm 770 Shaft Alignment Handbook, Third Edition ____ ____ ____ Difference between alignment and flexible coupling tolerances ____ ____ ____ Design principles of flexible and rigid couplings ____ ____ ____ Finding and correcting coupling problems ____ ____ ____ Design principles of bearings ____ ____ ____ Static and dynamic forces in machinery ____ ____ ____ Using vibration analysis to detect misalignment ____ ____ ____ Using infrared thermography to detect misalignment ____ ____ ____ Step-by-step procedure for the alignment process ____ ____ ____ How much time each step of the alignment process requires ____ ____ ____ How to measure runout on mechanical couplings and machinery shafts ____ ____ ____ What causes excessive runout conditions ____ ____ ____ Finding and correcting soft foot conditions ____ ____ ____ Finding and correcting excessive piping strain ____ ____ ____ Face–rim alignment method ____ ____ ____ Reverse indicator alignment method ____ ____ ____ Double radial alignment method ____ ____ ____ Shaft to coupling spool alignment method ____ ____ ____ Face–face alignment method ____ ____ ____ Measure and compensate for bracket=bar sag ____ ____ ____ Validity rule for alignment measurements ____ ____ ____ Mathematical corrections for face–rim ____ ____ ____ Mathematical corrections for reverse indicator ____ ____ ____ Mathematical corrections for double radial ____ ____ ____ Mathematical corrections for shaft to coupling spool ____ ____ ____ Mathematical corrections for face–face ____ ____ ____ Alignment graphing=modeling for face–rim ____ ____ ____ Alignment graphing=modeling for reverse indicator ____ ____ ____ Alignment graphing=modeling for double radial ____ ____ ____ Alignment graphing=modeling for shaft to coupling spool ____ ____ ____ Alignment graphing=modeling for face–face ____ ____ ____ Basic operating principle of all laser alignment systems ____ ____ ____ Basic operating principle for a specific laser alignment system ____ ____ ____ Aligning multiple element drive trains ____ ____ ____ Aligning right angled drives ____ ____ ____ Aligning vertically oriented shafts ____ ____ ____ Off-line to running (OL2R) machinery movement basics (aka ‘‘hot’’ and ‘‘cold’’ alignment) ____ ____ ____ Calculated machine case thermal expansion method ____ ____ ____ Inside micrometer-tooling ball-angle measurement methods ____ ____ ____ Proximity probes with water-cooled stands method ____ ____ ____ Optical alignment tooling method ____ ____ ____ Alignment bars with proximity probes method ____ ____ ____ Laser–detector systems method ____ ____ ____ Rod-tubing connector system method ____ ____ ____ Vernier-strobe method ____ ____ ____ Other OL2R machinery movement methods ____ ____ ____ Compensating for OL2R machinery movement ____ ____ ____ Other topics _____ ____ ____ ____ Other topics _____ ____ ____ ____ Other topics _____ ____ ____ ____ Other topics _____ ____ ____ ____ Other topics _____ ____ ____ ____ Other topics _____ ____ ____ ____ Other topics _____ Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_A001 Final Proof page 771 29.9.2006 7:46pm Appendix H 771 9. Do you offer or provide testing or exams for your courses? If so, what is the cost of the exams? Exam description _____ Exam cost _____ (U.S. dollars) Exam description _____ Exam cost _____ (U.S. dollars) Exam description _____ Exam cost _____ (U.S. dollars) Exam description _____ Exam cost _____ (U.S. dollars) 10. Are your tests or exams recognized by a professional affiliation or organizations? If so, what are the professional affiliation or organizations? Professional affiliation or organizations: __________ __________ __________ __________ __________ 11. Please indicate the number of years of experience of the training instructor(s), their previous job functions and time in that job, and educational experience. Instructors name _____ Training experience _____ years Alignment field experience _____ years Number of Years Job Description _____ Plant manager _____ Engineering manager _____ Maintenance manager _____ Mechanical engineer _____ Electrical engineer _____ Civil engineer _____ Industrial engineer _____ Other engineers, _____ _____ Front line supervisor=foreman=planner _____ Technician _____ Mechanic _____ Millwright _____ Pipefitter _____ Electrician _____ Electronic repair=instrumentation _____ Others (please list) __________ Formal Training _____ K–12 (elementary education) _____ Trade school _____ Junior college _____ Bachelor’s degree _____ Master’s degree Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_A001 Final Proof page 772 29.9.2006 7:46pm 772 Shaft Alignment Handbook, Third Edition _____ Doctoral degree Instructors name __________ Training experience _____ years Alignment field experience _____ years Number of Years Job Description _____ Plant manager _____ Engineering manager _____ Maintenance manager _____ Mechanical engineer _____ Electrical engineer _____ Civil engineer _____ Industrial engineer _____ Other engineers, _____ _____ Front line supervisor=foreman=planner _____ Technician _____ Mechanic _____ Millwright _____ Pipefitter _____ Electrician _____ Electronic repair=instrumentation _____ Other (please list) __________ Formal Training _____ K–12 (elementary education) _____ trade school _____ junior college _____ Bachelor’s degree _____ Master’s degree _____ Doctoral degree 12. Additional information __________ __________ __________ __________ __________ Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_A001 Final Proof page 773 29.9.2006 7:46pm Appendix H 773 Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_A001 Final Proof page 774 29.9.2006 7:46pm Appendix I Shaft Alignment Services Questionnaire If you decide that you would like to have an outside contractor perform shaft alignment services for you, this questionnaire should help in assessing the qualifications of the company or personnel who will be performing the services. 1. Indicate what geographical area your alignment services cover (cities, states, countries, etc.). __________ __________ __________ __________ __________ __________ __________ 2. Indicate what types of industrial rotating machinery you have worked on and for what period of time. Number of Years Machinery Type _____ Synchronous motors _____ Induction motors _____ Steam turbines _____ Gas turbines _____ Water turbines _____ Internal combustion engines _____ Drivers up to 50 hp _____ Drivers from 50 to 200 hp _____ Drivers from 200 to 1000 hp _____ Drivers from 1000 to 5000 hp _____ Drivers from 5000þ hp _____ Single stage centrifugal pumps _____ Multiple stage centrifugal pumps _____ Centrifugal air compressors _____ Reciprocating air compressors _____ Screw or sliding vane air compressors _____ Gearboxes _____ Fans _____ Blowers _____ AC generators _____ DC generators _____ Cooling tower fan drives Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_A001 Final Proof page 775 29.9.2006 7:46pm 775 _____ Multiple element drive trains _____ Other machinery (please list) _____ _____ _____ 3. Please fill out the following form for each employee performing shaft alignment in your organization. If there are several employees who perform these functions, please attach their information to this questionnaire. Part A. Job description Indicate the number of years of experience of the service personnel, their current job function(s), time in that job, and educational experience. If they perform more than one function, please indicate each one. Service personnel name __________ Alignment field experience _____ years Number of Years Job Description _____ Company president or director _____ Department manager _____ Engineering manager _____ Service manager _____ Mechanical engineer _____ Electrical engineer _____ Civil engineer _____ Industrial engineer _____ Other engineers, _____ _____ Front line supervisor=foreman=planner _____ Technician _____ Mechanic _____ Millwright _____ Pipefitter _____ Electrician _____ Electronic repair=instrumentation _____ Others (please list) _____ Part B. Education _____ K–12 (elementary education) _____ Trade school _____ Junior college _____ Bachelor’s degree _____ Master’s degree _____ Doctoral degree Part C. Alignment training Indicate what training you have received in the following shaft alignment methods, pro- cedures, or tasks. Formal training means they attended a training course, on the job training (OTJT) means you where shown this information by a coworker or you were self taught. Formal OTJT Shaft Alignment Method(s), Procedures, Tasks _____ _____ Foundation and baseplate=soleplate installation and repair _____ _____ Soft foot detection and correction _____ _____ Excessive runout detection and correction Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_A001 Final Proof page 776 29.9.2006 7:46pm 776 Shaft Alignment Handbook, Third Edition _____ _____ Excessive piping strain detection and correction _____ _____ Straightedge, eyeball, feeler gauge _____ _____ Face–rim indicator _____ _____ Reverse indicator _____ _____ Shaft to coupling spool _____ _____ Double radial _____ _____ Face–face _____ _____ Laser=detector system(s), model(s)_____ _____ _____ Calculating ‘‘growth’’ using the thermal strain equation _____ _____ Inside micrometer=tooling ball=angle measurement devices _____ _____ Proximity probes with water-cooled stands _____ _____ Optical alignment tooling _____ _____ Alignment bars and proximity probes (aka ‘‘Dodd’’=Dynalign bars) _____ _____ Laser=detector dystem(s), model(s)_____ _____ _____ Ball-rod-tubing connector system _____ _____ Vernier-strobe method _____ _____ Instrumented coupling system _____ _____ Shaft alignment software programs _____ _____ Others (please list) _____ Part D. Shaft alignment field experience Indicate what off-line shaft alignment methods you have performed and for what period of time. Number of Years Shaft Alignment Method(s) You Have Used _____ None _____ Eyeball _____ Straightedge, eyeball, feeler gauge _____ Face–rim indicator _____ Reverse indicator _____ Shaft to coupling spool _____ Double radial _____ Face–face _____ Optical alignment tooling _____ Laser=detector system(s), model(s) _____ _____ Others (please list)_____ _____ _____ _____ Indicate what off-line to running (OL2R) machinery movement measurement and align- ment compensation methods (aka ‘‘hot’’ and ‘‘cold’’ alignment) you have performed and for what period of time. Number of Years OL2R Machinery Movement Measurement Method(s) You Have Used _____ Calculating machine case thermal expansion (thermal strain equation) _____ Inside micrometer=tooling ball=angle measurement devices _____ Proximity probes with water-cooled stands _____ Optical alignment tooling _____ Alignment bars and proximity probes (aka ‘‘Dodd’’ bars=Dynalign system) _____ Laser=detector system(s), model(s) _____ Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_A001 Final Proof page 777 29.9.2006 7:46pm Appendix I 777 _____ Ball-rod-tubing connector system _____ Vernier-strobe method _____ Instrumented coupling system _____ Others (please list)_____ __________ __________ Part E. Additional talents and capabilities Indicate any additional tasks you have performed and for what period of time. Number of Years Skills or Tasks _____ Vibration analysis or monitoring _____ Shop balancing _____ Field balancing _____ Infrared thermography surveys _____ Oil analysis _____ Motor current signature analysis _____ Motor testing _____ Root cause failure analysis (RCFA) _____ Machinery overhaul and repair _____ Sliding bearing inspection, replacement, or repair _____ Rolling element bearing inspection or replacement _____ Rigging _____ Foundation installation (i.e., concrete, re-bar, forms, isolation, etc.) _____ Basic machine tool operation (e.g., lathe, mill, grinder) _____ Gas welding and cutting _____ MIG welding _____ TIG welding _____ Pipefitting _____ Hand tools (e.g., wrenches, ratchets, etc.) _____ Basic measuring tools (micrometers, dial indicators, slide calipers, etc.) _____ Power tools (e.g., drills, grinders, saws, air tools, etc.) _____ Fork truck operation _____ Crane operation _____ Lubrication _____ Flexible or rigid coupling inspection or replacement _____ Oil seal inspection or replacement _____ Mechanical packing inspection or replacement _____ Mechanical seal inspection or replacement _____ Pneumatic instrumentation _____ Electronic instrumentation _____ Hydraulics _____ Basic computer skills _____ Word processing software _____ Database or spreadsheet software _____ Presentation software _____ CAD _____ Illustration=graphics software _____ Desktop publishing software _____ Digital photography Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_A001 Final Proof page 778 29.9.2006 7:46pm 778 Shaft Alignment Handbook, Third Edition _____ Digital video _____ Local area network installation and maintenance _____ Internet and web browsers _____ Software programming languages (e.g., C, Pascal, Basic, Fortran, etc.) _____ Other skills (please list) _____ _____ _____ _____ Part F. Certification or accreditation Indicate any certification or achievements related to your work. Please show what level of achievement (e.g., Levels 1, 2, 3, etc.) was received, and the organization or institution the achievement was received from (e.g., ISO, ANSI, ASME, Vibration Institute, JATC, college, trade school, company, etc.). Level Organization Subject or Skill _____ _____ Shaft alignment _____ _____ Optical alignment _____ _____ Vibration analysis _____ _____ Balancing _____ _____ Infrared thermography _____ _____ Oil analysis _____ _____ Motor current signature analysis _____ _____ Motor testing _____ _____ Root cause failure analysis (RCFA) _____ _____ Machinery overhaul and repair _____ _____ Rigging _____ _____ Machine tool operation _____ _____ Gas welding and cutting _____ _____ MIG welding _____ _____ TIG welding _____ _____ Pipefitting _____ _____ Fork truck operation _____ _____ Crane operation _____ _____ Lubrication _____ _____ Pneumatic instrumentation _____ _____ Electronic instrumentation _____ _____ Hydraulics _____ _____ Basic computer skills _____ _____ Word processing software _____ _____ Database or spreadsheet software _____ _____ CAD _____ _____ Software programming languages _____ _____ Others _____ _____ _____ Others _____ _____ _____ Others _____ _____ _____ Others _____ Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_A001 Final Proof page 779 29.9.2006 7:46pm Appendix I 779 [...]... installed 172 173 Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_C023 Final Proof page 793 28.9.2006 11:01am 793 Index hydraulic expansion 172 175 installation of 173 174 interference fits 168 170 keyless taper bores 172 lubrication of 140 mechanically flexible 74 miniature 139–141 removal of 170 , 175 role of 138 thermal expansion for installation 169 thermal or hydraulic expansion 172 174 tolerances... severe misalignment 3, 20, 132, 193, 252, 389 shafts elastic bending of 5, 52, 252, 351, 389 shafts elastically bend due to the misalignment condition 406 shaft alignment measuring tools 219–287, 316, 319 shaft alignment measurement system 238, 313, 314, 343, 412, 416, 473 shaft alignment patents 176 , 405 shaft bending 1, 253 shaft expansion 625 shaft fretting 164, 168 shaft hunting 668 shaft lift... 0.807 in 0.799 in 0.802 in Top view 17. 796 in 0.811 in 17. 832 in 17. 840 in Pump 17. 840 in Pad H 0.811 in Steam turbine 17. 807 in 17. 808 in 17. 793 in North No 15 BFW Baseplate after grouting Pad A 17. 827 in Pad B Pad C Pad E 0.821 in 0.823 in 0.850 in 0.857 in 17. 839 in 17. 805 in 17. 799 in 0. 817 in 0.827 in 0.851 in 0.859 in 17. 831 in 17. 844 in 17. 814 in 17. 808 in Pad D 17. 859 in Pad F Pad G 0.825 in 0.857... (pump) 17. 800 in (turbine) Bolt plane 0.790 in (pump) 17. 790 in (turbine) Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_Plates Final Proof page 3 6.10.2006 5:37pm No 15 BFW Baseplate before grouting Pad A 17. 787 in Pad B Pad C Pad E 0.802 in 0.800 in 0.802 in 0.809 in 17. 799 in 17. 800 in 17. 797 in 0.806 in 0.801 in 0.802 in 0.810 in 17. 800 in 17. 812 in 17. 803 in 17. 788 in Pad D 17. 833... of a typical rigid foundation Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_Plates Final Proof page 2 6.10.2006 5:37pm No 15 BFW baseplate before grouting Pad A 17. 787 in Pad C Pad B Pad E 0.802 in 0.800 in 0.802 in 0.809 in 17. 799 in 17. 800 in 17. 797 in 0.806 in 0.801 in 0.802 in 0.810 in 17. 788in 17. 800 in 17. 812 in 17. 803 in Pad D 17. 833 in Pad F Pad G 0.800 in 0.799 in 0.806 in 17. 796... vertical generators 707–719 of multiple element drive trains 588–589 of parallel rolls 639–640 of vertical pumps 678–679 to center rotors in housing 668 alignment qualifications 26–27 alignment records 2, 33 alignment skills 19–23 alignment skills testing 19–23 alignment software 273–274 alignment solutions 319, 567 alignment steps 7 alignment survey 2–3 alignment tolerances 7, 14, 17 19, 52, 53, 135, 138,... hunting 668 shaft lift check 181, 187 shaft misalignment definition of 201, 319, 343–347 shaft seals 190, 202 shaft sleeve 190 Shaft to Coupling Spool Method 284 –285, 397–403, 414, 517 526, 553, 577, 654, 723 mathematics 400 used on multiple element drive 721 Shaft Alignment Handbook, Third Edition Shaft to Coupling Spool shoot for dial indicator readings 548 shaft to shaft distance 668, 673, 681, 726... precautionary measures 172 rough align 17, 204, 221 Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_C023 Final Proof page 798 28.9.2006 11:01am 798 RTD’s 477 rudder alignment 730 rulers 220–221 rules of thumb for shims 301 running shaft misalignment 137 running shaft positions 541–542, 548, 554 runout 40, 41, 52, 56, 59, 261–269, 300, 404, 735 acceptable limits 714, 717 alignment considerations...Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_A001 Final Proof page 780 29.9.2006 7:46pm Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_A001 Final Proof page 781 29.9.2006 7:46pm Appendix J Alignment Internet Web Sites Company or Organization Web Site Accushim Inc Alignment Services Inc Alignment Supplies Inc Automated Precision Brunson... measurements 703–705 aligning bent shafts 8, 201 aligning two hollow cylinders 622–626 aligning vertically oriented rotating machinery 249 alignment history of 735–751 alignment accuracy 344 alignment and coupling tolerances 341–352 alignment bars 515–522 alignment bars with proximity probes 515–522 alignment certification 26–31 alignment laws of multiple element drive trains 564 –566 alignment modeling 319–339, . coupling system _____ _____ Shaft alignment software programs _____ _____ Others (please list) _____ Part D. Shaft alignment field experience Indicate what off-line shaft alignment methods you have. information __________ __________ __________ __________ __________ Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_A001 Final Proof page 773 29.9.2006 7:46pm Appendix H 773 Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_A001 Final Proof page. ____ ____ Symptoms of misaligned rotating machinery ____ ____ ____ Definition of shaft misalignment ____ ____ ____ Alignment tolerance guidelines Piotrowski / Shaft Alignment Handbook, Third Edition