Chapter 9 Machine Installation in maintenance.ppt

it is about machine installation

1. Machine Installation and
Maintenance
Chapter 9
MACHINE INSTALLATION and
SAFEGUARDING

2. Introduction to Machine Installation
Objectives:
•Define concepts of machine installation and safeguarding
•Introduce requirements of foundation, Anchoring
methods, Leveling, Machine Alignment, and Isolation of
Foundations

3. Introduction to Machine Installation
Life Cycle Costing Profile

4. Introduction to Machine Installation
Machine:
It is a device that takes some energy as input and
transforms it to another useful form of energy
as output.
Machine Installation:
It is the process of fixing and erecting the
machinery in an industryso that they can be put
to use for productive purposes

5. Introduction … Cont’d
Why Machine installation is necessary?
It isthe first step in the productive process of any newly
established plant.
Where to install machinery?
The installation of light machinery used for domestic usemay
not require any expertise, where as the installation of the
machinery used in the industryneed attention as the
performance of the machinery largely depend upon proper
installation.
How to install machinery?
The installation process may differ from machine to machine
and it is largely depend upon the main specifications of the
machines to be installed.

6. Introduction … Cont’d
Factors to be considered before installing the
machinery
It is important that as much information as possible be
supplied regarding the machine to be installed, this will
include:
•Machine size and weights
•Any dynamic features of its operation
•Location including ground type, condition where optimal
performance is required
•Vibration analysis of the machine
•Site conditions

7. Introduction … Cont’d
FOUNDATION REQUIREMENTS
•Building Foundations

8. Introduction … Cont’d
Machine Foundations
The main purpose of machine foundations is to stabilize the
machine as well as to reduce the vibrations caused due to the
operation of the machine.
The foundation thus positively influences machine vibrationby
reducing the amplitude of oscillation.
Thefirststepinmachineinstallationistofindoutwhetheritis
requiredtobuildaspecialfoundationforinstallationoritis
possibletousetheexistingfloor.

9. Introduction … Cont’d
Foundation Requirements for machine installation
If the existing floor, where the machinery is to be installed, does
not meet the following minimum requirements, It is required to
build a foundation.
•The area of the floor where the machine frame is to be located
must be a single, homogeneous slab in good condition.
•The floor must be 4" to 6" thick(It is not a constant and may
change depending upon the type and weight of machinery).
•The floor must be capable of supporting3.5 tons/ft²(This is also
not a constant one and may subject to change depending upon
the type of machine going to be installed and the floor must be
level to 0.032"/ft).

10. Introduction … Cont’d
Methods of machine installation
There are two types of machine installations in practice, which
include both foundation anchoringand floor installation
procedures. The following sections will explain these methods.
Foundation Anchoring Procedure
Installing the machine
using foundation & J-bolt

11. Introduction … Cont’d
Floor anchoring method
Installing the machine using
existing floor & J-bolt

12. Introduction … Cont’d
Foundation / Floor J-bolt Mounting Procedure
Step 1.Saw cut or Core drill a hole in
the existing floor and remove the
underlying dirt to the required 24" depth.
Step 2.Set base plate over the hole
Step 3.Set the machine on the
base plate
Step 4.Set the J-bolt through the hole
in machine foot, attach washer and
nut to hold J-bolt in place.

13. Introduction … Cont’d
Foundation / Floor J-bolt Mounting Procedure
Step 5.Pour the Concrete. Ensure that the J-bolt remains correctly
aligned to the machine frame during the pouring and hardening time of
the concrete. Ensure that the concrete level is equal to the floor level
Step 6.To complete the mounting procedure, level the machine frame by
inserting leveling shims between the machine foot and base plate.

14. Introduction … Cont’d
MACHINE LEVELING
Proper Machine leveling is critical in the machine installation
for the desired machine performance.
Thetermleveling,withrespecttomachineryinstallation,
meanstheoperationofplacingmachineryorequipmenton
atruehorizontalplane.
The following materials and tools are
required for machine:
•Leveling shim stock
•Anchor bolts
•Spirit level capable of reading 0.0005"/ft
•One (1) 12 ton hydraulic bottle jack

15. Introduction … Cont’d
MACHINE LEVELING
Floor Condition: Crowned
Floor Condition: Sloped

16. Introduction … Cont’d
ALIGNMENT OF SHAFTS
Proper shaft alignment is achieved when the two centerlines
of coupled machinery are the same or collinear.
There are two types of coupling or shaft misalignment:
angular misalignment and parallel misalignment

17. Introduction … Cont’d
Angular misalignmentis a condition where two shaft
centerlines are at an angle to each other.
Parallel misalignmentis a condition where no angular
misalignment exists and the shafts are parallel, but offset
from each other.

18. Introduction … Cont’d
Four basic steps are required to correct misalignment:
1. Correct for angular misalignment in the side view plane
2. Correct for parallel misalignment
in the side view plane

19. Introduction … Cont’d
3. Correct for angular misalignment in the top view plane
4. Correct for parallel misalignment
in the top view plane

20. Introduction … Cont’d
FOUNDATION ISOLATION
Vibrations caused by the operations of machinery are partially
arrested by proper machine levelingand alignment.
In the case of heavy-duty machinerythese vibrations are so
strongthat they require additional setups to get arrested.
In addition to the machineryand equipment, subways, trains,
streetcars–are all sources of vibration in buildings and
structures.
Foundation and vibration isolationsare done to reduce the
vibrations produced by the machinery (also buildings and
structures) after installation.

21. Introduction … Cont’d
Foundation Isolation for Machinery and Equipment
Foundation insulation by using GK Block

22. Introduction … Cont’d
Foundation insulation by using insulation plates

23. Introduction … Cont’d
Shock Absorbers
Vibration insulation methods using Anti-Vibration Mountings
Anti-Vibration Waffle Pads

24. Introduction … Cont’d
Titan Shock Pads
Combination Press Pads

25. Introduction … Cont’d
SAW Vibration Mount

26. Basics of Machine Safeguarding
Introduction to Machine safeguarding
Safeguards are essential for protecting workers from
needless and preventable injuries.
A good rule to remember :
Any machine part, function or process that may cause injury
must be safeguarded.
Which part of machinery is to be safeguarded?
•The Point of Operation
•Power Transmission Apparatus
•Other Moving Parts

27. Basics of …Cont’d
Hazardous Mechanical Motions and Actions
Rotating motion
Examples of Typical Rotating Mechanisms
Examples of In-running Nip Points—Parallel Axes, Rotation in Opposite Directions

28. Basics of …Cont’d
Reciprocating motion Transversemotion
Cutting Action
Examples of Cutting Actions that can present hazards

29. Basics of …Cont’d
Punching Action Shearing Action
Bending Action

30. Basics of …Cont’d
Requirements for Safeguards
•Prevent Contact
•Be Secured to the Machine
•Protect From Falling Objects
•Not Create New Hazards
•Not Interfere With Job Performance
•Allow for Safe Lubrication of the Machine

31. Basics of …Cont’d
Methods of Machine Safeguarding