Installation

Factors involved in designing the machine

Foundation
Foundations: requirements for static machine
foundations, factors governing them.
Foundations: Requirements and factors affecting
rotating machine foundation.
Tools/instruments: Bearing puller, filler gauge, dial
indicator, spirit level, megger, earth tester, growler,
test lamps, multimeter, spanner sets, and screw
drivers.
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An Installation is a place that contains equipment and
machinery which are being used for a particular purpose.

• General Procedure of Machine Installation

Installation procedure of a machine involves a
series of activities like:
• a) Location and layout;
• b) Positioning of machines;
• c) Foundation;
• d) Leveling and alignment;
• e) Grouting;
• f) Fitting of other parts, accessories, piping etc.;
g) Final leveling and test runs
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 Machine foundation
Machine foundations are special types of foundations required for machines, machine
tools and heavy equipment which have wide range of speeds, loads and operating
conditions. These foundations are designed considering the shocks and vibrations
(dynamic forces) resulting from operation of machines. Following are the types of
machine foundations generally used:
1.Block Type Machine Foundation:. This type of foundation consists of a pedestal resting
on a footing have has large mass and a small natural frequency.
2. Box or Caisson Type Machine Foundation:Box type foundation consists of a hollow
concrete block. The mass of this foundation is less than block type machine foundation as
it is hollow. The natural frequency of the box type machine foundation is increased.
3.Wall Type Machine Foundation:
This type of machine foundation consists of a pair of walls with a slab resting on top. This
type of foundation is constructed of homogeneous materials. It is used for small
machines and the machine is rested on the top slab.
4. Framed Type Machine Foundation:
This type of machine foundation consists of vertical columns with horizontal frame at
their tops. It is used for larger machines. The machines are rested on the top of frames.
The vertical and horizontal members of this foundation can be constructed by different
materials.
5. Non-Rigid or Flexible foundation of Machine
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Factors involved in designing the machine Foundation
Machine foundations are not based on any definite calculations, but they are
more dependent on practical experience.

Definite calculations are not possible because the live load and other forces
are of very complex nature and indeterminate.

The machine foundation should fulfill the following requirements:

(i) The most important requirement is that foundation should absorb the
vibrations created by the machine while operating at its full capacity,
(ii) The foundation should spread over as much area that will not exceed the:
intensity of load over the soil more than its safe bearing capacity. This
will safeguard against sinking of foundation,
(iii) The frictional resistance between foundation block and the soil should be
sufficient to withstand the possible horizontal thrust caused by machine
while in operation. This will avoid sliding of foundation over the soil due
to horizontal thrust,
(iv) The foundation block should be so spread that the resultant of all the
forces should pass within the foundation block. This will safe guard
against overturning of the machine while in operation.
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The machine should be effectively fixed over the foundation block. This will
require fixation of machine over foundation with good type of anchor bolts. The
most critical point to be kept in view while designing a machine
foundation is that such arrangements should be made that will minimize the
vibrations caused by machine when working at its full load. Following
arrangements can be done to minimize the vibrations;
(a) The machine should be rigidly bolted to the foundation i.e. good
anchorage is necessary.
(b) The concrete foundation or the machine itself should be isolated from the
adjacent structures by some vibration absorbing material so that the vibrations
caused may not induce any adverse affect on the neighboring structures.

Isolation Methods:
(I) The isolation material is laid between the foundation and the ground on
which it is supported. This is the method which is employed in most of the
cases.
(II) The insulating material is laid between bed plate of machine and
foundation block.
(iii) The isolation material is laid between bed plate and machine. This is mostly
in the form of springs.
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Foundations: requirements for static machine foundations,
factors governing them
For installation of a power transformer, no special type of foundation is
required. The foundation should be strong enough to carry the heavy load of
transformer and it should be efficiently designed to prevent accumulation of
water below the transformer. It is essential to drain all the oil coming out from
transformer during any fire hazard and hence special oil drainage facilities
should be provided in the foundation design.
Transformer is one of the important static machines. Since, they operate
without moving parts, generally a simple foundation is satisfactory provided it
is firm, horizontal and dry.
 The transformer should not rock or bed-down unevenly so as to tilt, as this
may strain the connections, The base should be horizontal to keep the oil
level correct.
 For outdoor installations, a level concrete plinth above the maximum flood
or storm water level of the site, of correct size to accommodate the
transformer in such a way so that no person may step on the plinth.

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If necessary, bearing plates of sufficient size and strength, should be
provided for transformers. Where rollers are fitted, suitable rails or tracks
should be provided and when the transformer is in final position, the wheels
should be locked by locks or other means to prevent accidental movement of
the transformer. Where full height partition walls are built, adequate
clearances should be provided.
Flat paving stones may also be used for making platforms provided they
are laid on a firm foundation and can provide drainage and withstand the
weight
For installing pole mounted transformer, as far as possible, junction poles,
subsidiary poles and street lighting poles, should not be used as transformer
poles. Where unavoidable, special care should be taken to maintain proper
climbing space and to avoid crowding of wire and equipment. Transformer
should be installed only on poles strong enough to carry their weight.
Transformer poles should be straight and where necessary, guyed to prevent
leaning or raking of the pole after the transformer is hung. Double cross arms
should be provided for each transformer installation. The climbing space
should be carefully maintained so that it should not be necessary for a line
man to come close to the transformer tank in climbing up or down a pole. A
suitable anti-climbing device should be provided
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 Requirement of Foundations for Installing Rotating
Electrical Machines as Per IS

A solid foundation of concrete is provided for the installing of

rotating machine. To avoid misalignment of plate proper mounting
of the machines, the motor or prime mover and the driven machines
are mounted on the common foundation. Usually the manufacturer
put both the machines on common steel base. The size of the
foundation is decided from the drawing supplied by the
manufacturer. The foundation is designed taking into consideration
the dynamic as well as static load.

The foundation consists of following :

 Foundation made of cement, concrete material.

 The bed plate.
 Foundation bolts. MRSS. A V THAKARE LEE GP AMRAVATI
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 Foundations: Requirements and factors affecting rotating machine
foundation.
The plant at which the machine is manufactured give the basic dimensions
of the foundation,
•The concrete foundation should be about 15 cm larger in both length and
breadth than the machine feet or bed plate or side rails; these dimensions of
course refer to the top of the foundation block.
 The depth foundation is decided taking into consideration the work place,
panel height etc
•The depth of the foundation should be as given in Table but if it is desired
that the machine should stand up above the floor level i.e. on a plinth then the
height of that plinth must be added to the foundation depth.
Depth of Foundations
Horse Power Depth
10-25 15 to 20 cm
20-50 20 to 25 cm
50-75 25 to 32.5cm
75-100 32.5 to 60 cm
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• The above figures are for a normal sort of drive; in cases where
shock loading, large powers and vibrations are to be
encountered, manufacturers of machine be consulted.
• In some cases, it may be difficult: to reach hard ground, in this
case a large foundation will be necessary to support the weight of
the machine and the force of the drive such as the belt or chain
pull.
• In such cases, it becomes very difficult to decide on the
dimensions of the foundation block, and will be better to discuss
the problem with local authority or surveyor who can advice
correctly.
• In those rare cases where the foundation can be placed on solid
rock it will sufficient to cut out pockets for the fixing holes of the
motor to be grouted into and provide a concrete face or level where
the nature of rock make necessary.
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Making Concrete Foundations:
• The first step is to excavate the ground to the size and depth of
the] foundation pit. This excavation should be carried well down, and
the bottom] and sides should be tightly rammed to ensure that the
underlying earth the foundation and the machine, and that the sides
of the foundation pit are firm] to resist the drive forces.
• Around the outside edge of the foundation pit a wooden mould
should being placed to shape the plinth. It should be so arranged that
it should provide! cable trenches and pipes etc. if required.
• The plinth is usually tapered so that it is larger at the bottom than
the top, Supported from the top of the plinth moulds are the forms
for the pockets for grouting in the foundation bolts; or alternatively
the bolts may be placed in position and the concrete allowed to
solidify round them.

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• The best method is to leave holes in the concrete face into
which the bolts may then be grouted.
• For concrete foundation a concrete mix is made by employing
one part of cement, three parts of sharp sand and four parts of
broken stones (gravel) they are mixed in a concrete mixer with
proper portion of water and it is fed into the mould smoothed
down with a shovel as far as possible; and when
whole mass of the concrete is in position i.e. the concrete is level
with top of the plinth, it should be rammed down with a heavy
rammer until water just shows on the top surface.
This surface is then smoothed off. The block should be left to set
for approximately 24 hours. After which the wooden mould and
foundation bolt pockets should be removed, and the whole of the
foundation block smoothed down. It should then be cured with
water for at least a week.
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 Procedure for Levelling

(a) In case of direct drives, the first

consideration in lining up is that the motor
shaft should be levelled. The motor shaft
cannot be made level unless the shaft of the
driven machine is previously levelled. It is
therefore essential that the driven machine or
driven shaft is levelled first. The essential
requirement in this case is that the shafts
must be in line. In case of belt or gear drives
they must be parallel.
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• b) Direct Coupled Drives: In case of direct
coupled drives, also the two shafts must be in
line. If the driven shaft is first being levelled, the
method will be to bring the two couplings close
together and roughly line them up by eye. If the
driven machine's coupling is lower, either we
have to lift it or cut down the top of concrete
foundation to lower the motor. If instead the
motor shaft is lower, it can be raised by placing
packing, and the two couplings are brought in
line. The final result is that the two shafts are on
the same centre as shown in Fig.
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• Lining up Belt-Drives: The belt drives are those drives which use
Vee belts and chains for driving a driven machine. The lining up can
best be achieved by making measurements with a steel tape; from
the center of the driven shaft to the centre of the motor shaft and
at the opposite end of the motor to the appropriate point along the
driven shaft. These two measurer should be the same. When this is
achieved, it is sufficient to ensure that shafts are approximately in
line. The grouting of foundation bolts is carried out in this stage.
The final adjustments are done afterwards.
• When carrying out final alignment it will be necessary, in the case
types of drive, to ensure that the packing pieces placed between
bed or slide rails and the top of the foundation block are positioned
correctly! they must be at the position of the foundation bolt holes
and not in bet those positions and there must be enough of these
supports to ensure when the foundation bolts are tightened down
the bed plate or slide rails; not be bent.

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 Procedure of Alignment of Shaft of
Electrical Machine
• The alignment of direct - coupled
drives can be easily made by the
following three steps .

• Axial positioning of the shafts.

• Paralleling of shaft axis.
• Centering of the shaft axis.

• Fix the motor and driven machine on

the bed plate in their final position.
Level up the motor driven shaft with
proper positioning of shims. The
spirit level can be used to some
extent to check the alignment of the
shaft. A lining up tool as shown in the
Figure A can be used, which is most
useful .

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• After the shafts have linked
properly, the lining up tool is
bolted in position as shown
in the Figure B. It is so placed
that there is a small gap
exists between the two
points. The two shafts are
now rotated together and if
the two points do not diverge
then the shafts are parallel.
When the relative positions
of the points remain the
same throughout one
complete revolution of the
shaft, then the alignment of
the shaft is correct. It is
shown by the following
figure.

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• The difference in the height of axis of
drive shaft and driven shaft can be
checked by steel ruler. The straight
edge of the ruler is placed on the two
outside flanges of coupling as shown in
Figure C. If the center of heights are
the same the ruler edge touches each
flange along its whole length then they
are aligned. When steel ruler touches
only one flange, that will mean that
one shaft is lower than other. On the
other hand, when the couplings are on
the same center, with the shaft not in
line with the edge of ruler touches the
flange only one or two points.
To confirm the running true of two coupling halves the gap between two couplings is
checked with the help of the filler gauge. The gap is checked by turning the motor shah
through 90°, 180°, 270º, and 360° The readings should remain unchanged at all the
positions of the shaft. By using the above methods the alignment is checked. The
adjustment in driving and driven shaft is carried out packing shims. The foundation
bolts are slowly tightened and grouting is carried out, only after careful alignment of
two shaft

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 Alignments of Indirectly Coupled drives
• The alignment motor for rope and belt drive is carried out before grouting in
the slide rails. The motor is firmly bolted to the rails which stand loose on
the foundation and is then aligned. A spirit level is placed across the
machined surfaces of rails which are then levelled using shims. Only metallic
shims are used instead of wooden once. If wooden shims are used, it yields
under pressure and swells when moisture enters into wooden shim, while
grouting. The rails are levelled in both directions. The motor shaft is then
lined up with the driven line shaft and two pulleys, driving and driven are
brought into alignment.
• For the correct alignment ; the faces of the two pulleys lic in parallel planes.
This is achieved when two points on opposite sides of each pulley are
connected and a straight line results.

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 Location of Transformers
. Indoor Sites:
(i) The most important thing to be ensured with transformer installed indoors is proper
ventilation, than free movement of air round all the four sides. The level of the transformer
base should be higher than the highest flood and storm water level of that area.
(ii) The transformer should be kept well away from the wall. The minimum recommended
spacing between the walls of the transformer periphery from the point of proper ventilation
have been shown in fig
(iii) The site should be so chosen that it is not normally damp, besides corroding the tank body
and tubes, the damp may find its way to the bushings and may cause them to flash over. There
shall be no chance of water dripping either on the transformer or anywhere in the transformer
room itself, chemical fumes, particularly acid fumes, should not be allowed in the transformer
room as they corrode the tank and also cause the oil to deteriorate.
(iv) For indoor installations the air inlets and outlets shall be of adequate s\i and so placed as to
ensure proper air circulation for the efficient cooling the transformers,
(v) Minimum clearance between the highest point of the conservator tank to' ceiling of the
transformer room should be sufficient to remove the mounti on the transformer like the
conservator. However, this clearance should I be less than 0.5 m.
(vi) The transformer should be so installed that severe vibrations are I transmitted to its body.
(vii) Outdoor sites: Only transformers designed for outdoor use should ' installed outdoors. In
case of locations where the atmosphere is polluted, is desirable that the transformer is located in
suitable covered shelter minimize adverse effects of polluted atmosphere; also care should be tal
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DIFFERENT TOOLS USED IN THE MAINTENANCE

(a) Bearing Puller:

• Tools-of this type are most useful
for withdrawing bearings, sprockets,
gears etc. when the space at the back is
restricted. Fig. shows; a bearing wedge
applied to the driving end bearing of a
motor rotor where the use of ordinary
drawing gear is often difficult due to
limited space and danger of damage to
windings.

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(b) Filler Gauges
• The air gap should always be
checked after dismantling and
reassembly, it is also a part of routine
maintenance, particularly in case of
sleeve bearing machines.
• In making this measurement a
special long feeler gauge is inserted
through the apertures which are often
provided in the end bracket for the
purpose.
• These apertures are usually plugged
to exclude dirt, andthescrewed plugs
must be removed to permit insertion of
the feeler Gapping apertures are
usually provided at four points
separated by an angle 90°.
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(c) Dial test Indicator: Dial Indicators are measuring
devices used in mechanical and industrial applications. They are
designed to measure in vertical or horizontal positions and
typically used to measure clearances, tolerance, and variation in
tolerance of machined parts to ensure accuracy.
• Dial type indicators are used to check the run-out of rotating
parts (commutators, rotors, shafts). These indicators consist of
a system of interlinked levers or of gear wheels to magnify
small movements, enabling them to be read on a pointer type
dial.
• The indicator is secured to the holder and a vertical stand,
mounted on a base to permit it to be fixed at any angle.
Indicators can also be used to check the alignment of shafts in
electrical machines.
The indicators are generally provided with 0.01 mm scale
divisions. During measuring, the base is placed on a stationary
support and the measuring rod is set perpendicular to the shaft
axis.
Then the rod is made to bear upon the surface being checked.
Prior to taking the run-out reading, make sure that the indicator
is positioned correctly. For this purpose, lightly tap the indicator
case, the pointer, in this case, will oscillate. If after oscillation it
returns to its initial position, the indicator is set correctly.
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(d) Spirit level:
• When installing electrical machines, checking of foundation for correct level is to be
carried out. For this purpose, hydrostatic or spirit level is used.
• The operating principle of a spirit level is based on the fact that when it is in a
horizontal plane, a bubble in the bent glass tube filled with liquid rises to top centre.
• When the machine foundation is checked for levelness, first determine the direction
of the inclination if any and then its value.
• To obtain correct measurements, wipe off the bottom surface of the level and also
the surface on which it is to be placed, with rags.
• It should always be remembered that the sensitivity of spirit level will be impaired
by heat

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(e) Megger: For measurement of insulation resistance, which is very
high, a megger is used. Megger consists of a mega-ohm meter and
built-in generator, which is either hand driven or a motor driven.
• One terminal of the megger is connected to winding terminal and
other is connected to earth or frame of equipment.
• In case of fault between windings, both the terminals are
connected to separate winding terminals and the armature of the
generator is rotated at constant desired speed.
• If there is fault between the windings or winding snd earth, the
pointer will deflect at zero mark/ otherwise it measures the insulation
resistance in mega-ohms. From this value of insulation
resistance, quality of insulation is determined.
f) Earth Tester: A earth tester works on the same principle as a
megger. The difference being that slip-rings are also provided on the
hand driven generator to permit a.c. supply to the external circuit
through the soil to eliminate electrolytic effects. And a commutator
which will rectify the current before it is applied to the moving coil
elements.
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(g)Multimeter:This type of instrument is a must for a repair shop. It
is a battery operated instrument and mostly used for determining
continuity of the windings. This meter has facility to measure the
resistance values.
• By selecting the suitable range on the dial, almost correct value
of resistance can be measured.
• The meter also provides the facility to measure the current in
different ranges or voltage in different ranges.
(h) Growler: It is a equipment used for finding shorted turns of
armature coil or stator/rotor winding. It is essentially a single
winding transformer.When connected to single-phase a.c. it will
produce alternating flux, when this links with the shorted turns of
winding very large current flows through it producing a humming
tone or causing vibrations, or heck-saw blade placed on the slot
containing the faulty coil.It is available in two forms called as
external growler and internal growler and can be used to find out
shorted turn faults in armature windings or rotor and stator
windings
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