To begin with, GE turbines are complex machines that contain numerous components. When these components are not accurately aligned, it can result in increased wear and tear, vibration, and other issues that can compromise the performance of the turbine. This is where laser trackers come in.

Laser trackers are a powerful tool that can be used to ensure the internal alignment of GE turbines. These devices use lasers to measure the position and orientation of various components, providing highly accurate measurements that can be used to align the components of the turbine. The laser tracker is set up and calibrated to ensure that it is providing accurate measurements. Then, the laser tracker is used to measure the position and orientation of various components of the turbine, such as the bearings, casings, and seals.

Once the measurements are taken, they are used to calculate the adjustments needed to ensure that the components of the turbine are accurately aligned. These adjustments can be made by adjusting the position of the components, such as by machining down shims or making other modifications. By providing highly accurate measurements, laser trackers reduce the need for trial-and-error adjustments, which can be time-consuming and costly.

The benefits of internal alignment of a GE turbine utilizing laser trackers are many. First and foremost, this process ensures that the turbine is operating at peak performance, reducing wear and tear, and extending the lifespan of the turbine. It also helps to reduce vibration and other issues that can compromise the performance of the turbine. Additionally, internal alignment using laser trackers is a highly efficient process that can save time and money.

In conclusion, Internal alignment of a GE turbine utilizing laser trackers is an essential process that can have a significant impact on the performance and lifespan of the turbine. With the help of laser trackers, this process can be carried out efficiently and accurately, ensuring that the turbine is operating at peak performance and delivering the power and reliability that it was designed for.

Contact us for further information, questions, or a competitive estimate.

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Preserving turbines in optimal working condition and prolonging their lifespan is achieved through diligent turbine preventive maintenance. In industries heavily reliant on machinery, this type of maintenance guarantees that potential issues are addressed early, preventing them from escalating into significant problems that result in expensive interruptions. Meanwhile, consistently conducting alignment assessments is crucial to avert unplanned turbine repair work.

Why Does Misalignment Cause Issues?

Essentially, the entire issue lies in misalignment,

which is the leading cause of failure for turbines and other rotating machinery. Improperly aligned shafts result in heightened vibration, rotor distortion, and a domino effect of issues that culminate in early bearing failure and diminished seal longevity. As misalignment is a progressive problem, ignoring it can ultimately lead to complete equipment breakdown and the necessity for replacement. For that reason, prioritizing turbine preventive maintenance is fundamental in addressing this concern.

Precision Shaft Alignment for Turbine

Turbine preventive maintenance must incorporate accurate shaft alignment as a key aspect. Diligently observing components and conditions enables equipment operators to decrease the frequency of unforeseen turbine repairs. Key monitoring elements encompass flow rate, vibration, lubrication & lubricant, rotor speed, load, power, noise levels, and auxiliary system functioning. Recognizing shifts in these factors can assist in identifying early signs of alignment issues.

On the other hand, various causes can lead to shaft misalignments in turbines, such as alterations in thermal growth, piping stress, or misalignment during installation or overhaul.

Turbine Preventive Maintenance: Striking a Balance!

Alignment is critical to turbine preventive maintenance, ensuring the motor shaft’s centerline aligns with the drive shaft’s centerline. There are two primary types of misalignment: parallel or radial, further categorized as vertical or horizontal, and angular, also classified as vertical or horizontal. Misalignment may be caused by offset, angular, or a combination of both factors.

In parallel misalignment, the motor and drive shafts either move away from each other vertically while remaining on the horizontal plane (parallel vertical misalignment) or horizontally while staying parallel on the horizontal plane (parallel horizontal misalignment). Angular misalignment occurs when the shafts are at angles to one another, either on the vertical plane (angular vertical misalignment) or the horizontal plane (angular horizontal misalignment).

Although turbine preventative maintenance could cause an interruption in operations, the cost savings that occur from the subsequent decrease in the number of turbine repairs are considerable. There are two primary methods for performing alignments: static and dynamic.

Static

During this turbine preventive maintenance, equipment alignment typically occurs when the machine is inactive. Addressing soft foot problems, significant misalignment, and restoring the system to optimal tolerance levels are best accomplished during this static alignment phase.

Dynamic

During this type of turbine preventive maintenance, shaft alignment is conducted while the machinery remains in operation. This is favored among the two alignment methods since it allows technicians to observe alterations, thermal expansion, and shaft displacement as the equipment functions. The machine’s transition from a “cold-to-operating” state is determined and incorporated within the alignment parameters by implementing dynamic alignment. Eventually, this contributes to establishing precise tolerance differences, facilitating proactive monitoring.

Final Words

Regardless of the method used for attaining alignment, remember that most machines have stringent requirements regarding the tolerant range of alignment deviations. This highlights the importance of accurate shaft alignment in turbine preventive maintenance and restoration efforts.

Select Laser Alignment is the company to call for precise alignment and preventative maintenance on your turbines and other rotating equipment. Our focus is restoring and maintaining your rotating machinery’s optimal operation. Contact us if you want to find out how we can assist you.

The post Why Turbine Maintenance Needs Alignment appeared first on Select Laser Alignment.

When the manufacturing process is stopped due to machine misalignment, companies risk losing a significant amount of investment in the form of time delay and scraps. However, these costs can be avoided if companies take careful ownership of preventative maintenance, minimizing the likelihood of equipment failure or downtime drastically.

In fact, by adopting the preventative maintenance approach, quality management departments can also better ensure that products leaving the facility meet quality benchmarks, as well-maintained machines are the foundation of manufacturing processes. Besides, machine alignment significantly increases the lifespan of tools, which can be expensive to replace. For these reasons, companies have found it necessary to perform machine alignment regularly and efficiently.

Single-use tools vs. multi-function device

In the past, companies used to rely on traditional alignment methods that involved tools such as machinist levels, piano or tight wires, and optics (e.g., bore scopes, theodolites, etc.). While these tools worked well in most cases, they often served only single, dedicated function. Using these methods, calibration, and alignment would typically take days or even weeks to complete. It was also common to involve multiple instruments, which translated to higher costs and more time spent on setting up in each step.

Naturally, companies sought out better and faster ways for machine alignment to be done. In the early nineties, the use of laser trackers for industrial measurement became widespread. Compared to traditional methods, the laser tracker is a powerful device that can perform multiple measurement tasks in a much shorter time. By gathering X,Y,Z coordinates with the click of a button.

This device combines the capabilities of several traditional tools in one, including the ability to: check for plumb, level, squareness, and parallelism; verify and conduct positional checks of rotary axes and multi-axis heads; reposition a part on a table without a rotational bed; perform real-time adjustments of machine beds, rails, and ways; as well as measure bore alignment, coupling, and shaft alignment. More importantly, the laser tracker captures data points in a three-dimensional (3D) space, which provides users with higher precision and versatility in data usage.

Basic mechanics of a laser tracker

The laser tracker is a portable coordinate measuring machine (CMM) that is based on 3D coordinate technology. Fundamentally, these devices provide the benefits of CMMs with the added versatility of being portable, which allows the user to deploy wherever there is a need. Designed to handle larger working volumes, laser trackers offer extremely accurate measurements over long ranges. Put simply, a laser tracker establishes the precise location of a target in spherical space by measuring two angles and a distance, each time it takes a measurement. It does so by sending a laser beam to a retro-reflective target, which must be held against the object being measured. The return beam re-enters the laser tracker where the distance to the target can be determined using interferometry or phase shift analysis.

The horizontal and vertical angles to the target probe are determined using precision angular encoders attached to the mechanical axis of a gimbaled beam steering mechanism. Using the two angle measurements and distance determined by the laser, the laser tracker can report the coordinate location of the target probe to extremely high accuracy levels.

In addition, the laser tracker can follow or track the target probe as it moves in real time. This unique feature, coupled with the laser tracker’s ability to internally sample up to 16,000 times per second, enables the user to digitize data on complex surfaces or measure the location of moving objects.

In fact, laser trackers today have impressive measurement ranges and accuracies that provide users with more versatility and better results. For instance, the FARO^® Laser Tracker Vantage’s distance measuring range is 80m both ways (160m coverage), and at that range, it captures data at typical accuracies of up to 39 microns (0.039mm / 0.001”). Weighing just under 18kg, the Vantage offers portability and flexibility on measuring large parts, no matter where production is located within the plant. Manufacturers can achieve unprecedented speed and efficiency by capturing more with fewer device moves and shorter routines.

Laser Tracker in Machine Alignment Scenarios

The American Society of Mechanical Engineering established a set of standards for the correct and accepted methods to check and align machine tools with a laser tracker. Here are some documented scenarios of alignment being performed on a variety of machining centers, machinery, and other equipment.

American Society of Mechanical Engineering, ASME B5.54-2005 Methods for Performance Evaluation of Computer Numerically Controlled Machining Centers, 2005.

1. Machining Centers

Horizontal/Vertical Machines, Bridge, Column, or Gantry-type Machines

On these machines, the laser tracker can be used to check for surface level, straightness, flatness, and squareness. The target is placed on the machine bed to capture measurements, and users can either adjustments in real-time, or obtain a complete set of points before adjusting the machine bed afterwards.

For tool alignment, the target can be placed in the spindle, chuck, or quill of the machining center. Measurements can also be obtained by placing the target on a pin nest that gets mounted directly into the drill of the machine. Alternatively, it can also be placed in a ‘puck’, or a drift nest, which can be glued on to a moving bed. As the target sits on its respective locations, 3D data points are collected while the machine travels through a range of movements to check for alignment issues. Apart from checking the machine bed, the laser tracker can also be used to check for plumb, level, or ensure parallelism in the rails. Additionally, conducting 3D volumetric accuracy checks and re-mapping the machine are possible functions.

Boring Mills, Jig Borers, Gantry Drills, Routers, and Lathes

The same checks of levelling, squareness, alignment, and 3D volumetric accuracy checks can be made on these machines. For lathes laser trackers can perform turning center alignment by tracking a target that is affixed on to the headstock with a drift nest. Much like how machine beds are measured, data points are collected as the headstock turns, moving incrementally towards the tailstock in a circular fashion. Adjustments are then made to align the tailstock with the headstock accordingly.

2. Machinery

Presses – Platen, Stamping, and Brake Press

With presses, laser trackers are useful for checking perpendicularity and parallelism of posts, as well as platen parallelism. The ends of each pole on each side of the planes are measured and compared to ensure it lines up square (between pole and plane) and parallel (between planes) respectively. Any deviation can be corrected based on the readings acquired.

Rolls

Laser trackers are also effective at conducting shaft alignment checks in roller mill machinery. Shafts need to be in proper alignment and orientation in order to function well, and the laser tracker allows such checks to be performed easily on a roll (or series of rolls). Real-time adjustments can be made as measurements are being taken. Data points at both ends of a shaft are acquired by placing the target on the cylinder. The information collected by the software allows users to identify the movement that is required to put each roll back into alignment.

3. Other Equipment

Calibration of Robots

In this application, the target is ‘held’ by the robot while measurements are being taken. The laser tracker dynamically tracks the target as the robot moves through its programed path. By analyzing the data points, a user can tell how much the robot has deviated from its nominal path, thereby directing him on remapping, calibration, or error compensation actions that will allow the robot to move properly through its range of motions.

Drivelines – including Gearboxes, Shafts, and Couplings

In the assembly of power generation equipment like a driveline, the laser tracker can ensure that components are lined up correctly, according to design. The laser tracker is mounted with a magnet to hang off the side of a machine, so that it has a direct line of sight to all the features of interest. In this manner, the laser tracker can take measurements of the driveline while it remains on the machine tool. As checks are being made right on the shop floor, adjustments can be made without taking the set-up apart, which saves time and eliminates the need for rework.

Evidently, the laser tracker is an effective complement for the practice of preventative maintenance, which reduces downtime, enables cost-savings, and improves the quality of output. It is a robust tool that can be deployed anywhere on the shop floor, the laser tracker’s multiple functions can suitably replace a variety of hand tools. At Select Laser Alignment we have vast experience in utilizing laser trackers to their full capabilities and can align anything, anywhere, anytime. Give us a call.

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How often should alignment checks be performed?

There are guidelines for how often the alignment should be checked. According to Mr. John Piotrowski and his Shaft Alignment Handbook, for newly installed machinery the alignment should be checked following 500 to 2000 hours of off and on operation, or 1–3 months of nonstop operation. If there was no found shift in the alignment, then the following check should be made between 4500 and 9000 hours of off and on operation or 6 months to 1 year of nonstop operation. If no found shift occurred at any time, then measurements should be made every 2–3 years. This pace can of course be influenced by factors such as equipment importance etc.

If a mediocre shift in alignment happened at any time, then the equipment should be aligned to within tolerances. If a massive shift happened, then additional research should begin to determine what is causing the movement (root cause analysis). For example, any sign of excessive wear will also be a sign of “inadequate” machinery installation.

The importance of reporting.

To have reports on alignment checks is critical to avoid repeating the same install errors, or to find and follow up on the same problems over and over. As you of course know, there is no precise answer to the headline question. But the reporting will give you a solid understanding of what occurs on the way and help to keep your machinery aligned in optimal conditions as long as possible. We will provide you with an in-depth written report and drawings on every alignment check to compare as the equipment ages.

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