Maintenance of Machinery

1
 Chapter One

Introduction to Machine Installation

2
 Introduction to Machine Installation
Equipment Life – Cycle

OPERATIONAL INVOLVEMENT

MANUFACTURE COMMISSIONING OPERATION

SPECIFICATION DESIGN REPLACEMENT
INSTALLATION
- Conceptualization - Performance - Primary design - Design fault - Wear-out
- Reliabilty - Quality control fault control detection - Obsolescence
- Maintainability - Design fault - Technical - Maintenance
- Support system detection performance test optimization
- Maintainability - Maloperation
avoidance

LEARNING PERIOD

CONTINUAL FEEDBACK

Fig. 1.2 Equipment life-cycle

Figure:- Equipment Life Cycle

3
 Introduction to Machine installation

Definitions

• Machine installation refers to the process of fixing and erecting machinery

in an industrial setting to ensure that it operates effectively for productive
purposes

• Machinery installation is the process of assembling, positioning and

configuring industrial machinery and equipment within a designated area.

4
 Introduction…
• The purpose of machine installation:
• is multifaceted and essential for ensuring optimal performance and safety in industrial
operations. Here are the key objectives:
1. Operational Efficiency: Proper installation ensures that machines operate at their intended
performance levels, maximizing productivity.
2. Safety: Correct installation minimizes hazards associated with machine operation, protecting
operators and equipment from accidents.
3. Stability and Support: Establishing a solid foundation helps stabilize the machine, reducing
vibrations and wear that can lead to malfunctions or failures.
4. Alignment and Precision: Ensuring accurate alignment of machine components is vital for
maintaining precision in operations, which is critical in manufacturing processes.
5. Longevity: Proper installation contributes to the longevity of the machine by reducing stress
and wear on parts, resulting in fewer repairs and longer service life.
6. Compliance: Adhering to regulatory and industry standards during installation helps ensure
that the equipment meets safety and operational guidelines.
7. Maintenance Facilitation: A well-installed machine is easier to maintain and service,
allowing for quicker repairs and less downtime.
8. Vibration Control: Implementing isolation techniques reduces vibrations that can affect both
the machine and surrounding equipment, contributing to a safer and more efficient workspace. 5
 Introduction…

• 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

6
 Procedure for machinery installation

• A successful machinery and equipment installation involves a series of

activities:
I. Planning and Preparation
II. Location and layout;
III. Foundation;
IV. Positioning of machines;
V. Leveling and alignment;
VI. Grouting;
VII. Fitting of other parts, accessories, piping etc.;
VIII. Final leveling and test runs

7
 Procedure for … Cont’d

I. Planning and Preparation

• Before any physical work begins, a comprehensive project plan
should be established.
• This includes assessing the installation site, reviewing equipment
specifications, and identifying potential challenges.
• Safety measures should be outlined at this stage to minimize risks
during installation.

8
 Procedure for … Cont’d

II. Location and Layout

• The location of a machine depends on its purpose of installation,
definite types and sizes and other special requirements, if any.
• For example, a centrifugal pump location should be as close to the
source of water as possible when suction lift is present, or
• For a compressor location may be selected near the particular shop
where maximum air will be consumed and at the same time a clear
intake air will be available.

9
 Procedure for … Cont’d
• Moreover, the location plan should permit to have required wide space all-around
for continuing the erection work and should facilitate regular inspection, repairing,
etc.
• The location should also be finalized in such a fashion that it will not disturb or
obstruct the operation and maintenance work of other nearby machines.
• Once the location selection is finalized, the work of laying out the foundation plan
is to be undertaken.
• Laying out means marking of the foundation plan. It may be done with the help of
chalk on a concrete floor and by a string with a number of pegs
• The axis lines are to be drawn both longitudinally and crosswise to locate the
center of foundation.
• Excavation of soil may be started only when the layout is completed as per the
requirement.

10
 Procedure for … Cont’d

III. Foundation
• The shapes and sizes of the foundation differ according to the type and size
of the machines.
• They are also dependent on the property of the subsoil and the dynamic
loads of the machine during operation.
• If the weight of the installed machine is not too much or if the dynamic
loads are insignificant, the size of the foundation may be finalized on the
basis of design considerations.
• But when the dynamic loads predominant, the foundation should also serve
the purpose to protect the machine from external vibration and to lower
down the frequency of natural vibration by increasing its total mass.

11
 Procedure for … Cont’d

Dynamic and Static Loads

• For example, for a rotary machine, the following empirical formula may be
used to find out the equivalent static load (Pstatic):

Pstatic = G/g.e. (Πn/30)2kdynamic

Where, G = Weight of rotating masses.
g = acceleration due to gravity.
e = eccentricity of rotating masses.
n = Speed of the work-piece.
and ‘kdynamic ‘ is the dynamic co-efficient generally taken as 1.5 to 2.
• For a reciprocating machine, the general practice is to take the equivalent
static force as five or six times the value of cutting force.

12
 Procedure for … Cont’d

• The dimensions of the foundation block may be determined, primarily

finding out the weight of the foundation (WF) with the following
empirical formula:
• WF = KF.WM
• Where, KF is a factor, commonly taken as 2.3 for the machine tools with
dynamic load and WM is the weight of the ‘machine tool’.
• The height of the foundation = Weight of the foundation (WF) / Area of the base of
foundation X Specific weight of material.
• Of course, the height, so calculated should be sufficient enough to
accommodate the foundation bolts etc.
• The width and length of the foundation can be suitably calculated considering
the foundation drawing, its height and weight.

13
 Procedure for … Cont’d
Other Design Criteria for Foundation
• Besides the dimensions, as stated above, some other criteria are also
considered for suitable foundation work.
a. Ground Condition
• The nature of soil is obviously a vital criterion. For a hard soil or for a normal
soil, the construction of a concrete bed does not entangle too many complicacies.
It is rather most straightforward to consider the foundation plan supplied by the
manufacturer.
• But, for soft and loose soil, a large surface area with proper depth is needed for
the foundation of a machine.
• The problems encountered due to vibration may force to construct a concrete raft
(1) on piles (2), as shown in Figure 2.
14
Figure : (a) Raft on Piles; (b) Bondage of Raft with Pile.
• The main structure of the machine is erected on the piles. The piles
should have a stable and rigid bond with the raft as shown separately
in the Figure 2b.
• The bond may be a reinforced concrete having a steel-rod within it.
• For water-logged soils also, mostly the pile driven raft construction is
the means to avoid problems due to subsidence of soil.

15
 Procedure for … Cont’d
b. Vibration Consideration
• To avoid transmission of vibration to adjoining parts of buildings or other
foundations, it is necessary to provide a suitable isolation between the equipment
foundation and the joining structure.
• Usually a gap is maintained all around the foundation (like a trench), and is filled
by sand to avoid such transmission of vibration.
• Any vibration isolating material, other than sand, such as rubber, lead sheet, felt
etc. may also be used.
• As a rule, the equipment foundation shall not be allowed to serve as support for
other structures or for machineries not related to the particular equipment.
• The impact type machines, like stamping press, drop and forging hammer, need
special care during foundation. The depth of the foundation becomes very large to
make the foundation heavy.

16
 Procedure for … Cont’d
✓Figure 3a shows a sand-filled trench all-around the concrete foundation
block. Such a foundation design reduces vibration transmission.
✓Figure 3b shows that the foundation block is placed on some inserts,
below which the concrete (reinforced concrete) base is there.
✓The air gap is maintained all-around and at the same time there is an
elastic support (to provide cushioning effect) in between the foundation
block and the equipment.
✓Such a design avoids vibration transmission and absorbs shock as well. The
soft inserts may be cork or timber sleepers etc.

17
 Procedure for … Cont’d

Figure 3: (a) Sand-filled trench around foundation; (b) Soft insert below
foundation block.
C. Foundation bolts
• To install the machineries, foundation bolts will be specified and supplied
by the manufacturers. Some of the foundation bolts become rigid on
pouring concrete and some may be removable and adjustable bolts.
• A few type of foundation bolts, very commonly used, are discussed below.

18
 Procedure for … Cont’d
• Eye foundation bolts
• They are generally made of mild steel or wrought-iron and can be readily forged according to
the size. They are very much suitable to use for fastening the lids to tanks etc. (Fig. 4).

Figure 4: Eye Foundation Bolt.

• Rag bolt
• Rag bolts (Fig. 5a) are rectangular in cross-section but the width of the rectangle increases
gradually. They are having an indented or grooved edge.
• After suspension of the bolts, the gap around them may be filled up with molten lead.
• Such bolts cannot be removed easily after grouting.
19
 Procedure for … Cont’d
• Lewis bolt
• Such bolts can be removed easily, as a tapered key (1) is fitted through the side of the bolts to
make it rigid.
• It may be noted that the key is fitted on the straight face of the bolt body. (Fig. 5b)

Figure 5: (a) Rag bolt; (b) Lewis bolt.

• Cotter bolt
• To install heavy-machines, ‘cottered bolts’ are commonly used (Fig. 6a).
• A hand hold must be provided in the foundation block for the insertion of the cotter (1).
• The bolt possesses a rectangular slot to receive the cotter. A cast-iron washer (2) is also used as
a bearing surface of the cotter.
20
 Procedure for … Cont’d
• Split end bolts
• The end of these bolts are split. The bent split facilitates a rigid fixing of a
bolt.
• Such bolts are mostly used for medium-size machine tools. (Figure 6b).

Figure 6: (a) Cotter bolt; (b) Split end bolt.

21
 Procedure for … Cont’d
• Major activities of foundation work
• The foundation involves the activities like digging-up the soil (excavation), positioning of
foundation bolts, concrete mixture pouring and setting.
• Suppose the foundation plan of a ‘center lathe’ is supplied by the manufacturer as shown in
Figure (7) with proper dimensioning.

Figure 7: Foundation plan of a ‘center lathe’.

• The erection work is undertaken mostly when the foundation block has been set in and
hardened.
• The machine tool is placed on the foundation with the help of spacers or pads, leveling
wedges, etc.
22
 Procedure for … Cont’d

• Foundation plates are also supported similarly, for different machines

etc. At this time, a gap (minimum 50 to 70mm) depending on the type
of the machine is maintained between the top of the foundation block
and the bottom of the machine or base plate.
• The foundation bolts are positioned before positioning the machine
and the exact location of the machine is guided by the insertion of the
projected foundation-bolt ends through the holes, provided at the
machine footings or base plate.
• The bolt-ends should remain sufficiently projected to accommodate
the washers and nuts as well.
23
 Procedure for … Cont’d
IV. Positioning of Machines
• Positioning of the machine at the location is an important job, which
deserves care, skill an efficient teamwork.
• An equipment may have the weight of a few tons. But it is to be loaded or
unloaded, to be moved vertically or horizontally to bring it at the site and to
place it on the foundation as well.
• Different types of lifting devices like pulley blocks, chain hoists, overhead
cranes etc. may be used as per the availability and requirement.
• When the load is light, rope pulley blocks are widely used and chain pulley
blocks may be useful, but for a very heavy load, electric cranes are
generally employed.
• However, the slinging should be done with much care to avoid any impact
shock, to avoid formation of any scratches and breakages, etc

24
 Procedure for … Cont’d

• Care must be taken to sling the machine upright with weight

distributed evenly.
• Thus, the efficient fixing and passing of ropes or ‘chains’ through the
machine structure deserves skill and experience.
• Two typical slinging diagram (Fig. 1: a & b) are given for a lathe and a
vertical milling machine respectively to explain the complicacies of
slinging.

25
Figure1. (a) Slinging a Center Lathe; (b) Slinging a Universal
26
Milling Machine
 Procedure for … Cont’d
V. Leveling and Alignment
• After having the machine on the foundation, the important job is to
level and align it with other accessories.
• The leveling is performed with leveling wedges, shoes etc. as stated
before.
• The horizontal and slight vertical movements of the heavy mass of
machine is performed by pipes, rollers as shown in Fig. 8a or using
pinch bars (Fig. 8b).
• Straight edge, spiral level, dial indicator etc., are generally useful instruments
to level the machine.
• The leveling is to be checked in the both, longitudinal and transverse
direction.
27
Figure 8: (a) Rolling of Load, (b) Lifting of Load. 28
 Procedure for … Cont’d

• The parallelism, perpendicularity of different faces, axes should be

leveled and aligned, as are required.
• When leveling is completed, the foundation bolt cavity along with the
bolt may be made concreted. Pouring of cement concrete is generally
made through the gap provided at the top of the foundation, as shown
in Fig. 9.
• This concreting will provide a bondage of the foundation bolts with
the foundation block while performing grouting, discussed later.

29
 Procedure for … Cont’d

• Whenever, the foundation block is continuously made for a connected

accessory, (say, the alternator with the turbine) the relative alignment
should be established before concreting the foundation bolts.

Figure 9: Pouring concrete in bolt cavity.

30
 Procedure for … Cont’d

VI. Grouting
• Grouting is a procedure of connecting the machine with the foundation
by a concrete mixture of plastic consistency or cement mortar. It is
extensively used in installing most of the machines.
• Generally, a quick setting cement is used to perform grouting. The top
of the foundation block is made roughened, made moistened with
water and wooden partitions are placed all around the machine.
• The heights of such wooden boards are kept much higher than the gap
between the top or the foundation and the bottom of the machine.

31
 Procedure for … Cont’d

• Quick setting cement is then poured within the boundary with care to eliminate
any air gap within it.
• Once started, the pouring should be completed continuously and the machine must
be felt undisturbed for a few days after grouting to provide it time to set.

32
 Procedure for … Cont’d
VII. Fitting of other parts
• When the machine is erected, the other accessories may be joined
accordingly. But, while laying out the foundation plan, the overall
requirement should be kept in mind.
• Connect power sources, hydraulic systems, and other necessary
components as specified in the equipment’s documentation. Check for
proper wiring and ensure all connections are secure
• The auxiliary structures e.g. in case of a heavy-duty diesel engine
foundation, the structures for outer bearing pedestal, water pump
blocks etc. should be planned at a time.

33
 Procedure for … Cont’d

VII. Final leveling and test runs

• Accurate leveling can be carried out only when the grouting has set in
after a few days.
• The machine is to be made cleaned and leveled then. Such leveling
involves minor adjustments.

34
 Procedure for … Cont’d

• Everything should now be made ready to carry the test run. The style
of testing will differ from machine to machine.
• For instance, for metal-cutting machine tools, they are always sent out with a
test chart.
• ‘Test chart’ may be defined as the specification of accuracies of major
typical points like
• ‘straightness of guide ways’ ‘Trueness of spindles’ etc. which should
exist for the desired functioning of the respective machines.
• The accuracy shown in the chart will be reobtained only if the machine
is correctly erected and leveled.

35
 Responsibilities of an installer of machinery and
equipment
What are the responsibilities of an installer of machinery and equipment?
• The machine installer holds a critical role in the installation process, encompassing various responsibilities:
• Expertise: Installers should have a deep understanding of the machinery they are working with, including
its technical specifications and operational requirements.
• Safety: Ensuring the safety of all personnel involved is paramount. should adhere to safety protocols, wear
appropriate personal protective equipment (PPE), and conduct regular safety assessments.
• Precision: Machinery installers must demonstrate precision and attention to detail during alignment,
assembly, and connection tasks. Small errors during installation can lead to significant operational
problems later on.
• Documentation: Keep thorough records of the installation process, including measurements,
configurations, and test results. Proper documentation facilitates troubleshooting and maintenance in the
future.
• Communication: Effective communication with the client, equipment manufacturers, and other
stakeholders is essential to ensure a smooth installation process.
• Machinery installation is a complex process that requires careful planning, technical expertise, and a strong
commitment to safety. By following the key steps outlined in this article, installers can ensure that industrial
machinery installations are set up for optimal performance and longevity.
36
Thank you!
?

37