As seen in our previous article, the settings of vibration measurement are crucial if you want to achieve the right detection and diagnostic performances. But, this is not the only thing to consider in order to achieve the desired objectives. For instance, the sensor mounting method to collect vibration data can greatly impact the quality of the time wave form. As a rule of thumb, the closer you put your sensor to the machine, the better it senses the vibrations. This means that the type of mounting accessory used affects the measurement quality, depending on its type and size, and how well vibrations can be propagated through it.

As we know, high frequencies are very low in amplitude (and energy) and are the first type of content to be affected by the mounting method, as there may be loss of energy during transmission to the vibration sensor.

There are several mounting methods used today, each with pros and cons, so you need to make sure that the mounting technique you are using is in line with your strategy. For example, a probe tip may make it possible to reach a small or narrow area  ̶  to obtain a measurement that nothing else can  ̶  but is not be suitable to monitor high frequency problems, such as bearings, cavitation and gear problems. On the other hand, the best frequency response is achieved through a stud, meaning the machine must be properly drilled, which is often only the case for permanent monitoring applications.
Please see below the illustration of the different options and their frequency response.

At the end of the day, it is often a compromise between how early you want to detect problems  ̶ depending on the machine’s use and failure modes  ̶  and the solution’s “user-friendliness”.

For example, in order to capture high frequencies above 15 KHz, you may need to use an adhesive mounting pad or directly stud-mount the sensor. Practically, you will notice that all high-power rating gearboxes use antifriction bearings and rotate at slow speed. Also, monitoring this type of gearbox is a challenge. A Roller Press or a VRM gearbox in a cement mill, as well as a rolling mill gearbox in a steel plant, are examples of this.

Measurement repeatability is key

Beside the quality of the measurement in terms of frequency content, the mounting accessory can also affect the trending and diagnostic reliability. One of the common issues when running a portable vibration program (where data are collected manually on a periodic basis), is ensuring that the sensors are placed in the same location from time to time, so that measurements can be compared by the vibration analyst. Although magnets are often preferred by users, because of their ease of use, they run some measurement repeatability risks. Hopefully, different techniques or tips can be implemented when using magnet-based accessories, such as marking the machine with a permanent marker or taking pictures of the sensor position on the machine; the OneProd FALCON vibration data collector allows you to both take photos and display them. As a matter of fact, despite the additional time and effort needed, installing cementing studs remains the safest choice to avoid any measurement errors, and guarantees the best possible results for the analyst in charge. Note that to keep the data collection time as fast as possible when using a magnet base, you can install cementing studs compatible with the use of magnets on the machines. Just bear in mind that the metrological performances achieved are impacted by the magnet, as explained in the first part of this article.

In conclusion, keep in mind that the condition monitoring leader has to establish a methodology for monitoring to ensure that:

• The measurement location (place where the sensor is installed) is a good position, where you have good vibration transmission;
• Data are being collected at the same location every time, despite potential staff turnover;
• The frequency content captured matches with both the failure modes you are trying to detect and how early you want to get warned, according to your application.

As illustrated, some types of machines may not leave any room for compromise.

Have you considered investing in a laser alignment system, but hesitated for some reason? Well, maybe this article can convince you of the many benefits.

1. MACHINE ALIGNMENT IS ONE OF THE BEST INVESTMENTS YOU CAN MAKE FOR THE ENVIRONMENT

How is this possible, you might wonder? Well, if your machines are correctly aligned not only do you save energy, but you also minimize the use of replacement parts. This in turn means less energy is required for the manufacture and shipping of those parts. Automatically, the consumption of materials is also reduced. All this makes a large contribution to the environment.

2. PROPER ALIGNMENT MAKES PRODUCTION MORE EFFICIENT AND HELPS MINIMIZE WASTE

If you are a manufacturer, you probably have a lot of machinery such as CNC machines or extruders that need alignment. When out of alignment, they produce faulty parts. These out-of-tolerance parts either need to be re-machined, or new ones must be produced to replace them, because your customer still needs the same amount. Both solutions take time. If you throw the faulty parts in the bin, you also waste material.

3. AN ALIGNMENT SYSTEM WILL IMPROVE YOUR WORKING ENVIRONMENT

First, the working environment will be improved thanks to reduced leakage and less vibrations. A leaking seal in a pump caused by misalignment can cause workers to be exposed to potentially harmful liquids. With a correctly aligned machine this will be avoided. Secondly, a properly aligned machine will vibrate less, which means reduced noise level and a safer working environment for the staff.

4. CORRECTLY ALIGNED MACHINES REDUCE THE RISK OF EXPENSIVE BREAKDOWNS

As well as reduced costs for replacement parts, reduced energy consumption and time savings there is another problem you will avoid with a correctly aligned machine: loss of production time. With measurement systems for vibration checks and alignment of the machines it is possible to minimize downtime, which of course reduces production losses.

5. YOU WILL GAIN MORE THAN YOU FIRST THOUGHT

Why do we think so? Well, because the Easy-Laser systems are so versatile, many users find new ways to improve their machinery using the system. Our basic alignment systems are extremely flexible, but of course, if you stretch your budget just a little you will also get more possibilities for the future. Regardless of system, the investment will quickly pay for itself thanks to all of the above reasons. Great, isn’t it?

WANT TO KNOW MORE?

Now, we hope you have picked up on one or two points. But if you want to find out more about laser based alignment systems, do not hesitate to contact us and we will tell you all about our Easy-Laser Systems!

We recently had a request from a customer to do some pump alignment. When we normally think about pump alignment, we usually think of shaft to shaft alignment. In this case, they wanted bore alignment. They were installing a brand-new pump and when they rotated the shaft, they could hear grinding.

After further inspection one of the techs could see that the bearing housing had been moved – either during shipment or when it was stored. They could see that the dowel pin had been damaged.

If you pop the lid off this style of pump (See Figure 1 – photo courtesy of KSB Pumps Canada), we see the shaft and the center mounted impeller. On each side of the impeller we have the wear rings, which sit in the bores. Outside of that we have two stuffing boxes or seal bores and outside of these we have the bearing Journals which are also bores. All of these bore centers need to be colinear, meaning in a straight line.

The old traditional methods for doing this type of work was done using piano wire or a mandrel. They would use the stuffing box or the wearing bores as reference points then measure to see if the bearing bores where in alignment. This method was “hit and miss” because its so difficult to set up and measure in this way. It also took a very long time.

Bore Alignment with Lasers

Using a laser-based measurement system has significantly reduced the time taken to do bore alignment. More importantly, it has improved the accuracy significantly. There are now automatic reports that go with the final bore alignment that has been completed – a documented history of the work is very important.

There are many different applications where bore alignment is done using lasers. For example, extruder barrels that need to be aligned to a gearbox in the plastic industry, crankshaft bearing journal bores in diesel/natural gas engines or compressors in the oil & gas and energy industries and stern tube alignment in the shipping industry. These are just three examples that show how varied the type of alignment work is.

Reference Points

Before we begin let us review the meaning of reference points. The goal is to have the center point of each bore to be colinear, in the same line. Why? Because this will be the same line as the rotational center line of the shaft. So, in essence, we’re measuring straightness. In order to do this, we need two reference points.

Let’s say you wanted to measure the straightness of a rail. To do this you could use a straight edge and gauge blocks. You normally place the gauge blocks at either end of the object that you want to measure, and the straight edge goes on top as pictured in example A below. Then using the feeler gauge or a dial indicator you would measure along the rail so that it fills any potential gaps. The size of the gauge block (which is a known size) is subtracted and what’s left is the deviation. In this case, the reference points are the gauge blocks and it is important to know that they can be positioned anywhere at any point along the rail.

If you look at example B, you can see that the gauge blocks are at different positions along the rail and it gives us different results. Being able to position the two gauge blocks anywhere along the rail is a great benefit to us because we can decide the optimal position for adjustment of the rail. We could change the position of the reference points so that all values are negative numbers or change them so all the values are positive – whatever gives us the optimal adjustment/fix.

Having the ability to quickly change the reference points when using a laser speeds up the measurement process. It also gives us more options.

Bore Alignment on a Split Casing Pump

Back to our split casing pump application. The removable bearing journal housing in the photo below is actually bolted to the pumps casing. While waiting for the top cover to be replaced we can mount the laser. The Easy-Laser E950 Bore Alignment system was used for this application.

The D75 laser is mounted on a hub that has 3 legs supporting it and uses magnets to attach itself to the flange face. The laser beam can be adjusted in the offset and angle using the adjustment screws. This makes roughing in very simple.

Now that the cover is on (see Figure 4) we can adjust the detector to the center of the bore with just a measuring tape. We do this by sliding the detector up/down on the rods. Then we adjust the laser beam so that it hits the center of the detector. This is to make sure the laser will hit the detector at the farthest point.

The detector you see is mounted on a specialized bore bracket. It has four magnetic feet so that it can be rotated around the bore using the built-in electronic inclinometers for exact positioning.

Next, we position the detector close to the beam (see Figure 5, left) and adjust the beam to the center of the detector target using the hubs offset adjustment.

Then we place the detector to the far point (see Figure 5, right) and adjust the beam for angle. To do this electronically, we simply push the button zero (0) (in the Values program on our handheld display unit shown in Figure 6) when the detector is close and adjust the laser beam to zero when the detector is in the far position. This is all the roughing in it needs and it may take 10 minutes. Now we are ready to measure!

The plan for this bore alignment is to use the stuffing boxes as reference points. These are machined services or bores that are part of the pumps casing and cannot be adjusted. We will use these points to compare the values we take in the bearing journals. We intend to take a total of 6 measurements, 2 in each of the bearing housings and one each for the stuffing boxes. The reason why we take 2 in the bearing journals is so we can see if there is any angular misalignment. We measure at six positions – two each for the main bearing and one each for the stuffing box that we plan on using as a reference point.

We rotate the detector inside the bores and take measurements at 12, 3, 6 and 9 o’clock positions. Rotating the detector gives us the center of the bore. This is a great advantage for us as you cannot do this with older traditional methods.

The diameter of the bores on the main bearing is seven inches and the diameter of the bore for the stuffing box is five inches. Different bore sizes are not a problem. What we do is measure the large bore first then slide the detector on the rods to measure the smaller bores.

The detector you see in Figure 7 is in the stuffing box at the 9 o’clock position.

After referencing the bearing (stuffing box) points #3 and #4 to zero set, we get our adjustment points at the remaining four points (#1, #2, #5 and #6). If we average the adjustment data for the measurement points at each bearing, you can see in Figure 8 how much we need to move each bearing. Based on zero setting, the stuffing box bearings (#3 & #4), the adjustments would be 2 thou to the left and 3 thou down for the back bearing. For the front bearing (closest to the laser) the adjustment would be 5 thou to the left and 6 thou up. The front bearing was, in the end, adjusted back into the correct position.

Conclusion

As we mentioned before, this is, in essence, the measurement of a straight line. With rotation you can use that measurement to align the bores using two reference points. Measuring straightness comes under geometric measurement. Geometric measurement is the measurement straightness, level, flatness, square, plumb, parallel, etc. We use optical tooling such as lasers to take these measurements. The benefits of lasers are the speed that we can take measurements, the ability to change reference points allowing us to choose the optimal result/adjustment (meaning the least amount of work), greater accuracy that all can see digitally, the lower cost as compared to other optical tooling systems and most importantly, the documentation/report that is required for modern day alignment work.

These types of measurement are not just for bore alignment. Parallel measurements can be used for rolls in Steel Mills and Paper Mills. Squareness measurements can be used to qualify the accuracy of a milling machine in machine shops. We can use flatness to measure a machine base which is probably one of the most important things to do in machinery installation. And there is more a lot more. Have a look at your processes, what do you need to use geometric measurement for?

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Donec volutpat nibh sit amet libero ornare non laoreet arcu luctus. Donec id arcu quis mauris euismod placerat sit amet ut metus. Sed imperdiet fringilla sem eget euismod. Pellentesque habitant morbi tristique senectus et netus et malesuada fames ac turpis egestas. Pellentesque adipiscing, neque ut pulvinar tincidunt, est sem euismod odio, eu ullamcorper turpis nisl sit amet velit. Nullam vitae nibh odio, non scelerisque nibh. Vestibulum ut est augue, in varius purus. Proin dictum lobortis justo at pretium. Nunc malesuada ante sit amet purus ornare pulvinar. Donec suscipit dignissim ipsum at euismod. Sed imperdiet fringilla sem eget euismod. Pellentesque habitant.

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Donec volutpat nibh sit amet libero ornare non laoreet arcu luctus. Donec id arcu quis mauris euismod placerat sit amet ut metus. Sed imperdiet fringilla sem eget euismod. Pellentesque habitant morbi tristique senectus et netus et malesuada fames ac turpis egestas. Pellentesque adipiscing, neque ut pulvinar tincidunt, est sem euismod odio, eu ullamcorper turpis nisl sit amet velit. Nullam vitae nibh odio, non scelerisque nibh. Vestibulum ut est augue, in varius purus. Proin dictum lobortis justo at pretium. Nunc malesuada ante sit amet purus ornare pulvinar. Donec suscipit dignissim ipsum at euismod. Sed imperdiet fringilla sem eget euismod. Pellentesque habitant.

Donec volutpat nibh sit amet libero ornare non laoreet arcu luctus. Donec id arcu quis mauris euismod placerat sit amet ut metus. Sed imperdiet fringilla sem eget euismod. Pellentesque habitant morbi tristique senectus et netus et malesuada fames ac turpis egestas. Pellentesque adipiscing, neque ut pulvinar tincidunt, est sem euismod odio, eu ullamcorper turpis nisl sit amet velit. Nullam vitae nibh odio, non scelerisque nibh. Vestibulum ut est augue, in varius purus. Proin dictum lobortis justo at pretium. Nunc malesuada ante sit amet purus ornare pulvinar. Donec suscipit dignissim ipsum at euismod.

Ut eni ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Leatherbacks face an increased osmotic challenge compared to other species of sea turtle Sed ut perspiciatis unde omnis iste natus error sit. Sed ut perspiciatis unde.

totam rem aperiam, eaque ipsa quae ab illo. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Leatherbacks face an increased osmotic challenge compared to other species of sea turtle Sed ut perspiciatis unde omnis iste natus error sit. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur.

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Donec volutpat nibh sit amet libero ornare non laoreet arcu luctus. Donec id arcu quis mauris euismod placerat sit amet ut metus. Sed imperdiet fringilla sem eget euismod. Pellentesque habitant morbi tristique senectus et netus et malesuada fames ac turpis egestas. Pellentesque adipiscing, neque ut pulvinar tincidunt, est sem euismod odio, eu ullamcorper turpis nisl sit amet velit. Nullam vitae nibh odio, non scelerisque nibh. Vestibulum ut est augue, in varius purus. Proin dictum lobortis justo at pretium. Nunc malesuada ante sit amet purus ornare pulvinar. Donec suscipit dignissim ipsum at euismod. Sed imperdiet fringilla sem eget euismod. Pellentesque habitant.

Donec volutpat nibh sit amet libero ornare non laoreet arcu luctus. Donec id arcu quis mauris euismod placerat sit amet ut metus. Sed imperdiet fringilla sem eget euismod. Pellentesque habitant morbi tristique senectus et netus et malesuada fames ac turpis egestas. Pellentesque adipiscing, neque ut pulvinar tincidunt, est sem euismod odio, eu ullamcorper turpis nisl sit amet velit. Nullam vitae nibh odio, non scelerisque nibh. Vestibulum ut est augue, in varius purus. Proin dictum lobortis justo at pretium. Nunc malesuada ante sit amet purus ornare pulvinar. Donec suscipit dignissim ipsum at euismod.

Ut eni ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Leatherbacks face an increased osmotic challenge compared to other species of sea turtle Sed ut perspiciatis unde omnis iste natus error sit. Sed ut perspiciatis unde.

totam rem aperiam, eaque ipsa quae ab illo. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Leatherbacks face an increased osmotic challenge compared to other species of sea turtle Sed ut perspiciatis unde omnis iste natus error sit. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur.

Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip

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Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip

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