Boralign TRG PPT - 2k3 Aug019

Welcome
BORALIGN Training
(China)
MARK NG T.H.
(Far East Asia)
(Singapore)
Productive Maintenance Technology
Germany HeadQuarter Ismaning (Munich)
Company origins
Founded by Mr.
Dieter Busch in
1972
Copyright 2001 PRFTECHNIK Laser Alignment
Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
Company profile
Activities
Development, production, sales and service of

electronic and electrical instrumentation, especially
measurement and control systems
Founded
November 15, 1972
Headquarters
Ismaning near Munich, Germany
Annual sales
29 Mio Euro (2002)
Staff
approx. 250 employees (within Germany)
Patents
approx. 200 worldwide (granted or pending)
Trademarks
approx. 100 trademarks registered worldwide
Company structure
PRFTECHNIK AG Holding
Strategic Controlling
Resources
Accounting
Financing Investments
Human
Corporate Communications
Additional Duties
Product divisions
Sales & Service subsidiaries
PRFTECHNIK Alignment
PRFTECHNIK Condition Monitoring
PRFTECHNIK Non-destructive Testing
PRFTECHNIK LTD.
PRFTECHNIK N.V.
PRFTECHNIK SARL
PRFTECHNIK S.E.A
PRFTECHNIK Shanghai
PRFTECHNIK S.R.L.
PRFTECHNIK VD GmbH & Co. KG
PRFTECHNIK Wibrem
PRFTECHNIK Technology
Great Britain
Belgium/Holland
France
Singapore (Asia)
China (coming soon)
Italy
Germany
Poland
Poland
Worldwide
Plus 100 over distributors in 60 other countries
Our record
FOR THE RECORD ..

World leader in laser alignment systems
z Shaft alignment business from 1981
z Inventor of laser shaft alignment 1983 patented
z Engineering ingenuity - holder of over 200 patents
z Patented single/receiver laser technology
z Never compromised on accuracy all systems 1micron resolution
z ISO 9001
z CE certification for systems
z Standard and EX options
z IP 67 ratings components
z
Our record
FOR THE RECORD ..

1st shaft laser alignment system in world
z 1st laser alignment system with internal electronic inclinometers
z 1st shaft laser alignment system for multiple machines
z 1st centreline laser alignment system for Turbine machine
z 1st laser alignment system with infrared
z 1st system that monitors/tracks/documents live machine movement
during operation PERMALIGN
z PT only system that tracks laser drift due to time/temperature
SYSTEM 2 Long range CENTRALIGN
z
PRUFTECHNIK South East Asia Pte. Ltd.

(SINGAPORE)
Josef Grevenstein
President / Director
Jonathan Gough
Director
Nancy Wee
Admin. Manager
Sales Department
Jessie Phua
Admin. Assistant
Service Department
Mark Ng
Sam Cheok Whai
Sebastian Tan
Regional Manager
Divisional Manager
Field Specialist
Sales & Applications Sales & Applications

Engineer
Engineer
Service Engineer
Our customers 85% World wide Market Share
Laser Alignment
Productive Maintenance Technology
Is there a better way?
The Alignment Specialist?
State of Art
Alignment Instrument?
Causes of machine damage
Consequences of misalignment: machine damage

Excessive vibration
Increased temperature
= higher energy
consumption
Reduced bearing life!
Increased seal wear

from shaft bending
What is meant by alignment?
Rotating axes must be co-linear during operation
Benefits of precision laser alignment

zPrevention of
catastrophic failures,
better maintenance
planning
z Extended MTBF
(Mean Time Between
Failures) =avoidance
of downtime, reduced
production loss
z Avoidance of
consequential
damaged to
equipment = reduced
spare parts costs
zHigher
productivity: higher
operating speed,
greater machine
power
z Lower labor
costs, reduced
dependence on
specialists, greater
manpower reserves
z Reduced spare
parts inventory
requirements
Laser alignment help reduces repair incidence
30%
50%
Laser-optical alignments cuts vibration alarms

Vibration alarms /year
Misalignment
Others
(Bearing
damage,
unbalance,
looseness)
Sources: Shell Petroleum, Stanlow, UK
Alignment methods in comparison

Straightedge
Dial Indicator
Laser Alignment
Method
Operator
Training
required
Alignment
resolution
The Wizard
Years of
experience
Max 4 mils
1/10mm
The
Specialist
Weeks to
months
Anyone with
technical
background
A few hours
0.4 mil
1/100mm
0.04 mil
1/1000 mm
How accurate are dial indicator reading?

Indicator bracket sag
Play in mechanical
linkages
Internal friction /
hystersis
Resolution
1/100mm (0.4mil)
(rounding loss)
Reading errors:
sign error
Parallax error
Mirror image
readings
Tilted dial indicator
Axial shaft play
Laser alignment products overview

Shaft Alignment
MASTERLIGN Series
OPTALIGN Plus
SmartALIGN
ROTALIGN
ROTALIGN Pro
Alignment of
Bores,
bearing
pedestals &
circular
elements
Alignment of Turbine
bearing pockets & diaphragms
SYSTEM 2
CENTRALIGN
- TURBALIGN
CNC machine
spindle Alignment
SPINDALIGN
BORALIGN
Straightness /Flatness
Pully Alignment
PULLALIGN
On-line Alignment
Monitoring
(thermal growth variations)
PERMALIGN
BORALIGN Laser System

Laser alignment comes full circle
Functions of BORALIGN Laser System
Determine the bores centreline

Set the centreline relative to any fixed bores
Determine out of roundness of bore
Calculate the minimum corrections required
View the differential alignment between bores
Align the bores to a rotating shaft or a boring
machine to the centreline
Advantages of BORALIGN Laser System
Non user dependent measurement

Repeatability
Documentation for traceability
Ease of use
Fast in-plane measuring
Abililty of calling two or more bores fixed
Start BORALIGN Application
BORALIGN Application
Bore Alignment System for:

Engines
Compressors
Boiler Feed Pumps Steam Turbine
Small Power Generating Turbine
Small Ships Bearings to Stern Tube
Gear Boxes Bearing Pockets
Extruder Barrel to Gear Box
Pumps
BORALIGN on Engines
BORALIGN on Compressors
BORALIGN on Steam Turbines
BORALIGN on Steam Turbines
BORALIGN on Small Power Turbine
BORALIGN on Small Power Turbine
BORALIGN on Bearing Pockets
BORALIGN on Bearing Pockets
Customers Statement
We used the Boralign on a Patterson

Tumbler Dryer to align the bearing pedestals.
The Boralign proved the bearings to be about
75 mils out of alignment, which was causing
premature bearing failure. This job alone
probably paid for the unit.
Steve Quillen, Eastman Chemical
BORALIGN on Small Ship Bearing to Stern Tube
BORALIGN on Pumps
BORALIGN on Pumps
Preparation for bore alignment
1. Thoroughly clean the bores / channels to be

measured
2. Ensure that the bores or bores machine are
readily moveable horizontally and vertically
3. Select laser set-up
i) Static Laser set-up
ii) Rotating Laser set-up
Internal Bore Bracket

Set up the brackets
Internal Bore Bracket

Set up the brackets for large bores diameter I.e. > 435mm
Receiver on mounting base
Setting up receiver for measurement
Press the top of the

sensor holder down to
engage the locking pin
Locking screw
Locking pin
At least half of the cylindrical

magnetic base should be
positioned in the bore
Bore Measurement
Laser emitter on fix
bracket support
Laser beam
Bore brackets assembly

with Receiver
Laser Mode
Static Laser Set-up
- Suitable for most alignment job, where the
bores can be adjusted by moving them into
position. The laser is mounted on a solid
base at one end of the machine.
-This method calculates the alignment of the
bores relative to each other, and determines
the best centerline through the measured
bores
Laser Mode
Rotating Laser Set-up

-Thos mode is used to recut the bores
with a cutting machine the laser is
mounted on the cutting machine tool
head, which then gives user the
alignment of bores relative to the
cutting machine.
-Set-up and measurement require
positioning and rotation of the cutting
machine.
- The results will indicate the ideal
position for the cutting machine, in
order to recut the bores.
STATIC Laser Set-up

STATIC LASER: Press Prev step and Next step softkeys
and follows on-screen instructions for set-up procedure.
Static Laser Set-up Procedure
Static Laser Set-up Procedure

Procedure (I)
a.
b.
c.
d.
e.
f.
Laser mounted on a bracket to the left of the machine, and at least

300mm from the nearest bore to be measured, and roughly central
to the bore axis.
Switch on the laser, leave the dust cap on, and allow laser to warmup (recommended time 20 mins).
Adjust the laser thumbwheels to start approx. in the middle of the
travel ranges.
Go to the farthest bore and use a tape measure to find the center of
the bore. Adjust the laser beam angle with the two yellow
thumbwheels only.
Then go to the bore nearest to the laser with tape measure, and find
its center. Move the laser housing vertically & horizontally so that
the beam strikes the tape center. Do not adjust the yellow
thumbwheels at this step.
Repeat step d. e. until the beam is within 0.5mm of the center at
each end.
ROTATING Laser Set-up

ROTATING LASER: Single screen appears with target
allowing user to center the laser beam on the receiver.
Rotating Laser Set-up Procedure

Rotation on boring tool head
with laser mounted
Bore end
BORALIGN Program Structure

Press soft-key to enter BORALIGN application
program from main screen.
Define Machine Set-up

or
Press soft-key Add Bore to begin

building machine bore to be measured.
Bore Types
Simple:
Normal bore with 1-measurement plane
Long:
Cylindrical bore that can be measured at both
ends. (Length required)
Complex:
Long bore with freely definable adjustment
points (usually jacking points). Enter these
points.
Gauge:
Machine reference surface e.g. work piece
split line.
Correction:
A non-measured point used for adjustment
purposes e.g. a jacking point.
Bore Properties
Select Bore to Measure
Selected bore
S = measured static
r = measured rotating
Laser mode: Static

or Rotating
To start bore
measurement
Show all laser

setups for this job
Example - Complete Bore Set-up

BORALIGN assumes that the laser is on the left and
that bores are numbered increasing towards the right.
Laser Set-up
Press Measure button to begin laser set-up
and start bore measurement.
Measurement Function
The Multipoint measurement mode is set by default
and is suitable for most purposes.
Laser mode
(Static)
Measurement mode
(Multipoint)
Calculated
bore center
Display of
measured
angular
positions &
range
Points
taken
Edit
measurement
Receiver Inclinometer &
angle in degrees
View Results
Press Results to display the
calculated bore positions.
Scale
Vertical (Y) and

Horizontal (X)
corrections
Edit Measurements
Laser setup
number
Measurement
number
Calculated Bore
center
Standard deviation
(indicates the spread of
points in the measurement)
Average bore
center for all
selected
measurements
Lists extended info: I) No. of average

ii) Date/time of measurement
Display individual
measurements
Select / deselect
measurement
III) Serial no. of receiver unit
View Settings
Press View to displays a series of view settings.
Centerline:
a) Through fixed points
b) Rotating Laser Axis
c) Static Laser Line
d) Optimise all
Display Format:
a) Normal
b) Differential ( Diesel engine)
c) View Long Bore Angles
Data Display:
a) Measured Values (only)
b) Measured Values minus
Presets
c) Preset Data
MOVE Correction
Press MOVE to bore alignment correction
Graphical scale
(Change with the
auto scale button)
Explorer Software

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Welcome

Productive Maintenance Technology

Germany HeadQuarter Ismaning (Munich)

Copyright 2001 PRFTECHNIK Laser Alignment

Development, production, sales and service of

November 15, 1972

Ismaning near Munich, Germany

29 Mio Euro (2002)

approx. 250 employees (within Germany)

approx. 200 worldwide (granted or pending)

approx. 100 trademarks registered worldwide

Copyright 2001 PRFTECHNIK Laser Alignment

Sales & Service subsidiaries

Copyright 2001 PRFTECHNIK Laser Alignment

Plus 100 over distributors in 60 other countries

Copyright 2001 PRFTECHNIK Laser Alignment

FOR THE RECORD ..

Copyright 2001 PRFTECHNIK Laser Alignment

FOR THE RECORD ..

Copyright 2001 PRFTECHNIK Laser Alignment

PRUFTECHNIK South East Asia Pte. Ltd.

Sam Cheok Whai

Sales & Applications Sales & Applications

Our customers 85% World wide Market Share

Productive Maintenance Technology

Is there a better way?

The Alignment Specialist?

Copyright 2001 PRFTECHNIK Laser Alignment

Causes of machine damage

Copyright 2001 PRFTECHNIK Laser Alignment

Consequences of misalignment: machine damage

Copyright 2001 PRFTECHNIK Laser Alignment

Reduced bearing life!

Increased seal wear

What is meant by alignment?

Rotating axes must be co-linear during operation

Copyright 2001 PRFTECHNIK Laser Alignment

Benefits of precision laser alignment

Copyright 2001 PRFTECHNIK Laser Alignment

Laser alignment help reduces repair incidence

Copyright 2001 PRFTECHNIK Laser Alignment

Laser-optical alignments cuts vibration alarms

Sources: Shell Petroleum, Stanlow, UK

Copyright 2001 PRFTECHNIK Laser Alignment

Alignment methods in comparison

How accurate are dial indicator reading?

Tilted dial indicator

Axial shaft play

Laser alignment products overview

BORALIGN Laser System

Copyright 2001 PRFTECHNIK Laser Alignment

Functions of BORALIGN Laser System

Determine the bores centreline

Copyright 2001 PRFTECHNIK Laser Alignment

Advantages of BORALIGN Laser System

Non user dependent measurement

Copyright 2001 PRFTECHNIK Laser Alignment

Start BORALIGN Application

Copyright 2001 PRFTECHNIK Laser Alignment