METHOD OF DETERMINING OPTIMAL TORQUE OF A FOUNDATION FASTENER

Abstract

A method of determining and verifying an acceptable torque value for a foundation fastener used to secure a pair of adjacently located rotating machines having their shafts coupled together. An alignment engineer enters characteristics respective to a proposed foundation fastener into a software directed processing device. The processor analyzes the fastener characteristics when applied to the specific application of the adjacently located rotating machines to determine a target torque value. The processing device utilizes the calculated torque to determine an anticipated elongation of the fastener. The anticipated elongation is compared to an acceptable elongation range to determine if the proposed target torque value is acceptable. Once the software determines the proposed fastener and target torque value are acceptable for the application, the software informs the alignment engineer accordingly.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a National Stage patent application claiming the benefit of International Application Number PCT/EP2011/073808 filed on 22 Dec. 2011, which claims priority to United States Non-Provisional application Ser. No. 13/331,368 filed on Dec. 20, 2011, and U.S. Provisional Patent Application Ser. No. 61/426,089, filed on Dec. 22, 2010, which are incorporated herein in their entireties by reference.

BACKGROUND OF THE INVENTION

1. Technical Field of the Invention

The present invention relates to a process of aligning and retaining alignment of a series of rotating equipment coupled together for cooperative operation. More specifically, a method of determining an optimal torque value for footing or foundation bolts.

2. Background Art

Rotating machinery, equipment, or other devices can be provided in many form factors, such as an electrical motor, a combustion motor, a pump, a transmission or other gear box, and the like. Rotating equipment is commonly configured coupling at least two rotating devices together, referred to as a machine train. The configuration can couple two or more like devices together, such as motors, pumps, and the like to provide serial addition of power or parallel functionality, respectively. Alternatively, the configuration can couple two or more dissimilar devices together, such as coupling a motor and a transmission, coupling a motor and a pump, and the like to provide joint functionality. In any configuration, alignment between two adjacent components impacts the efficiency and reliability of the equipment.

Many factors can impact alignment between equipment. Alignment of the equipment dictates that the equipment remains stationary, and thus the alignment process is completed when the equipment is completion in a non-operational state. Additionally, the alignment process is commonly completed in an ambient environment. Unfortunately, this requirement removes a number of variables, which impact the alignment during operation, where those variables are only present during operation. Examples include thermal effects on each element of the equipment, balance of rotating elements, changes in compressive components such as soft feet, changes due to torsional effects, and the like. The operational environment commonly changes in temperature, which affects the mounting area, the equipment, and the like. In most operational scenarios, the equipment and operating environment increases in temperature, impacting the alignment between adjacent equipment.

Each individual machine arrangement is different resulting from each arrangements unique characteristics. Even identical sets of machinery can dictate different terms for alignment. Factors of each configuration including location, mounting schematics, and the like affect the alignment.

Laser alignment was introduced in the 1980's. This process utilized one or more diode lasers and detectors (PSD's). The PSD's were able to detect fairly accurately (within 10 μm's) relative positioning between two adjacent shafts. Information is provided to the service person through a display unit. The system determines what information needs to be conveyed to the service person in order to direct the service person on what is required to optimize alignment between two adjacent components. The display unit can be provided in any of many known form factors, including a computer, preferably comprising a wireless interface. Software converts the detector signals into a set of instructions in an understandable format for the operator or service person. Alignment or registration between two adjacent components is commonly defined in two components:

• • A. Angular misalignment
  • B. Parallel or offset misalignment

Parallel registration can be defined in two directions, horizontal and vertical, basically referring to respectively X-axis and Y-axis.

Another component that could be considered is end-to-end registration, ensuring sufficient gap is provided for thermal expansion, vibration, and the like.

The fundamental setup of the laser alignment instrumentation has remained unchanged since its inception in the 1980's, including a diode laser based system with a detector and a portable computer with standard alignment software.

As technology has evolved, the technological advances have been integrated into the process. Examples include the introduction of wireless technology changed the method of data transfer from the laser/detector to the portable computer, by removing cables previously connecting therebetween. Although technology has advanced and aided the user in certain areas, the overall fundamentals of the process, including the hardware and respective software have remained unchanged over the years.

Most craftspeople that align machinery already understand the phenomenon of what is usually called machinery “soft foot.” Soft Foot is a common term used for machine frame distortion. The distortion is caused when one or more feet of a machine differ in height from the others. This in turn may be due to differences when the machine was manufactured, a squishy footage with oil film etc. between foot and base, a bent foot, or it may be induced by a pipe to which the machine is attached (e.g. a pipe on top of a pump), which prevents the machine from touching all its feet to its base.

As many vibration specialists have never actually aligned machinery, they may have heard of “soft feet” but may not always understand the result in vibration. Soft feet can cause increased vibration amplitudes. Although “soft feet” does not necessarily magnify machine vibration, it should be reduced for many reasons, including preventing vibration magnification.

The current alignment process includes the following steps:

• • A. Position alignment equipment as directed for aligning two adjacent rotating machines;
  • B. Measure the soft foot;
  • C. Correct the soft foot;
  • D. Measure the current alignment;
  • E. Enter a tolerance into the software, wherein the tolerance may be a target;
  • F. Correct any misalignment between two adjacent rotating machines until the alignment is within the established tolerance or target; and
  • G. Record the measurements, such as entering the measurements into an electronic database and optionally uploading the information to a remote database.

It is well know that unless soft foot conditions are checked, alignment may be impossible or the improvement in alignment may be short-lived.

The current alignment process is dependent upon the experience level of the alignment engineer. Most experienced alignment engineers are disappearing. Each configuration between adjacent rotating machines is different, thus being unique in alignment. The level of experience of the alignment engineer impacts the time and quality of the alignment. Lack of knowledge respective to the details is only a portion of the problem. The lack of awareness that results in not searching for the answer contributes to the problem. Another contributing factor is when the alignment engineer fails to apply the correct details, which is certainly a problem.

One of the components adjusted during the alignment process is the threaded mounting fastener used as the holding down bolts or foundation bolts. Alignment of a pair of adjacently located rotating machinery having shafts coupled together (such as via the inter-machine coupler) utilizes a scope of activities that altogether should result in a correct, sustainable alignment during an operational condition of the rotating machinery. Providing a sustainable alignment is a key concern to ensure extended, reliable functionality of the rotating machinery. One primary contributor to the sustainable alignment is an installation of the threaded mounting fastener used as the holding down bolts or foundation bolts. The alignment operator usually does not know what the correct torque force is to secure the bolts properly. This forms a risk for the machine owner. There is an increased probability that bolts come loose due to a too low tension in the bolt or break due to a too high tension (bolt gets “overstretched”).

Thus, what is desired is a process to identify the most optimum torque value and related stretch of a clamping portion of a threaded shaft of the threaded mounting fasteners and a process to ensure the desired torque is applied.

DISCLOSURE OF THE INVENTION

The present invention is directed to a method of determining a target bolt torque and acceptable elongation respective to mounting of two adjacent rotating machines in conjunction with an alignment process.

In a first aspect of the present invention, a method of determining a target bolt torque value comprising steps of:

• • obtaining a computing device comprising a microprocessor, a digital data storage device, a user input interface enabling an alignment engineer to enter data, a display for providing information to the alignment engineer, circuitry providing operable interconnectivity between components, an instruction set provided in a form of a torque calculation and verification software program, and respective power to operate the computing device;
  • entering fastener specifications of a proposed foundation fastener into the torque calculation and verification software program;
  • entering a clamping dimension into the torque calculation and verification software program;
  • calculating a target value for a torque for use during installation of the proposed foundation fastener;
  • completing an alignment process for aligning a pair of coupled shafts of adjacently located rotating machines; and
  • securing the adjacently located rotating machines in position by installing the proposed foundation fastener to secure the adjacently located rotating machines in position.

A second aspect of the present invention, a method of determining a target bolt torque value comprising steps of:

• • obtaining a computing device comprising a microprocessor, a digital data storage device, a user input interface enabling an alignment engineer to enter data, a display for providing information to the alignment engineer, circuitry providing operable interconnectivity between components, an instruction set provided in a form of torque calculation and elongation verification software program, and respective power to operate the computing device;
  • entering fastener specifications of a proposed foundation fastener into the torque calculation and verification software program;
  • entering a clamping dimension into the torque calculation and verification software program;
  • calculating a target value for a torque for use during installation of the proposed foundation fastener;
  • determining a stretch of the proposed foundation fastener;
  • completing an alignment process for aligning a pair of coupled shafts of adjacently located rotating machines; and
  • securing the adjacently located rotating machines in position by installing the proposed foundation fastener to secure the adjacently located rotating machines in position.

These and other features, aspects, and advantages of the invention will be further understood and appreciated by those skilled in the art by reference to the following written specification, claims and appended drawings, which follow.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature of the present invention, reference should be made to the accompanying drawings in which:

FIG. 1 presents an elevation view of an exemplary pair of adjacent rotating machines illustrated in desired alignment;

FIG. 2 presents an elevation view of the exemplary pair of adjacent rotating machines introduced in FIG. 1, the illustration demonstrating parallel misalignment therebetween in accordance with a vertical registration;

FIG. 3 presents an elevation view of the exemplary pair of adjacent rotating machines introduced in FIG. 1, the illustration demonstrating angular misalignment therebetween;

FIG. 4 presents a top view of the exemplary pair of adjacent rotating machines originally introduced in FIG. 1, the illustration demonstrating a desired alignment therebetween;

FIG. 5 presents a top view of the exemplary pair of adjacent rotating machines introduced in FIG. 4, the illustration demonstrating parallel misalignment therebetween in accordance with a horizontal registration;

FIG. 6 presents a top view of the exemplary pair of adjacent rotating machines introduced in FIG. 4, the illustration demonstrating angular misalignment therebetween;

FIG. 7 presents an exemplary alignment overview block flow diagram;

FIG. 8 presents an exemplary set of monitored conditions used for predicting and optimizing alignment between coupled machines;

FIG. 9 presents an exemplary generic process for each individual machine;

FIG. 10 presents an exemplary side sectioned view of an exemplary foundation bolt securing a mounting foot to a foundation;

FIG. 11 presents an exemplary threaded mounting fastener shown representative of a preinstalled state and a respective tensioned state; and

FIG. 12 presents an exemplary bolt torque calculation and elongation confirmation process flow diagram.

Like reference numerals refer to like parts throughout the several views of the drawings.

MODES FOR CARRYING OUT THE INVENTION

The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. For purposes of description herein, the terms “upper”, “lower”, “left”, “rear”, “right”, “front”, “vertical”, “horizontal”, and derivatives thereof shall relate to the invention as oriented in FIG. 1. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

Rotating machinery commonly involves coupling adjacent machines together for operation as illustrated in FIGS. 1 through 6. Misalignment between adjacent rotating machines can impact the configuration in a variety of ways, including premature failure. The following are examples of the impact of premature failure caused by misaligned machinery:

Increased frequency of replacing parts, such as bearings, couplings, seals, and the like, which result in additional operational costs including replacement parts and labor;

Increased logistic costs, including materials procurement, inventory holding costs, materials management costs, and the like;

Increased frequency of interventions, including man hours, materials, tools, transportation, and the like, and thus adding associated intervention costs to the overall operating budget; and

• • where applicable, impacts from resultant downtime of the machinery, including reduction in productivity, reduced labor efficiencies (revenue per labor cost), reduced real estate efficiency (revenue per area of real estate), lost revenue, and the like.

Alignment of the rotating machinery is accomplished while the machinery is in a non-operational state. The alignment process considers any relation between two adjacent pieces of rotating machines. The term machine can refer to any device comprising a rotating mechanism, and should be considered synonymous with machine, equipment, device, apparatus, and the like.

In the exemplary embodiment, a mounted first rotating machine assembly 100 is located adjacent to a mounted second rotating machine assembly 150. The exemplary mounted first rotating machine assembly 100 and mounted second rotating machine assembly 150 are motors, wherein it can be appreciated by those skilled in the art that the mounted first rotating machine assembly 100 and mounted second rotating machine assembly 150 are only exemplary and could include any rotating machinery, including electrically operated motors, combustion motors, transmissions, pumps, and the like.

The mounted first rotating machine assembly 100 and mounted second rotating machine assembly 150 are mounted upon a surface by a series of mounting feet 112, 114, 162, 164. The mounting feet 112, 114, 162, 164 enable adjustments for alignment, absorb vibrational energy, and support the mounted rotating machine assemblies 100, 150. Each rotating machine assembly 100, 150 includes a rotating shaft. The rotating shaft can extend outward from one or both ends of the rotating machine assembly 100, 150. The exemplary embodiment includes a rotating shaft having an end extending from each end of the rotating machine assembly 100; the respective shaft being described as including a first shaft portion 120 extending from a first end of the first rotating machine 110 and a second shaft portion 124 extending from a second, opposite end of the first rotating machine 110, which terminates at a second shaft portion coupling end 126. Similarly the exemplary rotating machine assembly 150 comprises a rotating shaft having an end extending from each end thereof; the respective shaft being described as including a first shaft portion 170 extending from a first end of the second rotating machine 160, which terminates at a second shaft portion coupling end 172 and a second shaft portion 174 extending from a second, opposite end of the second rotating machine 160.

Each rotating machine 110, 160 includes a rotating machine base 112, 162. A series of feet 114, 116, 164, 166 are attached to each rotating machine base 112, 162, respectively. The feet 114, 116, 164, 166 are generally secured to a supporting surface by a series of threaded mounting fasteners 700. Alignment shims 119 can be inserted as deemed necessary to aid in alignment between abutting shaft ends, such as the first shaft portion 120 and second shaft portion 174 shown in the exemplary illustrations.

Considering the fact that there is no revolutionary change in technology that could be applied in the hardware the software side has significant potential.

Over the number of years, the software has been developing into a “mature” stage where basically all alignment situations or applications are covered. Examples include: normal shaft alignment, cardan shaft alignment, spacer shaft alignment, soft foot measurement using laser/sensor.

The software could hold the “anticipated alignment values” in different formats. Alignment Targets (anticipated alignment values) were calculated and expressed in different formats. For example, angular target per 100 mm or angular target as “gap” on coupling diameter or simply on the “feet” of the machine. In turbo-machinery it is quite common to use “reverse-rim” as a format to express the alignment target. There is only one problem there, if the specified target is expressed in one format and the software shows the results in another format it is very confusing to the operator to be able to judge whether the alignment values that were measured are correct, according the specified target.

Considering the example above, the software has a critical function in the process to bring clarity to the operator. The software should support the alignment engineer during the entire process of alignment and in every detail.

This philosophy requires a very accurate definition of the alignment process in terms of:

• • Scope, essentially what needs to be covered.
  • Detailed levels: it is noted that one missed/wrong detail could cause failure of the machine.
  • Sequence of the activities.

The present invention provides a process for aligning mating shaft portions of coupled machines 110, 160, more specifically, as presented in the exemplary illustration, the first shaft portion 120 of the first rotating machine 110 and the second shaft portion 174 of the second rotating machine 160. The first shaft portion 120 and second shaft portion 174 are coupled via an inter-machine coupler 199. Alignment between the first shaft portion 120 and second shaft portion 174 is critical to the operation and reliability of the system. Each of the FIGS. 1 through 6 include a portion of the illustration representative of the rotational axis of each of the shafts 120, 170, illustrated as a representative first shaft rotational axis 220 and a representative second shaft rotational axis 270. The ends of the representative first shaft rotational axis 220 are referenced as a representative first shaft coupling end 222 and a representative first shaft available end 226. Similarly, the ends of the representative second shaft rotational axis 270 are referenced as a representative second shaft coupling end 272 and a representative second shaft available end 276. The representative first shaft coupling end 222 and representative second shaft available end 276 are representative of the coupled section of the mating shaft portions, more specifically the first shaft portion 120 of the first rotating machine 110 and the second shaft portion 174 of the second rotating machine 160. The desired alignment positions the representative first shaft rotational axis 220 and representative second shaft rotational axis 270 in a parallel relation in both an elevation target alignment 210 (vertical registration) (FIG. 1) and a plan target alignment 211 (horizontal registration) (FIG. 4) during operation of the train of the rotation machine assemblies 100, 150.

The alignment process utilizes alignment equipment, such as straight edges, dial gauges, shaft alignment lasers, and the like. The process is commonly supported by software, which provides step-by-step guidance to an alignment engineer through the process of aligning adjacent, coupled rotating machines 110, 160. The computer and respective software utilize data defining the initial alignment between the representative first shaft rotational axis 220 and representative second shaft rotational axis 270 to calculate and provide instructions to the alignment engineer, which direct the necessary adjustments. The computer includes a microprocessor, which is operated by a series of instructions provided by programming. Memory storage media is provided in data communication with the microprocessor. One or both rotating machine assemblies 100, 150 can be adjusted in accordance with a vertical adjustment 230 to compensate for a vertical offset 212 as illustrated in FIG. 2. One or both rotating machine assemblies 100, 150 can be adjusted in accordance with a horizontal adjustment 234 to compensate for a horizontal offset 213 as illustrated in FIG. 5. In addition to linear offsets, the rotating machine assemblies 100, 150 can be positioned having an angular offset, including an elevation angular offset 214, as demonstrated in the illustration presented in FIG. 3 and a plan angular offset 215, as demonstrated in the illustration presented in FIG. 6. One or both rotating machine assemblies 100, 150 can be adjusted in accordance with an elevation angular adjustment 232 to compensate for an elevation angular offset 214. Similarly, one or both rotating machine assemblies 100, 150 can be adjusted in accordance with a plan angular adjustment 236 to compensate for a plan angular offset 215. The methods of adjusting the linear relation and/or angular relation would be consistent with those known by those skilled in the art.

As previously mentioned alignment process is completed when the equipment is in a non-operational state, and preferably at an ambient temperature condition. One significant drawback of this process is that the alignment changes when the equipment is subjected to factors that only occur during operation. Examples of these are rotational torsion applied between the shafts, torsional forces applied to shaft bearings, thermal expansion of the various components, strain subjected to the mounting hardware 700 and feet 114, 116, 164, 166, and the like. Any misalignment during operation can affect uptime of the equipment 110, 160, long term reliability of the various components, efficiency of the system, and the like.

The present invention provides an improved method of aligning the representative first shaft rotational axis 220 and representative second shaft rotational axis 270, where the alignment process determines optimal alignment of the machinery 110, 160 when the rotating machine assemblies, 110, 160 are in operation by using data previously obtained during operation. The improved or predictive alignment method is described in the exemplary rotating machinery predictive alignment process 400 presented in FIG. 7. Considering the current offering and the Gap the solution is to establish a structure (process) that is not only a predefined and static process, but a predefined dynamic process that can be adapted to each individual situation or setup of rotating equipment to be able to capture all details that are potentially a risk for premature failure. Although the arrangement can provided general information for similar configurations, the actual date would beset be suited specifically for the individual machine setup and would be used to optimize the sequence of the process where desirable. The process is considered to be dynamic, because it anticipates also to environmental changes that influence the result of the process.

The predictive alignment process initiates with a start step 402. The rotating machine assemblies, 110, 160 are inspected in accordance with a provided procedure (step 404). The alignment engineer determines if any operational correlation information is available. The alignment engineer proceeds in completing an initial alignment process between the two rotating machines 110, 160 as directed by instructions provided by the procedure (step 406). Operation of the equipment is then initiated (step 410). The mounted first rotating machine assembly 100 and mounted second rotating machine assembly 150 are preferably outfitted with various monitoring devices, which are placed in signal communication with a data recording device, such as a computer. The system would be monitored and the respective data would be recorded (step 412). The computer would include a data storage media, such as a magnetic media integrated into a hard drive, a non-volatile memory device such as a solid state data recording media, and the like. The signal communication interface can be provided by either cabling or a wireless communication protocol. A microprocessor can be integrated into the computer for deciphering the signal information, directing storage of the data, and correlating the information respective to the alignment status. Examples of the environment and equipment conditions that are monitored in accordance with step 412 are presented in FIG. 8 and will be subsequently described herein.

In parallel, the alignment monitoring system additionally monitors and records machine alignment and operational efficiency (step 414). The environment and equipment conditions data is correlated to the machine alignment and efficiency data to determine alignment characteristics and how the data can be utilized when aligning the system at an ambient, non-operation state to optimize alignment during operation (step 416). The system can optionally monitor the alignment, compare the actual alignment against acceptable or target data, and determine if the rotating machines 110, 160 need realignment (step 418). Alternatively, the rotating machines 110, 160 can be inspected to determine if the rotating machines 110, 160 need realignment (step 418). If the rotating machines 110, 160 do not need realignment, the process continued monitoring the assemblies 100, 150 and recording the respective data. If the rotating machines 110, 160 need realignment, the rotating machines 110, 160 are placed in a non-operational state and the alignment engineer obtains and utilizes the information gathered during operation (step 420) to correlate the alignment between the rotating machines 110, 160 to the required positional relationship therebetween, where the rotating machines 110, 160 are in optimal alignment during operation. The predictive alignment process utilizes the obtained data to determine predictive alignment values. Once the required positional relationship is calculated, the alignment engineer then completes the alignment process (step 422) in accordance with the predictive values.

The assemblies 100, 150 and respective environment can be monitored, as described in step 412 by any of many different factors. The data is preferably recorded locally and/or uploaded to a central database for reference at a later date. A series of exemplary factors are presented in FIG. 8, including:

Recording original alignment values as recited in step 502. This is preferably completed during or immediately following the alignment process.

Attaching strain gauges to predetermined components and/or locations on the assemblies 100, 150 to monitor mechanical strain values (step 504). Examples of the components and/or locations can include a housing of the rotating machine 110, 160; the rotating machine base 112, 162; the mounting feet 114, 116, 164, 166; the coupled portion of the shafts 120, 174; and the like. The strain gauges would be monitored either in a continuous manner or cyclical where data is recorded over spatial time intervals.

Attaching one or more monitoring devices to the mounting feet 114, 116, 164, 166 to determine or monitor soft foot conditions (step 506). The monitoring devices can measure acceleration (vibration), strain, deformation, and the like.

Monitor and record torque values of the threaded mounting fasteners 700 (step 508). This can be accomplished by manually or automatically measuring and recording the respective torque values for each threaded mounting fastener 700.

Monitor and record torque values of fasteners utilized within the inter-machine coupler 199 (step 510). This can be accomplished by manually or automatically measuring and recording the respective torque values for each fastener utilized by the inter-machine coupler 199.

Monitoring and recording the axial distance between the mounted first rotating machine assembly 100 and mounted second rotating machine assembly 150 (Step 512). This can include measurements between the first rotating machine 110 and second rotating machine 160, including the axial distance between the central locations of each machine 110, 160 to determine any change in axial distance therebetween, the axial distance between each respective edge to determine any angular change therebetween, and the like.

Monitoring and recording the axial distance between the first shaft portion 120 and first shaft portion 170 (Step 514). This can include measurements between the first shaft portion coupling end 122 and second shaft portion coupling end 176, including the axial distance therebetween; the horizontal offset therebetween, and the vertical offset therebetween. This can include a method of determine any off-balance scenario between each shaft first shaft portion 120 and first shaft portion 170.

Monitoring and recording the radial positioning and clearance of the shafts 120, 124,170, 174 within the bearings (step 516).

Monitoring and recording the chocking materials and any changes in the respective properties (Step 518). This can include monitoring the thickness, nominal heights, deflections, dimensions, material grade, type/brand used, surface status, contact area, and the like.

Monitoring and recording the machinery system for any leakages that might occur at any seals or other potential area where leakages might occur (step 520).

Monitoring and recording the oil levels of the machinery system (step 522).

Monitoring and recording various elements for wear, lubrication, load, or any other element that could impact the lifecycle of the coupling including the inter-machine coupler 199, the first shaft portion coupling end 122, and the second shaft portion coupling end 176; the threaded mounting fasteners 700 and/or other fasteners; the chocking materials, the shafts 120, 170, the bearings, the seals, and the like (step 524).

Monitoring and recording any correlation between vibrational measurements and alignment related items (step 526).

Monitoring and recording any correlation between lubrication inspections or results of any related analysis and alignment related items (step 528).

Monitoring and recording any correlation between internal disturbance or deviation of geometry in rotating components and alignment related items (step 530).

Monitoring and recording any correlation between operational conditions and alignment scope activities, results, or analysis (step 532). This can include environmental temperature changes, equipment temperature changes, environmental pressure changes, environmental humidity changes, and the like.

Monitoring and recording any correlation between a transfer of power from a first shaft to a second shaft and the alignment of the coupled shafts of adjacent rotating machines (step 534).

Each of the monitored and recorded data points collected can be analyzed against alignment data obtained at the same point in time during operation. The alignment information obtained during operation can also be compared against alignment information when the rotating machines are in a non-operational condition. The analysis can provide coefficients, tables, or other correlating data that can be utilized to modify non-operational alignment information to calculate and provide predictive operational alignment information to the alignment engineer for use during the alignment process. The monitored and recorded data is preferably recorded and stored within a digital data storage media, such as a common magnetic hard drive, a solid state memory media, such as a non-volatile memory circuit, and the like. The information can be stored locally on a personal computer or remotely at an information data server.

The step of monitoring and recording environmental and equipment conditions 412 of the rotating machinery predictive alignment process 400 determines and records series of various types of data. The collected data and results of subsequent analysis of the data provide a predicted optimal alignment configuration for the rotational machinery system. As the volume of recorded data increases, the accuracy of the predicted optimal alignment configuration for the rotational machinery system also increases. The predicted optimal alignment configuration can be correlated to a non-operational configuration, enabling the alignment engineer to optimally align the rotating machines 110, 160 when the machines are in a non-operational state, while targeting optimal alignment when the rotating machines 110, 160 are in operation.

The alignment engineer would prepare for execution of the predictive alignment process by following the preparation process flow 600 presented in FIG. 9. The alignment engineer refers to the alignment process procedure to initially identify common and specific tools required for the alignment process (step 610). These can include alignment tools (such as lasers, dial meters, and the like), sockets, wrenches, pliers, cantilevers, screwdrivers, star drive bits, wedges, torque wrenches, and the like. In addition to tools, the alignment engineer needs to obtain materials for execution of the alignment process. The procedure identifies the common and specific materials required for the alignment process (step 620). Several exemplary items that could be suggested for use during the alignment process (step 620) can include the following:

A plurality of shims (referenced by block 621), where the procedure would identify a series of shims having dimensions defined by a length, a width, and a thickness. The procedure may additionally include a specific material or several suggested materials.

A plurality of steel chocks (referenced by block 622), where the procedure would identify a series of shims having dimensions defined by a length, a width, and a thickness.

A plurality of resilient chocks (referenced by block 623), where the procedure would identify a series of properties, including a deflection specification, a limiter specification, a load height, a presetting value for alignment target (in both an initial installation configuration and in a settled configuration) min. and max height in all installed situations.

One or more epoxy resins (referenced by block 624): where the procedure would identify a series of properties, including: dimensions (length and width), nominal thickness, target hardness, net volume, gross volume, damming materials needed, temperature logging, checkpoints pollution, defined sprayed areas, static and dynamic loads and related max accepted limits table (manufacturer, classification societies), offset values for alignment targets and the like.

Vibracons (referenced by block 625): where the procedure would identify a series of properties, including: nominal height, min/max height, nominal, min/max load on the element, applied bolt and related torque, offset values for alignment targets, and the like.

Bolts (referenced by block 626): where the procedure would identify the properties, such as the grade and dimensions of the foundation bolts and other fastener hardware for each component. The dimensioning contains: M-size or UNC/UNF/WW with the pitch value of the thread. Also the procedure would identify the total length of the bolt. In addition to the physical properties of the bolts/fasteners, the procedure would additionally provide the torque force required for assembly and any details regarding lubrication (where applicable). The torque force is either entered manually or calculated or retrieved by the instrument. Also the elongation (target) is stated and a warning (optionally presented in green/yellow/red) can be made available to the alignment engineer to inform the alignment engineer if the entered value would be structurally adequate. A clamping length is required to be included to determine the anticipated and allowable elongation of the mounting fastener.

In general the end result of the alignment job is an alignment summary report that states all relevant details to be captured. The exemplary report includes three or more different situations:

• • As found configuration
  • As specified (specifications and guidelines as stated in the structure)
  • As corrected configuration

Bolt Torque and Elongation Generator and Calculator

It is desired that the preinstalled threaded mounting fasteners 700 are installed to a proper applied torque 750 as illustrated in FIGS. 10 and 11. If the preinstalled threaded mounting fastener 700 is installed using a applied torque 750 that is too low, the preinstalled threaded mounting fastener 700 may loosen and the installation risks shifting away from an optimal alignment. If the preinstalled threaded mounting fastener 700 is installed using a applied torque 750 that is too high, the preinstalled threaded mounting fastener 700 may break as a result of being overstretched and the installation risks damage from a loose foundation. Excessive tension results in excessive stretch, extending into a plastic deformation range, where the bolt becomes permanently disfigured. This weakens the preinstalled threaded mounting fastener 700. Any additional tension, shear, or other force applied to the preinstalled threaded mounting fastener 700, eventually resulting in failure.

The preinstalled threaded mounting fastener 700 comprises a threaded shaft, defined having a fastener clamping body segment 710 and a fastener non-tensioned body segment 714. A clamping distance 730 is defined between a bolt head clamping surface 713 of the fastener non-tensioned body segment 714 and a threaded receptacle clamping surface 722 of a threaded receptacle 720. The illustrated exemplary threaded receptacle 720 is a nut. It is understood by those skilled in the art that the threaded receptacle 720 can be any threaded shaft receiving device, including a tapped hole, and the like. The fastener clamping body segment 710 is defines as a portion of the threaded shaft located within the clamping distance 730 of the assembly, wherein the fastener clamping body segment 710 is subjected to a tension and resulting elongation when properly installed. The fastener non-tensioned body segment 714 is defined as a portion of the threaded shaft extending beyond the threaded receptacle 720, where the fastener non-tensioned body segment 714 is not subjected to any tension when installed. Selection of threaded mounting fastener 700 needs to consider a preinstalled fastener length 740 that is of a sufficient length enabling the threaded shaft to extend through the various mounting components 112, 114, 119 and optionally through a foundation 190, continue to support an adequate threaded receptacle 720 and include a fastener non-tensioned body segment 714 which extends beyond the threaded receptacle 720 to meet established engineering guidelines. The preinstalled fastener length 740 can be measured from the bolt head clamping surface 713 to a fastener body tip 716, located at an opposite end of the threaded shaft.

A plurality of threaded mounting fasteners 700 are used to secure the rotating machine assembly 100, 150 to a foundation 190, as illustrated in the exemplary cross sectioned side view illustrated in FIG. 10. The threaded shaft of the preinstalled threaded mounting fastener 700 is inserted through a series of foundation mount apertures 130 formed through each of the rotating machine base 112, the first mounting foot 114, and the alignment shim 119. In a first configuration, the threaded shaft can be inserted through the foundation mount apertures 130 of a foundation 190 and secured using a threaded receptacle 720. The rotating machine base 112, first mounting foot 114, alignment shim 119, and foundation 190 are clamped between the bolt head clamping surface 713 and the threaded receptacle clamping surface 722. In a second configuration, the foundation mount apertures 130 formed into or through the foundation 190 can include threading, thus eliminating a needs for the threaded receptacle 720. The rotating machine base 112, first mounting foot 114, and alignment shim 119 are clamped between the bolt head clamping surface 713 and the foundation 190. An example of this would be threading the threaded shaft in the foundation 190, where the foundation 190 is a cement base, a thick metal plate, and the like.

The threaded mounting fastener 700 is initially installed into the foundation assembly in a preinstalled state. The preinstalled threaded mounting fastener 700 transitions into a tensioned threaded mounting fastener 702 when the applied torque 750 is applied to the fastener head 712. As the applied torque 750 is applied to the tensioned threaded mounting fastener 702, a tensile force is generated between the bolt head clamping surface 713 and the threaded receptacle clamping surface 722. The tensile force elongates the fastener clamping body segment 710 into a fastener tensioned clamping body section 711. The elongation of the fastener clamping body segment 710 into the fastener tensioned clamping body section 711 also elongates the preinstalled fastener length 740 into a tensioned fastener length 742. The tensioned fastener length 742 can be measured from the bolt head clamping surface 713 to a tensioned fastener body tip 717, located at an opposite end of the threaded shaft. A tensioned fastener length delta 744 is calculated as the difference between the tensioned fastener length 742 and the preinstalled fastener length 740 after application of a predetermined applied torque 750. The tensioned fastener length delta 744 is the same distance as the difference between the clamping distance 730 and the effective tensioned length 732, as the tensile force is not applied to the fastener non-tensioned body segment 714, and therefore the fastener non-tensioned body segment 714 is not subjected to any elongation.

An exemplary method of calculating an optimal torque value and respective elongation is presented in a torque calculation process flow diagram 800 presented in FIG. 12. The process 800 initiates with a start step 802. The alignment engineer would enter thread dimensions of a selected bolt into the program as directed in step 804. The initial bolt thread dimensions include the fastener thread width 718 and fastener thread pitch 719, such as M30×3.5, UNC 1″, and the like. The bolt thread information can be selected from a pre-populated table, manually entered, and the like. The alignment engineer continues, entering a suggested preinstalled fastener length 740 of the proposed bolt into the program as directed in step 806. The preinstalled fastener length 740 information can be selected from a pre-populated table, manually entered, and the like. The alignment engineer enters a suggested grade of the proposed fastener into the program as directed in step 808. The proposed grade of the preinstalled fastener length 740 can be selected from a pre-populated table, manually entered, and the like.

The alignment engineer enters the clamping distance 730 into the program in accordance with step 810. The clamping distance 730 can be determined by physically measuring the respective components or calculated based upon specifications of the respective components.

Certain applications suggest utilizing a lubricant when installing the preinstalled threaded mounting fastener 700. The utilization of a lubricant affects the value of the applied torque 750, therefore, the alignment engineer would enter if and if so, which lubricant or sliding additive is being used into the program as described in step 812.

Once all of the above-identified information is entered into the program, the program analyzes the information to calculate a target value for the applied torque 750 in accordance with step 814 and an anticipated elongation or tensioned fastener length delta 744 in accordance with step 816. The calculations are completed using well-known mechanical engineering algorithms. The algorithm can be enhanced by including compression of the various materials, settlement of a portion or the entire system and supporting surface, effects of the pre-tensioning over time, and the like. The program compares the tensioned fastener length delta 744 with preset reference values as referenced in step 818 to determine if the applied torque 750 and respective tensioned fastener length delta 744 are acceptable as directed in step 820. The program conveys the acceptable torque and respective elongation to the alignment engineer in accordance with step 822. The information can be conveyed in any format, including a numeric output, a color representation, such as green (acceptable), amber (marginal), and red (unacceptable), and the like. Although the torque calculation process can provide suggestions to the alignment engineer, the alignment engineer can ultimately decide whether to select a different fastener 700 or use the originally selected fastener 700.

The torque calculation process can optionally advise the user to increase or reduce the number of alignment shims 119, increase, reduce the fastener thread width 718 (diameter of the bolt), provide a minimum fastener thread width 718, increase or decrease a clamping dimension, and the like.

Alternatively, the torque calculation process flow diagram 800 can utilizes an index table to utilize and interpret entered information to return appropriate values for the applied torque 750. By optimizing the applied torque 750 for installation of the threaded mounting fasteners 700, the alignment process maximizes potential operational reliability and cost efficiencies of the coupled rotating machine arrangement.

Since many modifications, variations, and changes in detail can be made to the described preferred embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalence.

Ref. No. Description
100      mounted first rotating machine assembly
110      first rotating machine
112      rotating machine base
114      first mounting foot
116      second mounting foot
118      mounting foot spacer
119      alignment shim
120      first shaft portion
122      first shaft portion coupling end
124      second shaft portion
126      second shaft portion coupling end
130      foundation mount apertures
150      mounted second rotating machine assembly
160      second rotating machine
162      rotating machine base
164      first mounting foot
166      second mounting foot
170      first shaft portion
172      first shaft portion coupling end
174      second shaft portion
176      second shaft portion coupling end
190      foundation
199      inter-machine coupler
210      elevation target alignment
211      plan target alignment
212      vertical offset
213      horizontal offset
214      elevation angular offset
215      plan angular offset
216      effective linear distal offset representation
217      effective linear distal offset
218      effective angular offset
220      representative first shaft rotational axis
222      representative first shaft coupling end
226      representative first shaft available end
230      vertical adjustment
232      elevation angular adjustment
234      horizontal adjustment 236 plan angular adjustment
270      representative second shaft rotational axis
272      representative second shaft coupling end
276      representative second shaft available end
400 rotating machinery predictive alignment process
600      preparation process flow
700      preinstalled threaded mounting fastener
702      tensioned threaded mounting fastener
710      fastener clamping body segment
711      fastener tensioned clamping body section
712      fastener head
713      bolt head clamping surface
714      fastener non-tensioned body segment
716      fastener body tip
717      tensioned fastener body tip
718      fastener thread width
719      fastener thread pitch
720      threaded receptacle
722      threaded receptacle clamping surface
730      clamping distance
732      effective tensioned length
740      preinstalled fastener length
742      tensioned fastener length
744      tensioned fastener length delta
750      applied torque

Claims

1. A method of determining an optimal torque value for a foundation fastener to maximize operational reliability and cost efficiencies of the coupled rotating machine arrangement comprising steps of:

obtaining a computing device comprising a microprocessor, a digital data storage device, a user input interface enabling an alignment engineer to enter data, a display for providing information to the alignment engineer, circuitry providing operable interconnectivity between components, an instruction set provided in a form of a torque calculation and verification software program, and respective power to operate the computing device;

entering fastener specifications of a proposed foundation fastener into the torque calculation and verification software program;

entering a clamping dimension into the torque calculation and verification software program;

calculating an optimal torque value for use during installation of the proposed foundation fastener, wherein the calculation is based upon a clamping dimension and fastener specifications, wherein the clamping dimension is a distance between facing surfaces of a fastener head and a terminal location of a female threaded member;

determining a stretch of the proposed foundation fastener;

determining if the entered foundation fastener is acceptable based upon the optimal torque and respective stretch by comparing the determined stretch of the proposed foundation fastener against a preset reference value;

in a condition where the entered foundation fastener is determined to be unacceptable, the operator enters a different foundation fastener and the process is repeated until the entered foundation fastener is deemed to be acceptable, where in which the optimal torque is conveyed to the operator;

completing an alignment process for aligning a pair of coupled shafts of adjacently located rotating machines; and

securing the adjacently located rotating machines in position by installing the proposed foundation fastener to secure the adjacently located rotating machines in position.

2. A method of determining an optimal torque value for a foundation fastener as recited in claim 1, further comprising a step of:

comparing the target torque value with a predetermined acceptable torque range of fastener stretch to determine if the target torque value is within the predetermined acceptable torque range.

3. A method of determining an optimal torque value for a foundation fastener as recited in claim 1, wherein the step of entering fastener specifications into the torque calculation and verification software program further comprising entering at least one of:

a fastener thread diameter;

a fastener thread pitch; and

a fastener material grade.

4. A method of determining an optimal torque value for a foundation fastener as recited in claim 3, further comprising a steps of:

entering lubricant information into the torque calculation and verification software program; and

compensating the target value for the fastener installation torque by accounting for the inclusion of the lubricant.

5. A method of determining an optimal torque value for a foundation fastener as recited in claim 1, further comprising a steps of:

entering lubricant information into the torque calculation and verification software program; and

compensating the target value for the fastener installation torque by accounting for the inclusion of the lubricant.

6. A method of determining an optimal torque value for a foundation fastener to maximize operational reliability and cost efficiencies of the coupled rotating machine arrangement comprising steps of:

obtaining a computing device comprising a microprocessor, a digital data storage device, a user input interface enabling an alignment engineer to enter data, a display for providing information to the alignment engineer, circuitry providing operable interconnectivity between components, an instruction set provided in a form of a torque calculation and verification software program, and respective power to operate the computing device;

providing fastener specifications of a series of proposed foundation fasteners into a table associated with the torque calculation and verification software program;

selecting a proposed foundation fastener from the table of foundation fasteners;

entering a clamping dimension into the torque calculation and verification software program;

calculating an optimal torque value for a torque for use during installation of the proposed foundation fastener, wherein the calculation is based upon the clamping dimension and fastener specifications, wherein the clamping dimension is a distance between facing surfaces of a fastener head and a terminal location of a female threaded member;

determining a stretch of the proposed foundation fastener;

determining if the selected foundation fastener is acceptable based upon the optimal torque and respective stretch by comparing the determined stretch of the proposed foundation fastener against a preset reference value;

in a condition where the selected foundation fastener is determined to be unacceptable, the operator selects a different foundation fastener and the process is repeated until the selected foundation fastener is deemed to be acceptable, where in which the optimal torque is conveyed to the operator;

completing an alignment process for aligning a pair of coupled shafts of adjacently located rotating machines; and

securing the adjacently located rotating machines in position by installing the proposed foundation fastener to secure the adjacently located rotating machines in position.

7. A method of determining an optimal torque value for a foundation fastener as recited in claim 6, further comprising a step of:

comparing the calculated stretch with a predetermined acceptable stretch range of fastener stretch to determine if the fastener stretch is within the predetermined acceptable stretch range.

8. A method of determining an optimal torque value for a foundation fastener as recited in claim 6, further comprising a step of:

comparing the target torque value with a predetermined acceptable torque range of fastener stretch to determine if the target torque value is within the predetermined acceptable torque range.

9. A method of determining an optimal torque value for a foundation fastener as recited in claim 6, wherein the step of entering fastener specifications into the torque calculation and verification software program further comprising entering at least one of:

a fastener thread diameter;

a fastener thread pitch; and

a fastener material grade.

10. A method of determining an optimal torque value for a foundation fastener as recited in claim 9, further comprising a steps of:

entering lubricant information into the torque calculation and verification software program; and

compensating the target value for the fastener installation torque by accounting for the inclusion of the lubricant.

11. A method of determining an optimal torque value for a foundation fastener as recited in claim 6, further comprising a steps of:

entering lubricant information into the torque calculation and verification software program; and

compensating the target value for the fastener installation torque by accounting for the inclusion of the lubricant.