TECHNICAL ORDERING DATA.pdf

ICN: 9938891002-H01 JML: 23113773

Purchase Specifications for a Laser Shaft Alignment System

Scope 1.1 These specifications cover minimum requirements for the acquisition of a Laser Shaft

Alignment System.

1.2 System Computer shall have NIST Traceable Calibration Inspection.

2.0 Equipment and Functional Requirements

2.1 Laser Emitter: The Laser Emitter shall incorporate a Class II Visible InGaAlP semiconductor laser with a nominal wave length of 635 nm, a beam diameter of 5 mm, beam divergence less than

0.3 mRad, beam power less than 1 mW, powered by a Lithium Polymer rechargeable battery.

Operating time shall not be less than 70 hours of continuous operation, or powered directly from the computer via a cabled connection, or powered directly from a supplied mains adapter/charger. The Laser Emitter shall incorporate Micro Electro Mechanical Systems (MEMs) allowing the measurement of component rotational angle and vibration, and shall transmit this information, together with battery status to the Receiver for detailed analysis of measurement quality factors. The Laser Emitter shall be enclosed in a temperaturestabilized aluminum-magnesium housing. It must be shockproof, waterproof and dustproof to an Ingress Protection rating of not less than IP-65.

2.2 The Receiver: The Receiver shall contain a 2-plane 7-parameter detector that is fully linearized throughout the entire area of the detector with a total RMS error less than 1%, with a dynamically extendible unlimited measurement range and a resolution of 1 μm (0.00004"), and angular resolution better than 2 μRad with less than 1% error. The Receiver shall be enclosed in a temperature-stabilized aluminum-magnesium housing. It must be shockproof, waterproof and dustproof to an Ingress Protection rating of not less than IP-65. Maximum measurement range between Laser and Receiver shall be not less than 33 feet. The Receiver shall NOT incorporate

Wireless Bluetooth communications capability with internal antenna. The Receiver shall incorporate Micro Electro Mechanical Systems (MEMs) allowing the measurement of component rotational angle and vibration. The Receiver shall be powered by a Lithium Polymer rechargeable battery, with an operating time of not less than 12 hours continuous use, or powered directly from the computer via a cabled connection, or powered directly from a supplied mains adapter/charger. The receiver shall perform automatic diagnostics of collected measurement data, excluding questionable readings to provide the most accurate measurement possible and provide a detailed analysis of quality factors for the measurement.

2.3 The Computer shall be waterproof, dustproof, and shockproof with an Ingress Protection rating of not less than IP-65 for industrial environments; Computer shall be capable of non-volatile memory storage of more than 1,000 machinery files with labels, comments, etc. Computer shall be capable of direct communication to printers and PC’s via a USB connection. Computer shall be able to support additional optional measurement applications as described in §5.0.

2.4 Power Supply Options: The Computer shall be powered by a Rechargeable Li-Ion battery. A housing for disposable alkaline batteries (6 × C-cell) shall be optionally available. A mains adapter and battery charger shall be included that shall allow the unit to be operated directly from mains power even when the battery is depleted.

2.5 Power Management Options: Power consumption profiles (characteristics) shall be fully editable by the user to suit the user’s particular operating preferences.

2.6 The Computer shall have a transflective backlit full VGA Color Display of not less than 4.5" ×

4.0", operated by a 520 MHz processor or better; the Computer shall have a backlit keyboard. The

Computer shall have at least 6 LEDs to visually describe laser position, measurement and tolerance status, and battery status. Computer shall have not less than 256 MB RAM, 1 GB Internal flash, 1 GB Compact flash, and shall possess hard keys for direct access to the three principal alignment task screens for DIMENSIONS, MEASUREMENT, and RESULTS.

3.0 The Alignment System

3.1 System shall be portable in a high quality molded carrying case with proper interior padding to protect all component parts.

3.2 Coupling Arrangements: The System shall allow for selection of at least four coupling arrangements: 1) Short-flex couplings; 2) spacer shafts or spoolpieces; 3) Single flex plane couplings for single-bearing machine applications; and 4) Cardan drive shafts.

3.3 Measurement Modes: The System shall have at least five measurement modes: 1) A continuous sweep measurement mode that allows alignment readings to be taken automatically and continuously as the shafts are rotated, starting in any position, and stopping in any position, and rotating in any direction; 2) Multiple points at random angles of rotation; 3) Measurement at fixed clock positions 12:00, 1:30, 3:00, 4:30, 6:00, 7:30, 9:00 and 10:30 o’clock positions for use on vertically oriented shafts and other applications; 4) Pass mode for uncoupled shafts, permitting both shafts to be rotated independently of each other while still collecting alignment readings automatically; and 5) Dial indicator measurement, with the capability to input dial indicator readings for a variety of different rim and face setups as well as a reverse indicator setup. Valid measurements with laser shall be obtainable with just 60 degrees rotation of the shafts, in either direction, and from any starting position.

3.4 Measurement Averaging: The System shall be able to extend the time over which a single data point is taken (up to 120 seconds) in order to stabilize the value obtained under severe vibration conditions.

3.5 Backlash Suppression: The system shall automatically suppress the effects of coupling backlash (rotational or torsional play) upon alignment readings and compensate for such effects through measurement quality factor analysis.

3.6 Measurement Table: The System shall be able to automatically store at least 100 measurement events (such as alignment readings or monitored machine moves) in a table. Said table shall display the Standard Deviation of all alignment readings taken, allow repeatability to be checked and shall allow multiple alignment readings to be averaged together. The averaged values shall be used for results display.

3.7 Measurement Point Analysis and Editing: The system shall permit individual reading sets within the table to be analyzed and edited by the user to permit the Standard Deviation to be improved by enabling or disabling any individual data points collected.

3.8 Date & Time: The System shall record the date and time of every measurement event in the

Measurement Table described in §3.6.

3.9 Dial Indicator Readings & Conversion: System shall be able to convert any display coupling misalignment values into dial indicator readings in any of at least five dial indicator configurations, including the Reverse Indicator configuration and several Rim & Face configurations. The system shall also accept input of dial indicators in any of at least five dial indicator configurations, including the

Reverse Indicator configuration and several Rim & Face configurations, and calculate misalignment values at the coupling from these as well as machine foot positions.

3.10 Alignment Results Display Formats (Coupling): The System shall be able to display results in any of several formats. For single-plane or short-flex couplings at least Gap/Offset or Angle/Offset; for spacer shaft couplings at least the Offset/Offset format, Angle/Angle (Alpha/Beta) format, Gap/Gap format, Gap/Offset Consolidated at the Left End of the Spacer format, Gap/Offset Consolidated at the Right End of the Spacer format, Angle/Offset Consolidated at the Left End of the Spacer format, and Angle/Offset

Consolidated at the Right End of the Spacer format.

3.11 Alignment Results Display Formats (Machine Feet and Flanges): For foot-mounted machines, the

System shall be able to display alignment position results for any or all of the machine feet in the machine train; For Flange-mounted machines the System shall be able to display offset corrections for the flange(s) and shimming corrections for the flange(s).

3.12 Machine Trains: The System shall be able to display machine trains consisting of from two to at least fourteen machines. Any of the machine feet may be designated stationary, and the moveable machine foot or feet may be on either or both sides of the stationary feet. The system shall be able to display from two to at least fourteen machines with all feet, couplings, target specifications, thermal growth values and tolerance parameters accounted for on each machine.

3.13 Static Feet and Machine Centerline Optimization: The System shall be capable of displaying an optimized centerline for the machine train through any or all of the machines in the train. The system shall allow from none to all pairs of feet to be individually fixed, and shall calculate the optimized centerline and alignment corrections for the movable feet accordingly.

3.14 Graphical result displays: The System shall allow graphical displays of alignment results to scale, including all couplings and machine feet, as well as to any of several other scaling options to include at least fixed support point separations and fixed machine lengths. The system shall be able to display the misalignment results for all configured machines simultaneously. It shall also be able to zoom views to show only horizontal or only vertical results for all machines, or for a single coupling.

3.15 Soft Foot Measurement: The system shall measure and record soft foot values. These values shall be provided on the alignment report.

3.16 Soft Foot Diagnosis: The system shall possess a “Soft Foot Wizard” capability to not only measure soft foot but also diagnose all the principal varieties of the soft foot conditions that were measured and suggest possible corrections for the soft foot condition diagnosed.

3.17 Machinery Templates: The system shall allow the user to create, configure, modify and delete alignment template files directly within the computer to facilitate ready access to preferred machine configurations with working files. Any one of these templates may be selected by the user to be the default template from which the working file is created when the Shaft Alignment application is launched.

3.18 Three-Dimensional machine setup displays: The System shall, at the user’s discretion, allow the depiction of machine icons in three-dimensional graphic form according to type of machine selected, and allow machine dimensions to be entered in this view.

3.19 Graphical machine setup displays: The System shall depict machine icons according to type of machine selected. Machines shall be configurable as to support options to have no feet, or any number of pairs of feet up to ten, or be flange-mounted on either side of the machine. Corrections are to be computed based on type of mounting, and allow for shimming the support flanges on either side of the flange. Machine flanges shall be configurable at the user’s discretion as to shape of the flange (i.e.

circular, elliptical, square, rectangular or polygonal), and shape of the support bolt pattern (i.e. circular, elliptical, square, rectangular or polygonal). The display shall include corrections for each bolt around the machinery mounting flange, having the ability to display at least 50 bolts. System must correctly show corrections, whether the mounting is on the coupling side or the reverse side of the flange. System shall be able to monitor offset corrections of the support flange(s) in real time.

3.20 Live ‘Move’ Monitoring Function: The system shall have a “live” computer-monitored “move function” to facilitate vertical and horizontal corrections without the use of dial indicators. It shall be able to monitor the move of any machine in the train, so long as at least one component (laser or receiver) of the system is mounted on the machine to be moved. The system shall permit the machine moves to be monitored with the laser and sensor in any rotational position.

3.21 Alignment Tolerances: The system shall support complete control of the tolerance display system.

The user shall be able to add, edit, or delete entire tolerance tables. The system shall have the capability to automatically evaluate the measured alignment condition and indicate whether it is out-of-tolerance, acceptable, or excellent. The system shall allow alignment tolerances to be selected from standard industry tolerance tables, or from user defined tolerance tables. In addition, the system shall allow the entry of individually editable maximum alignment tolerance values for any coupling. The system shall permit alignment tolerances to be considered as vector values or separately in the horizontal and vertical planes, at the user’s discretion. A symbol corresponding to the condition of the measured alignment with respect to the selected tolerances will appear on the computer screen, at the user’s discretion. A scaled tolerance envelope shall be displayed on the results screen, at the user’s discretion.

3.22 Sliding Velocity Tolerances: For spacer couplings, the system shall also permit alignment tolerances to be entered in the sliding velocity format.

3.23 Target Specifications at the Coupling: The system shall allow entry of target specifications for thermal growth at the coupling, in any format desired by the user for either side of the coupling.

3.24 Thermal Growth Values at Machine Supports: The system shall allow entry of expected thermal growth values at the machine supports, for any or all machines in the train.

3.25 Combination of Thermal Growth and Target Specifications: Target specifications and thermal growth values shall both be able to be considered independently and/or collectively, at the user’s discretion.

3.26 Vertically-oriented machines: The system shall take misalignment measurements on vertically oriented shafts by rotating the shafts to any three of eight 45-degree rotational positions, taken in any order. The system must be able to take readings on vertical shafts for both flange mounted and foot mounted machines alike.

3.27 Vibration Readings: The system shall permit the user to collect vibration readings directly with the built-in sensor and automatically evaluate and compare these to the ISO 10816-3 international vibration severity standard. The vibration data collected shall be color-coded to indicate where they fall with respect to the ISO 10816-3 machine classification threshold. The values shall be displayed at the measurement locations on a three-dimensional graphic of the machine train or in tabular form at the user’s discretion. This data shall be saved and printed in the alignment report.

3.28 User Preference Settings: The system shall be capable of being configured with individual operating preferences for multiple users, including an Administrator who shall retain ultimate control over the system’s principal operation settings. Alignment job files shall be saved to each user’s personal directory within the system. At a minimum, user-editable preference settings shall include unit of measure (inch or metric), unit of temperature (Degrees Celsius or Fahrenheit), Workflow assistant, and

Sound Options, and File Resume options.

3.29 User Login Settings: The system shall be capable of being configured with the individual user login credentials for multiple users, requiring each user to input a passcode upon startup of the device in order to proceed. This capability shall be configurable by the system Administrator to be enabled or disabled and visible or hidden at the Administrator’s discretion.

4.0 Brackets

4.1 Brackets: The system shall include chain-type brackets, for shaft or coupling diameter of up to 8-

1/2", with at least 5 lengths of support posts, with not less than 4 posts per length. Support posts are to be stored in a roll-up storage pouch. Brackets shall have optional lengths of chain allowing user to mount brackets on shafts and couplings of up to 20" in diameter. Brackets shall be able to be stored fully assembled in the system carrying case.

5.0 Options: The system shall offer the following as optional capabilities or add-on functionality:

5.1 Straightness & Flatness measurement applications: The system shall allow optional firmware modules to be loaded directly into the device, to permit the measurement and display of surface straightness and flatness conditions, and provide the necessary bracketing hardware to accomplish accurate straightness and flatness measurement.

5.2 Bore Alignment measurement application: The system shall allow optional firmware modules to be loaded directly into the device, to permit the measurement and display of the alignment of bores, bearing pockets, diaphragms or other circular objects positioned in sequence axially, and provide the necessary bracketing hardware to accomplish accurate bore alignment measurement.

5.3 Vibration Acceptance Check: The system shall allow vibration velocity measurements to be collected with an external vibration data collection device and have this data wirelessly transmitted to the computer for evaluation and display. The measurement data collected shall be automatically evaluated and compared to the ISO 10816-3 international vibration severity standard, and the displayed values color-coded to indicate where they fall with respect to the ISO 10816-3 machine classification threshold.

The values shall be displayed at the measurement locations on a three dimensional graphic of the machine train or in tabular form at the user’s discretion. This data shall be saved and printed in the alignment report.

5.4 Positional Change Monitoring: The system shall allow a real time or live continuous monitoring and trending of relative positional changes between running machines over time and shall display the collected data in tabular form or as a video graph that can be replayed by the user at will. The data shall also be displayed as a trend plot of horizontal and vertical shaft alignment values at the coupling and feet position values. The system shall allow the user to input a flexible selection of markers to indicate or flag events during measurement. This data shall be saved and printed in the alignment report.

5.5 Simultaneous Measurement of Machine Trains of Three or More Machines: For the fast and accurate alignment measurement of turbine trains and other multiple coupling machine trains, the system shall allow a simultaneous and continuous alignment measurement of up to five couplings in a six-machine train and also allow ‘live’ correction of the alignment condition of up to six machines simultaneously. The system shall allow wireless data transfer between the system computer and the sensors. The system shall possess a three-dimensional set-up screen for a clear view of the machines to be aligned. Different measurement modes shall be available and configurable for the simultaneous measurement of each individual coupling. In addition, the Standard Deviation of all measurements collected shall be instantly calculated and displayed at the user’s discretion for each coupling.

5.6 Microsoft Windows®-based PC software package: The system shall have available an optional PC software for moving files to and from a PC, for backup and storage of alignment data files. Said software shall be capable of creating, storing, displaying, and manipulating all machine parameters and alignment data, as well as generating alignment reports in full color both with and without graphs and graphics.

The printed report shall have the option of including the purchaser’s logo or other graphic image in several standard formats (such as JPEG, TIFF, PNG or BMP) in the report.

5.7 Tolerance Editor: The system shall allow tolerance tables to be created and edited by the user and loaded into the shaft alignment application by the user.