DEBRE MARKOS UNIVERSITY

INSTITUTE OF TECHNOLOGY
SCHOOL OF MECHANICAL AND INDUSTRIAL
ENGINEERING

Maintenance And Installation of

Machinery

Chapter One– Introduction

By: Haileyesus D. [MSc]

March, 2023 G.C

3/27/2023 13 - 1
 Introduction to
Machine
Installation
3/27/2023 13 - 2
 What is Machine?
• It is a device that takes some energy as input and
transforms it to another useful form of energy as
output.

What is Installation?
• It is the process of fixing and erecting the machinery
in an industry so that they can be put to use for
productive purposes.

3/27/2023 13 - 3
 Why Machine installation is necessary?
• It is the first step in the productive process of any newly established plant.

Where to install machinery?

• The installation of light machinery used for domestic use may not require
any expertise, where as the installation of the machinery used in the
industry need attention as the performance of the machinery largely
depend upon proper installation.

How to install machinery?

• The installation process may differ from machine to machine and it
is largely depend upon the main specifications of the machines to
be installed.
3/27/2023 13 - 4
 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

3/27/2023 13 - 5
 Machinery installation Requirements
• Follow these steps to avoid downtime, poor product quality, reduced
capacity and high operating costs.
• Proper machine installation is critical in maximizing reliability and
minimizing life cycle costs.
• Conversely, improper installation is a chronic source of downtime, poor
product quality, reduced capacity and high operating costs.
• While installation requirements vary depending on the type of machine and
its function, there are basic best practices that must be followed. The
requirements are;
 Foundation
 Anchoring
 Isolation
 Levelling and
 Alignment
3/27/2023 13 - 6
 FOUNDATION
• Foundation is one of the most important parts of the building. It plays a
crucial role in the structure and it is the lowermost part of the building below
the ground level which provides a base for the structure.
• The foundation must be capable of carrying the applied load without
settlement, flexing or crushing.
• Foundations for heavy machinery are usually concrete or structural steel
structures. For these installations, an independent concrete pad is poured
that has sufficient mass and stiffness to support the machine-train and absorb
the forces generated by normal operations.
• The total foundation mass and its related support structures should be at
least five times the total rotating or moving mass of the machine-train.

• In general, foundations in-terms of installation can be classified as;

Building foundation and
Machine foundation
3/27/2023 13 - 7
 Building Foundations
Cont…
• Footings and foundations as having two functions;

1. To transfer the live and dead loads of the building to the soil over
a large enough area so that neither the soil nor the building will
move.

2. In areas where frost occurs, to prevent frost from moving the

building.

• Dead loads are the weight of the

building materials and the soil
surrounding the foundations.
• Live loads include the weight of
people, furniture, snow, rain, and
wind.
Fig.1.Building Foundation in Construction
3/27/2023 13 - 8
 Cont…
Machine Foundations
• A machinery foundation is a built-up structure regardless of
shape and size, supporting downward or side pressure, and
designed to support and maintain the correct position of a given
machine.

• The main purpose of machine foundations is to stabilize the

machine as well as to reduce the vibrations caused due to the
operation of the machine.

• The foundation thus positively influences machine vibration by

reducing the amplitude of oscillation.

3/27/2023 13 - 9
 Types of Machine Foundations
• Machine foundations can be classified as;
1. Block type
2. Box type
3. Wall type and
4. Frame type

1. Block type: it is a solid foundation of cement concrete or sometimes

brick masonry, in which foundation bolts are grouted and the machine
rests over its top surface.

3/27/2023 13 - 10
 Cont…
2. Box type: it is a hollow box type construction of cement concrete. The
machine is placed over its top roof. The mass of this foundation is less than
block type machine foundation as it is hollow.

3/27/2023 13 - 11
 Cont…
3. Wall type: it may be made either in cement concrete or brick
masonry. In either case, it consists of strong base over which are
erected two parallel vertical walls. The machine is supported over
the two walls.

3/27/2023 13 - 12
 Cont…
4. Frame type: it is more or less a wall type foundation carrying a
fabricated frame at its top. The machine is placed and supported over
the framework at the top. This type of foundation is specially favoured
for rotating machines and those operating at high speeds.

3/27/2023 13 - 13
 Requirements of good foundation

• There are various requirements of a good foundation. This are

listed below;
1. Location of the Foundation
2. Settlement of Foundation
3. Durability of Foundation
4. Stability of Foundation

1. Location of the Foundation:

•The location of the foundation should be such that it can be able to resist
the total load of the structure.
•Foundation must be located at an appropriate location and design as per
the bearing capacity of the soil.

3/27/2023 13 - 14
 Cont…
2. Settlement of Foundation:
•The main function of the foundation is to prevent the settlement of the
foundation. The settlement of the foundation mainly depends upon soil strata.
•The foundation of the structure should not be settled under the action of load
and it should prevent the differential settlement of the structure.

3/27/2023 13 - 15
 Cont…
3. Durability of Foundation

• Durability is also important aspects should be considered while foundation

construction.
• The foundation of the structure should be constructed such that it should be
durable.
• The foundation should be designed such that it should be able to carry the
Load of the structure and prevent settlement of the foundation.

3/27/2023 13 - 16
 Cont…
4. Stability of Foundation

• One of the most important functions of the foundation is to provide

stability such that it should be able to safely transfer the load into
the soil.

3/27/2023 13 - 17
 FOUNDATION PLAN
• Foundation plan is a detailed drawing which contains the following
information:
1. Principal dimension and profile of the machine.
2. Size and shape of the foundation to be prepared.
3. Type of foundation and material to be used in its preparation.
4. Location of mechanism, areas needed for opening of base
doors, operator’s position etc.
5. Location of holes and recesses to accommodate the foundation
bolts and projection in machine base, if any.
6. Weight of the machine.
7. Location of current supply, power cables, etc.
 With the help of these drawings, which are also known as erection
drawings, the excavation details can be easily worked out.
3/27/2023 13 - 18
 • The foundation is an important part of the machine tool installation and
it needs to be made very carefully because it is required to perform
following functions;
1. To act as the base to the support the entire weight of the
machine tool, workpiece, tooling, mounting, accessories etc.
2. To help in maintenance of the alignment of machine tool, its
mechanism and moving parts.
3. To absorb vibration produced during the operation.
4. To prevent transmission of vibrations from one machine to
another.
5. To provide such height to the machine tool that its operation
is convenient to the operator.
3/27/2023 13 - 19
 • In general, the following factors effect the choice of a particular type
of foundation and its overall size etc.
1. Weight of machine
2. Type of soils
3. Vibrations
4. Power of driving motor
5. Direction of motion

1. Weight of machine: Heavier machines need stronger foundation

and lighter machines will need lighter foundations or no foundations.
• For example, a 250mm deep concrete foundation or 500mm
deep brick foundation can be used for drilling, milling etc up
to 4 tons.
3/27/2023 13 - 20
 Cont…
2.Type of soil: Different type of soils have different bearing capacities, i.e.,
the capacity to bear load without settling down or disintegrating.

• Since the entire weight of the machine tool is ultimately transferred to the
soil, its bearing capacity must be taken into consideration, while
designing the foundation.

• For example, a marshy soil which has poor bearing capacity (5000kg per
sq. meter) will essentially need a larger foundation of R.C.C.

3.Vibrations: Vibration in the machine tools are caused by unbalanced forces,

such as due to shock loads, misaligned parts and similar other reasons.
• As such, a proper foundation is required to be built, so that it can not only
absorb the vibration but also prevent their transmission to other
machines.
3/27/2023 13 - 21
 Cont…
4.Power of driving motor: The horse power to be transmitted by the
driving motor of the machine tool has a direct bearing on the size of the
foundation.
• As a general rule, the higher the horse power of the driving motor the
deeper should be the foundation of the machine.

5. Direction of motion: The direction of cutting motion in the machine tool

has a significant bearing on the size of foundation.

• A horizontal machine tool will need a heavier foundation than a vertical

machine tool of the same type.

3/27/2023 13 - 22
 Anchoring
• An anchor is a piece of steel used to transfer loads to concrete. They can be
cast into the concrete or put into a piece of hardened concrete later.
• Anchoring is fixing of machine tools to the concrete foundations using anchors.
• There are several kinds of cast-in anchors, but headed bolts, hooked bolts
(J- or L-bolts), and headed studs are the most common.

Figure: Concrete foundation with metal anchor

bolts designed for the installation of metal
columns. Figure: Anchored machine tool
3/27/2023 13 - 23
 PRINCIPLES OF ANCHORING

• The principles of anchoring can be;

 Friction
 Keying
 Bonding
 Combination of the above.
• Mechanical anchors work on the principle of friction
and keying.
• Chemical anchors work on the principle of bonding.

3/27/2023 13 - 24
 ANCHORING EQUIPMENTS

• Anchor bolts secure the machine to its foundation. The use of proper
methods ensures a rigid, permanent mating of parts.
• When machines are anchored to a concrete foundation, J-bolts are fixed
into the concrete as it is poured. Size bolts to ensure adequate holding
torque and to prevent them from loosening over time.

• For the anchored machines, the anchor bolts must perform two critical
functions;
• they must fix the machine in place so it cannot flex, bend or
deflect; and
• they must isolate the machine from the foundation to prevent
transmission of generated energies into the foundation.

3/27/2023 13 - 25
 Cont…
Types of Concrete Anchors

1. Wedge Concrete Anchors: Wedge concrete anchors are commonly used

because they are simple to install, last a long time, and don’t rust.

2. Stud Concrete Anchors: The stud anchor’s top needs to be pounded to

extend it. The expansion anchor has a vertical slot at the bottom and a screw
hole at the top.

3/27/2023 13 - 26
 Cont…
3. Split Drive Concrete Anchors: A split drive anchor is a single-piece fastener that
splits at the bottom and pushes against the sides of the hole when it is driven into the
ground.
 For the best grip, the diameter of the hole drilled for a split drive anchor must be
the same as the diameter of the anchor’s base.
 Split-drive concrete anchors are great for light-duty uses and can be used with
concrete, block, and brick.

4. Drop-In Concrete Anchor: Drop-in anchors are female anchors inserted into
a drilled hole and are often mistaken for wedge anchors due to their comparable
expansion.

3/27/2023 13 - 27
 Cont…

5. J-Bolt: J Bolts are headless bolt fasteners with bent

profile in shape of letter J, used for anchoring pipes, round
or square profile.

3/27/2023 13 - 28
 Preparation and anchoring
• As seen in Figure 1, the floor should be a minimum of 6 in. of reinforced concrete.
• Anchor bolts are required to firmly tie the unit to the floor.
• You do not need a sleeve around the bolt. Wrap the bolt with tape so the grout and concrete don’t
stick to the bolt.
• The bolt needs to be allowed to free-stretch over a length of 10 times the bolt’s diameter. This is just
a rough estimation tool. Normally you can take your anchor bolts and cover 45% with tape. If you
do have a sleeve, either wrap it with tape before you fill it with grout or fill it with expanding foam
that comes in a can.

3/27/2023 13 - 29
 Steps of installing the anchor foundation bolt Cont…

• First of all, do the preparatory work.

 Check the marked locations carefully for further installation of the
foundation bolts.
• Install the embedded parts in the base of the foundation.
 The anchor should sink in the middle of the concrete base and
the distance between the foundation bolts should be twice the
penetration depth.
• Wait until the concrete mixture has completely hardened.
• Then you can start bonding.
 The foundation bolts are tightened using a metal plate or wooden
plank.

3/27/2023 13 - 30
 ISOLATION
• Machinery generates energy (vibration) that must be either absorbed
by the foundation or trapped within the machine.
• When a machine is mounted on a concrete pad, the pad should be
independent from the surrounding floor. This allows energies
generated by the machine to be absorbed and prevents outside
sources of vibration from entering the machine.
• When a machine must be mounted directly on the floor, isolation must
be accomplished by using springs or elastomeric pads specifically
designed to absorb or stop transmission of generated energy.

3/27/2023 13 - 31
 Cont…
Energy Sources

 Typical sources of energy that may need to be isolated, locked and

tagged out include;

3/27/2023 13 - 32
 Cont…
IF YOU DON’T ISOLATE
Types of hazardous energy with risks;

3/27/2023 13 - 33
 LEVELING
• With few exceptions, machinery is designed to operate on a true
horizontal plane.
• The surfaces must be flat and parallel to ensure there are no voids or
flexing in the final bolted joints.
• The operation of levelling of the machine is performed very carefully
because the accuracy of the machine tool largely depends on its
perfect levelling.
• Normally, a liquid level is sufficient to level a machine properly, but
new techniques such as;
 Sprit level
 Digital level and
 laser alignment devices can also be used.
3/27/2023 13 - 34
 Cont…
• Proper Machine leveling is critical in the machine installation for
the desired machine performance.
• The term leveling, with respect to machinery installation,
means the operation of placing machinery or equipment on a
true horizontal plane.
• The flatness of the floor plays an important step in the
levelling procedure of the machine.

3/27/2023 13 - 35
 ALIGNMENT
• Alignment can be defined as arrangement or position in a straight
line or in parallel lines. Or
• Alignment is the process of adjusting parts so that they are in proper
relative position:
• Alignment specifications vary depending on machine type.
• But normally, the shafts must be parallel and in the same plane
within a maximum of 0.001 in to 0.002 in.

 Angular misalignment is a condition where two shaft

centerlines are at an angle to each other.

3/27/2023 13 - 36
 Cont…
 Parallel misalignment is a condition where no angular
misalignment exists and the shafts are parallel, but offset from
each other.

 Combined misalignment is the above two misalignment happened.

3/27/2023 13 - 37
 Objectives of accurate alignment

3/27/2023 13 - 38
 Alignment Techniques

Straight edge method

Dial gauge method

Feeler gauge method

3/27/2023 13 - 39
 Symptoms of misalignment

3/27/2023 13 - 40
 Consequences of misalignment

3/27/2023 13 - 41
 • Installation procedure of a machine involves a
series of activities like:

3/27/2023 13 - 42
 a) 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.
• 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.
3/27/2023 13 - 43
 Cont…
• Once the location 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 general procedure is to indicate the outlines as per

specification of the machine.

• 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.
3/27/2023 13 - 44
 b) Positioning of Machines

• Positioning of the machine at the location is an important job, which

deserves care, skill and 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.

3/27/2023 13 - 45
 Cont…

3/27/2023 13 - 46
 c) Foundation

3/27/2023 13 - 47
 Cont…

3/27/2023 13 - 48
 Cont…

3/27/2023 13 - 49
 Cont…

3/27/2023 13 - 50
 Cont…

3/27/2023 13 - 51
 Cont…

3/27/2023 13 - 52
 Cont…

3/27/2023 13 - 53
 Cont…

3/27/2023 13 - 54
 Cont…

3/27/2023 13 - 55
 Cont…

3/27/2023 13 - 56
 Cont…

3/27/2023 13 - 57
 Cont…

3/27/2023 13 - 58
3/27/2023 13 - 59
 Cont…

3/27/2023 13 - 60
 Cont…

3/27/2023 13 - 61
 Cont…

3/27/2023 13 - 62
3/27/2023 13 - 63
3/27/2023 13 - 64
3/27/2023 13 - 65
 Cont…

3/27/2023 13 - 66
 Student activity
Go to the DMU Mechanical Engineering
machine shop and;

1. Identify the type of installed machineries

2. See the type of foundation works for each machine
3. Identify the type of anchoring mechanisms
4. Which machine is appropriately installed? Why?

3/27/2023 13 - 67