Pruftechnik Blog

machinery alignment

Making machine installations a breeze: Aligning a new rewinder at a paper converter plant

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Paper Industry Roosevelt Paper, a paper converter and distributor founded 87 years ago in Philadelphia, maintains long-held traditions behind its paper, providing fast, reliable deliveries and offering pricing that gives its customers a competitive edge. From customer savings to quality assurance and innovation, Roosevelt Paper is devoted to a culture of commitment. The company makes it a priority to invest in state-of-the-art machinery to continue saving its customers time and money while providing flexibility and customization.

Roosevelt Paper saves time and money by using a gyroscopic alignment service to align its machines during preliminary installations and routine shutdowns to ensure proper alignment throughout the lifetime of the machine. The technology is known as PARALIGN and the service is provided by Fluke Reliability’s alignment team for all three of Roosevelt’s plants in Illinois, Kentucky, and New Jersey. Across these three locations, Roosevelt Paper houses eight sheeter machines and a handful of rewinders.

During Fluke Reliability’s recent visit to Alsip, IL, the team measured a Rewinder containing 13 rolls in 20 minutes. Adding the initial set-up time of roughly 30 minutes to the time it took to make adjustments to the machine, Fluke Reliability’s team completed the scope of work to align the machine in less than five hours. During this time, the Fluke service team also completed shaft alignments on two separate motor to roll configurations. This particular project was a new machine installation. Upon initial start-up, the rewinder ran flawlessly. The results of the project follow.

Step by step new machine alignment: Rewinder

Front Motor Initial

Front Motor Initial

Front Motor Final

Front Motor Final

Rear Motor Initial

Rear Motor Initial

Rear Motor Final

Rear Motor Final

 

Initial PARALIGN Measurements

 

Initial PARALIGN Measurements

Final PARALIGN Measurements

Final PARALIGN Measurements

What to do if you’re not getting what you expect from your laser alignment system

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Wrong alignment tool for the situation or asset? Need a more experienced user to get the job done? Many complexities can arise when attempting to diagnose and correct machinery misalignment with laser shaft alignment solutions not built for the challenge.

In an August 2020 webinar, Jonathan Gough, PRUFTECHNIK Product Manager at Fluke Reliability, addressed four of the “most costly pitfalls in laser shaft alignment—and how to avoid them.” You can watch the full webinar online at the Fluke Reliability website.

Gough isn’t asking anyone to lower their expectations. He urges that users choose Adaptive Alignment systems to reap these benefits of laser systems, as outlined below in Figure 1:

  • Lowering of pump repairs
  • Reduction in seal replacements
  • Increase in bearings’ life cycle
  • Reduction in power consumption

Experience in using laser systems can go a long way toward anticipating and avoiding common mistakes during an alignment procedure, he notes. But Adaptive Alignment tools are better equipped to guide newer users because of corrective features that avoid the pitfalls lead them quickly to precise measurement results.

“Even with laser alignment systems,” Gough notes, however, “things can still go wrong.” In his webinar, Gough uses extensive video demonstrations to illustrate what not to do, and then what you can do with the correct tool to complete the alignment task successfully.

Here are short summaries of the four pitfalls detailed in the webinar.
Figure 1. Benefits promised by laser alignment

Figure 1. Benefits promised by laser alignment

 

Example 1: Initial misalignment

Line-over-length can affect the detector measurement range. In other words, the longer the separation distance, the less misalignment can be measured. This complication can arise in many different settings, from overhauling a motor to working with machines with pre-set targets on, for example, wind turbines.

The pitfall: With basic double laser-and-sensor alignment systems, it’s not always possible to measure the initial position of the machine. This predicament forces the user to resort to rough alignment procedures and, therefore, not able to document the “as-found” alignment state.

The advice: Adaptive Alignment systems feature single-laser technology, which helps ease this situation. Gough coaches us to use Freeze Frame in single-laser systems to avoid the laser going outside the measurement range.

“Get the laser in the crosshairs, so that you’re measuring at the coupling, and calculate what’s happening at the feet. This info enables you to know A) the ‘as-found’ state as well as B) how much you have to move the machine,” Gough said.

Figure 2. Using Freeze Frame to measure the initial position of a machine.

Figure 2. Using Freeze Frame to measure the initial position of a machine.

 

Example 2: Coupling-Play / Backlash

Backlash or coupling play is a common mechanical phenomenon that occurs when the coupling has high torsional flexibility (is flexible by design) to avoid inadvertent damage to the driven machinery.

The pitfall: Coupling flex or play impacts the alignment measurement, as the change in relative coupling shaft positions change the Y sensor values. During the measurement, as the laser moves or “floats” from left to right, these differences between the heads impact the measurement result, lowering accuracy.

The advice: If your laser alignment tool has Active Situational Intelligence software—another key feature of adaptive systems—use the “Sweep” measurement mode to detect coupling backlash data automatically. Then let the laser alignment tool, with software analytics, remove that data from the calculation.

Figure 3: Using data quality enhancement to override the bad data induced by coupling play/backlash

Figure 3: Using data quality enhancement to override the bad data induced by coupling play/backlash

 

Example 3: Coupled vs. uncoupled shaft alignment

The question here is: Where do you start the alignment? Is it when the machine is coupled or uncoupled?

“If you have a misaligned machine and you try to bolt the coupling together, you’ll have some residual forces and friction to deal with,” Gough says.

The pitfall: If you measure with a coupled-mounted shaft application, you could effectively be measuring a loaded/bent shaft. If you don’t measure the exact unloaded position of the machine, then after you move those values, you won’t correct the misalignment entirely. This situation is particularly challenging to overcome with a double-laser system.

The advice: If you have a shaft alignment application with anti-friction bearings and initial misalignment, remove the tire coupling element, align it uncoupled, and then reconnect the coupling. During the alignment procedure, use the uncoupled PASS mode, another capability in Adaptive Alignment systems. Simply rotate the shafts and let the single laser and sensor head pass across each other, so the measurement points are automatically taken when the heads are in the same relative angular position.

Figure 4: Uncoupled alignment and uncoupled shaft awareness.

Figure 4: Uncoupled alignment and uncoupled shaft awareness.

 

Example 4: The movable machine

Back to the line-over-length dilemma. If you need to move a machine during an alignment procedure, which end do you move?

The pitfall: If you move a machine with a laser on, due to line-over-length, you can very quickly slip out of the sensor detector range, forcing you to stop and re-measure before continuing to re-position the machine. Unfortunately, with the double-laser systems, there are always laser and sensor heads on both the moveable and stationary machines.

The advice: Due to the single laser technology, if you move the sensor-side of the machine—not the laser—the problem won’t occur. The line-over-length issue doesn’t take place, and the laser stays well within the sensor detector range while enabling full measurement. Therefore, the single laser should always be mounted onto the shaft of the stationary machine.

Figure 5: Moving the sensor-end of the machine vs. the laser-end.

Figure 5: Moving the sensor-end of the machine vs. the laser-end.

 

Gough asserts that users are well within their rights to expect quick, consistent, and high-precision results from their laser alignment systems. The trick sometimes is to know where the pitfalls lie. For more alignment demonstrations by Gough, watch his other alignment webinar on the Fluke Reliability website.

Innovators or Imitators?

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ROTALIGNIt looks like we’ve struck a nerve in the laser shaft alignment market with our announcement of Adaptive Alignment systems.

All of a sudden, various forms of the word “adaptable” have been popping up on social media posts about laser alignment systems that do not possess Adaptive Alignment technology.

We at PRUFTECHNIK are glad to see others admit that adaptability is indeed a valuable must-have in laser alignment systems. We welcome them to the conversation.

Of course, it’s easy to use words like “adaptable” in a social media post. The hard part is actually engineering Adaptive Alignment capabilities into a laser alignment system. By that, we mean features that make adaptability happen during an alignment job, – such as single-laser technology and Active Situational Intelligence (see our white paper here).

Breakthrough engineering work is what separates innovators from imitators. PRUFTECHNIK—the undisputed world leader in laser shaft alignment—has continued to revolutionize with patented inventions that are realized in our Adaptive Alignment solutions.

But when many vendors freely use the word “adaptable,” how can maintenance practitioners separate true Adaptive Alignment systems that deliver higher precision with faster job completion from imitators that still operate in a basic way?

By asking, “How.”  How do systems claiming to be adaptable actually deliver Adaptive Alignment benefits?  Here are some specific questions:

  • Does the system include single-laser technology?
    If not, it cannot adapt to situations such as large misalignments. Common workarounds that add time and potentially compromise precision include recommendations to do “rough alignment” or “pre-alignment” before tackling the rest of the job.
  • Does the system deliver real-time feedback during, as opposed to after, the measurement?
    If not, it is not adapting to user needs.
  • Does the system automatically detect and eliminate coupling backlash as measurements are taken?
    Basic systems leave it up to the user to make sure backlash is not influencing the measurement.
  • Does the system include the ability to share measurements over the cloud to support team collaboration?
    If not, the technician is on his own at the machine, and the system is not adapting to teams that need collaborative capabilities
  • Is the system automatically aware of and can handle uncoupled shafts?
    A common installation-time need, Uncoupled Shaft Awareness, eliminates the manual positioning exercises commonly needed with basic alignment systems.

There are other questions that practitioners could and should ask before investing in a laser shaft alignment system. If you want to know what they are, don’t hesitate to contact us.

In the meantime, we at PRUFTECHNIK, a division of Fluke Reliability, welcome the marketplace validation of the value of Adaptive Alignment.

As with any advance that is imitated, sly usage of similar terms can make it difficult for users to separate the innovation from the imitation. We encourage maintenance leaders to learn about the key ingredients of Adaptive Alignment – which they can do here.

In the end, it’s not merely a battle over the meaning of the word “adaptable.” For maintenance teams charged with keeping their machines at peak performance while operating at peak efficiency themselves, Adaptive Alignment is one key to a successful future.

If you’d like to learn more about our Adaptive Alignment systems, we suggest digging into the information on this page or getting in touch with your PRUFTECHNIK sales representative today!

What does it mean for a laser shaft alignment system to be ‘adaptive’?

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Adaptive AlignmentAdaptive, adaptable. What’s the difference?

If you want the ultimate in shaft alignment technology, the difference is huge. It’s the difference between maximizing production time and team efficiency or squandering time and money.  It’s the difference between minimizing downtime or watching the clock tick as the maintenance team tries to apply an “adaptable” solution to a complicated situation.

Above all, it’s the advantage a company gains when it uses alignment systems that minimize human error while delivering new levels of accuracy and speed.

That’s the promise of Adaptive (not adaptable) Alignment. Delivering on this promise means capitalizing on the core innovations of single-laser technology and Active Situational Intelligence. We own patents for these and other fundamental Adaptive Alignment components.

Here’s a quick refresher course on what makes Adaptive Alignment genuinely adaptive.

  • Single-laser technology. A system with just one laser and one sensor speeds set up and eliminates the frustration and risk of inaccuracies that occur when working with two lasers firing in opposite directions. It also enables the faster completion of alignment tasks and results in higher precision.
  • Active Situational Intelligence (ASI). This analytics software equips maintenance teams with real-time, actionable insights. Yes, usable intelligence while the measurements are taking place, not after the fact. ASI dynamically reacts to everything involved in the alignment process. It uses predictive intelligence to enable technicians to evaluate different possible courses of action before embarking on the time-consuming task of moving a machine.

This is what maintenance teams need: innovative Adaptive Alignment products that automatically adapt to the asset, to the specific situation, and also to the needs of the team—all in real time.

The big difference between Adaptive Alignment products and an “adaptable” solution is in who does the adapting. For years, maintenance technicians have had to adapt to the limitations of various other laser alignment systems. These limitations include, for example:

  • Only available in dual laser configurations
  • Can’t provide users with instantaneous visual feedback on measurement quality during the rotation
  • Have no optimization for working with uncoupled shafts during installation
  • Can’t automatically detect and eliminate coupling backlash.

The list goes on. You quickly wonder how applicable the word “adaptable” is to these systems.

PRUFTECHNIK, on the other hand, is the first to deliver true Adaptive Alignment. We chose “adaptive” because it means “serving or able to adapt; showing or contributing to adaptation.” And this clearly describes what we have done: we’ve incorporated the adaptive capabilities into all our alignment products as an inherent feature.

PRUFTECHNIK Adaptive Alignment products have built-in intelligence that adapts to the maintenance team needs automatically and in real time. We created this functionality as a direct response to issues customers historically told us they were having on their machines.

If you’d like to see what a real Adaptive Alignment system can do, get in touch with us for a demo. We’re the only company that can show you one.

Learn more about the powerful Adaptive Alignment concept and feature set are built into PRUFTECHNIK systems at our website, where you can download the Adaptive Alignment white paper or request to speak to a specialist.

The benefits of performing precision alignment at installation

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precision alignment

Measuring for precise alignment when installing a coupling driven asset is a smart and cost-effective way to help assure a longer machine life — right from the beginning of its active use.

Maintenance teams that measure alignment during initial machinery installation often see benefits in machine performance, efficiency, and health.

Using PRUFTECHNIK Adaptive Alignment systems can be especially valuable during machine installation because the results are highly accurate, getting measurements can be quick, and moving the machine may not be necessary.

Here are three alignment problems that can be minimized or resolved by measuring the alignment during installation phase.

1. Soft foot

Soft foot is a commonly used industry term describing distortion of the machine frame and “feet.” It occurs when a rotating machine set on its base, frame, or soleplate is off-kilter because one or more of its “feet” fails to make contact with all of the “foot-plates” on the frame.

It is the root cause of most alignment issues and a critical aspect to check before performing an alignment. Eliminating soft foot saves substantial time and money, especially since an estimated two-thirds of all rotating machinery have soft foot conditions. Addressing it right from the beginning typically makes subsequent alignments much easier.

Additionally, if the soft foot correction is successful, the bearing and motor typically have longer lives because the frame is no longer under tension and because there’s a better vibration signature when the soft foot is eliminated. Correcting soft foot improves seal and bearing life and reduces vibration—all of which contribute to a healthier machine.

Diagnosing and correcting soft foot when installing a machine enables maintenance teams to protect against further occurrences. The soft foot diagnostics tool in Adaptive Alignment systems provide a simple, convenient way to confirm the presence of soft foot and dirive and inform the user which type of soft foot and corrective action required to remove the soft foot.

2. Bolt-bound or base-bound

During initial machine installation, it’s essential to align the motor so there is some clearance in the bolt holes.

The most logical method for preventing a bolt-bound or base-bound condition is to install the stationary and movable machines properly before any piping, ductwork, or other attachments are added.

The absolute best time to use a laser shaft alignment tool to avoid this condition is during the initial installation.

3. Pipe strain

Pipe strain is likewise best addressed when machinery is first put in place. Pipe strain occurs when piping puts stress on the machine due to poor alignment of the pipes before they are bolted up.

The amount of this stress can be measured using the Live Trend feature of Adaptive Alignment laser tools. Measurements can also be performed by watching the pump during live-move or alternatively by taking an alignment measurement but instead of then moving the machine, unbolt the pipes, and taking another set of measurements and then compare the differences between the two sets measurement results.

The objective is to determine how much influence the pipes attached to the pump have on the alignment. It’s much more effective to address pipe strain when machines are being installed because teams can easily locate and correct pipes that are poorly aligned.

Using reports as a baseline for future inspections

Adaptive Alignment systems provide documented PDF reports about the condition of alignment and the presence of soft foot or pipe strain. Optional PC software is available for storing this information, making it easy to keep a running trend of machinery condition. This type of reporting tool is invaluable, especially in new installations, because it provides baseline data to reference when performing subsequent alignments.

Get more information about Adaptive Alignment at the PRUFTECHNIK.com website. Also, learn more about the Adaptive Alignment concept and feature set in PRUFTECHNIK systems by downloading the white paper on this webpage.

Watch Adaptive Alignment features come to life through webinar video demos

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It’s commonly known among maintenance teams that misalignment in rotating equipment is caused by excessive loading, vibration, worn couplings, soft foot, and more. But diagnosing and correcting misalignment in machinery often is considered specialized work—reserved for the team’s most experienced millwrights and engineers.

Fast forward to today, with modern Adaptive Alignment laser systems from PRUFTECHNIK, which feature the ability to adapt to any situation, asset, or user skill level.

In the webinar, “Adaptive Alignment: the next generation in laser shaft alignment systems,” Jonathan Gough, Fluke Reliability product manager for PRUFTECHNIK, used a series of video demonstrations to illustrate how laser alignment tools assist the user through a range of difficult alignment situations. This technology makes it possible for even inexperienced technicians to perform alignments and achieve precision results.

Until 1984, machinists used the kind of straight edge and feeler gauges or dial indicators pictured in Figure 1 to align the shafts of rotating equipment, utilizing years of experience and technique to get as close as possible to precision alignment. Then, when PRUFTECHNIK introduced its OPTALIGN® system, the world’s first laser alignment tool, it became clear that even the best manual alignment was less precise than what laser alignment could accomplish.

Figure 1. The PRUFTECHNIK ALI2000 Dial alignment tool circa 1982 versus the PRUFTECHNIK OPTALIGN laser alignment tool introduced in 1984. Figure 1. The PRUFTECHNIK ALI2000 Dial alignment tool circa 1982 versus the PRUFTECHNIK OPTALIGN laser alignment tool introduced in 1984.

Figure 1. The PRUFTECHNIK ALI2000 Dial alignment tool circa 1982 versus the PRUFTECHNIK OPTALIGN laser alignment tool introduced in 1984.

In past decades, as illustrated in Figure 2, each type of alignment system required a different level of skill to do the job. Performing a manual alignment with a straight edge took exceptional talent. Using a dial indicator required a more specialized type of skill. But when the laser alignment tool entered the picture, it became feasible for less experienced machinists and more general technicians to perform quality alignments, down to 0.05 mils (0.001 mm).

Figure 2. Degree of precision in alignment results and skill level required to perform the alignment by alignment method.

Figure 2. Degree of precision in alignment results and skill level required to perform the alignment by alignment method.

With today’s advancements in laser shaft alignment systems, including Active Situational Intelligence (ASI), the corrective capabilities more than ever can support users of all skill levels.

According to Gough, Adaptive Alignment occurs when the alignment system adjusts to the situation encountered in real time, as well as to the skill level of the person performing the alignment. Adaptive Alignment systems can adjust to the:

  • Asset itself
  • Alignment situation or challenge
  • Technician and team charged with completing the alignment task

The built-in software known as ASI detects difficulties and compensates for them on the fly during the work. Multiple quality factors such as rotation angle, speed, and evenness are evaluated in real time, allowing the tool to provide instant feedback to the user.

In the videos presented, Gough demonstrated how alignment jobs could be done faster and with higher precision because of the technology’s ability to adapt in real time, eliminate errors, and correct for situational challenges.

To best grasp Gough’s demos, watch the full webinar online. Here are indicative shots, in freeze-frame, of the first video demonstration (there are eight demonstrations in all).

Figure 3a. A coupled machine in continuous sweep mode

Figure 3a. A coupled machine in continuous sweep mode

Gough starts by demonstrating a ROTALIGN touch single-laser, double XY detector alignment system mounted on a coupled machine. The touch screen used then shows the instructions, measurements, and feedback provided as the alignment progresses. Misalignment is identified, instructions are provided to correct the feet, instant feedback given during the realignment and then re-measurement and confirmation occur.

Figure 3b. Coupling play

Figure 3b. Coupling play

In the next example, the user has not initially centered the laser into the middle of the detector area. The ASI software flags the issue before the alignment begins and coaches the user on how to correct the setup. Once that’s fixed, a coupling backlash or “play” occurs, changing the relative position of the laser during the measurement and threatening its accuracy.  In this case, the system notifies the user of coupling play and removes the inaccurate data from the final qualified measurement result.

Figure 3c. User issues

Figure 3c. User issues

If the user doesn’t perform the alignment correctly (opposite directions, rough rotations, and other problems), the system identifies the issues and filters them out. It guides the user on how to correct the problem for next time and compensates for it in the final measurement result.

 

Using single-laser technology and Active Situational Intelligence, Adaptive Alignment acclimates in real time during alignment tasks, supporting the technician and a broad range of critical rotating asset types and alignment challenges.

Get more information about Adaptive Alignment at the PRUFTECHNIK.com website. Also, learn more about the Adaptive Alignment concept and feature set in PRUFTECHNIK systems by downloading the white paper at this webpage.