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www.esi-alphatec.com

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LASER ALIGNMENT


SERVICES• Insitu Machine Regrouting & Chocking •

• Foundation Repair & Strengthening •• Laser Alignment •

• Machinery Installation & Relocation •• Anchor Bolt Design & Manufacture •

• Controlled Bolting •• Biomechanics Force Plate Systems •

• Precision Grouting •• Structural Clamping •• Robotic Demolition •• Hydro Demolition •• Concrete Cutting •• Concrete Drilling •

• Wire Sawing •

PRODUCTS• Chockfast Orange® •• Epocast Celloflex •

• Epocast 36® •• KS-Jackscrews •

• RotaChock® •• Thordon Polymer Bearings •



ABOUT US

BEGINNINGSESI Alphatec began in 1989 as Alphatec Engineering – a highly specialised and efficient enterprise in the heavy industrial and marine fields. A restructure in 2003 saw the integration of our mechanical services company, Engineered Solutions International (ESI), and the renaming of the company to ESI Alphatec.

TODAYToday, ESI Alphatec has grown to a group with more than 9000 contracts completed in Australia, New Zealand, Papua New Guinea, South-East Asia and Africa. We provide highly specialised services in the industries of Mining, Oil & Gas, Petrochemical, Off Shore Structures, Marine, Defence, Energy, Cement and Manufacturing.

SPECIALIST SERVICESDuring our 25 years of very successful operation, ESI Alphatec has developed a reputation of excellence and safety in such areas as insitu machinery regrouting, machinery & geometric alignment, controlled bolt tensioning/torque & foundation bolt design, relocation of machinery & production lines, and machinery foundation refurbishment & structural repairs.

These specialised services commonly involve work on a wide range of equipment and machines including reciprocating compressors, diesel engines, turbines, crushers, ball & sag mills, stamping presses, and paper & plastic manufacturing equipment.

Our specialist services group provides survey and set out to new equipment facilities and construction projects, and laser & optical alignment service – including thermal growth studies to generators, pumps, compressors and gearboxes. ESI Alphatec also specialises in geometric alignments such as measuring the straightness, flatness, parallelism and bore alignment up to 60 metres.

ESI Alphatec Engineering Service also includes research and development into machinery mounting products and the advancement of machinery installation techniques. We also design, manufacture and supply specialist rolled thread fasteners complete with tension monitoring devices where applicable.

SPECIALIST PRODUCTSWe are the authorized distributors and applicator of Chockfast Orange, Epocast, Rotachock, and other society approved marine machinery mounting systems. We provide support to owners, builders and engineering activities in obtaining classification society approvals or military qualification for machinery mountings. We also provide other industrial solutions including Thordon Bearings and KS-Jackscrews.

CUSTOMER SATISFACTIONTo ESI Alphatec, customer satisfaction is paramount. We believe in meeting and exceeding the continuing demand for more innovative methods of engineering, project execution and management techniques to provide construction and maintenance processes that are safer, more efficient and more cost effective.


LASER ALIGNMENTWe cover a number of critical alignment issues to deliver savings in power consumption, elimination of premature repairs and the reduction of loss of income due to machinery system failures. We are highly proficient at performing accurate recordable readings and can provide you with full hard copy reports for your reference.

ESI Alphatec regularly provide Laser Alignment services to cover a number of critical alignment issues. We are highly proficient at performing accurate recordable readings and can provide you with full hard copy reports for your reference.

COST SAVINGPrecision Laser Alignment, as provided by ESI Alphatec, is a highly cost effective investment. The cost is small when compared to losses in production, should machinery fail. Our accurate laser alignment delivers savings in power consumption, elimination of premature repairs and the reduction of loss of income due to machinery system failures.

Laser Alignment equipment had a great advantage in that the work can be quickly performed reducing downtime and minimising production losses. It can also be made with a high degree of precision and the results documented.

ROTATING MACHINESPoor Laser Alignment is a leading contributor in the premature failing of rotating machinery. More than half of all excessive vibration in machinery can be attributed to misalignment. This is a result of not enough consideration being given to the dynamic movements of the machine.

Shaft misalignment can cause -

• Bearing failure • Shaft failure • Sealing failure • Coupling wear

• Overheating • Energy loss • High vibration

MANUFACTURING MACHINESMisaligned manufacturing machines will suffer unnecessary vibration and this can lead to -

• Loss in quality of the finished product • Needless and/or premature wear on tools • Loss of time for adjustment of tooled details • Possible machine breakdowns • Loss of energy and its associated costs

LASER ALIGNMENT


MEASUREMENT & ALIGNMENT SOLUTIONSESI Alphatec offer the following measurement solutions

Horizontal 9-12-3 For alignment of horizontally mounted machines according to the 9-12-3 method.

Partial Turn For alignment of horizontally mounted machines. Only a total of 40o rotation of shafts needed.

Cardan Shows angular error and adjustment values for cardan coupled/offset mounted machines.

Vertical For alignment of vertically and flange mounted machines.

Machine Train For alignment of two to ten machines in a row - nine couplings.

Thermal Growth Compensation For shaft alignment. Compensates for difference in thermal growth between the machines.

Softfoot To ensure that the machine is resting evenly on its feet before alignment.

Offset and Angle For offset and angular error for example between two shafts.

Values For measurement values live. For both shaft alignment, straightness and dynamic measurement.

Straightness For straightness measurement of, for example, machine foundations, bearing journals and machine tools.

Flatness For measurement of flatness/twist, for example, on machine foundations and machine tables.

Squareness For measurement of squareness in machinery and plant, for example, in drilling and milling machines.

Parallelism For measurement of parallelism, for example, between rolls or machine sides.

Centre of Circle For straightness measurement of bearing journals with different diametres, for example, in diesel engines.

Half-Circle For straightness measurement of bearing journals and diaphragm. Allows different diameters.

Plumbline For measurement of plumbline (vertical) and straightness, for example, of turbine and generator shafts.

Flange For flatness measurement of flanges and circular planes, for example, in slewing bearings.


ALIGNMENT PRODUCTSTo deliver our customers the best possible solution within our range of services, ESI Alphatec seek out products that ensure we are at the cutting edge of best practice within our areas of expertise. This allows us to provide not only a unique service to our clients, but also an exciting and challenging environment for our employees who are exposed to current technology and ongoing training opportunities for a range of product solutions.

Chockfast Orange®Chockfast Orange is a conveniently pourable, two-component, structural epoxy “chock” that replaces tediously fitted steel shims (or steel chocks), ensuring intimate contact with machined or un-machined equipment bedplates.

Virtually 100% effective bearing underneath supported equipment.

The pourable properties of Chockfast Orange also make it an ideal solution for the installation of stern tube bearings. Using traditional methods of interference fitting can be a labour-intensive and time-consuming job. Boring bars and hydraulic jacks are difficult to set up and operate, and any resulting alignment errors are difficult to correct.

The use of pourable epoxy chocking compounds to install stern tube bearings, is a technique which has been in existence since 1979 and has been used world-wide. After the epoxy cures, the bearing is “captured” (encapsulated) in the bore with virtually 100% surface contact.

Epocast 36®EPOCAST 36® is a two-component pourable chocking compound enriched with high-grade fillers. Modern manufacturing methods, filling and testing systems, guarantee constant compliance with the physical and chemical properties required for EPOCAST 36® by Classification Societies and other institutions.

EPOCAST 36® is suitable for use as an equivalent to steel liners when mounting main and auxiliary engines, gear boxes, steering gears, thrust bearings, stern tubes, and rudder bushes.

EPOCAST 36® offers the following advantages:• Simple to use • No machining of the foundation• Compensates for any distortions of the foundations• Can form large thick chock• High compressive and impact strength• Seawater and chemical resistant• Reduces noise and vibrations• Viscosity adjustable according to ambient temperatures• Weight saving• Prevents crevice corrosion• Relatively uniform loading over the chock surface

KS-JackscrewsA KS-Jackscrew is an aid for easily levelling base plates and sole plates during construction activities typically associated with rotating machines, general equipment, pipe supports and steel construction found in industrial complexes. The KS-Jackscrew can also be used for foundations of buildings and bridges.

KS-Jackscrew are inserted between the foundation and the machine plate or base frame. The final height can be set following installation of the equipment or building element by adjusting the nut of the KS-Jackscrew. Use of the KS-Jackscrew avoids the need to constantly use cranes.

The KS-Jackscrew can be inserted with the machine plate or base frame once the construction part has been secured. Unlike multiple steel plates and or shims, the Condisk allows for uniform contact without high spots and associated load concentrations. The initial height can be set prior to the base plate being installed saving time and money.

KS-Jackscrews can also be used as a lifting instrument where cranes and other lifting machines are too big or costly.

Chockfast Orange®

EPOCAST 36®

ks-jackscrews


RotaChock®ESI Alphatec are the Australian distributor for the RotaChock, a recent development focusing on all sectors and industries where large machinery and engines need accurate alignment. RotaChocks are used in industries from shipping to mining and metalworking, and from petrochemicals to the transport sector.

Benefits of the Rotachock

1) Speed - A RotaChock is installed quickly. A machine set up on a RotaChock can generally be realigned and secured within one day.

2) Optimum contact surface - The RotaChock has a spherical bearing that ensures the best possible contact surface, even if the foundations and the machine foot are not parallel. In addition, the RotaChock is height-adjustable.

3) Any desired torque - The RotaChock’s behaviour is that of a solid steel chock, and the RotaChock allows the foundation bolt to be tensioned to any required torque.

4) High loads - RotaChock’s competitive edge is that it has a big footprint: the surface area of the lower ring that is in contact with the foundation is greater, so the pressure exerted on that surface is less.

EQUIPMENTESI Alphatec uses the following Laser & optical alignment equipment

• Pruftechnic Rotalign Pro • Pruftechnic Boralign • Easy Laser Geometric

• Optical Telescope, Jig Transit & Tilting Level • Digital Crank Deflection • Digital Bore Measurements

MACHINERY FOUNDATIONS

A solid and rigid foundation is a critical factor in successful Laser Alignment. Should your machinery foundations require attention, ESI Alphatec also offer highly specialised services in Foundation Repair & Strengthening and Insitu Machine Regrouting & Chocking.

Insitu Machine Regrouting & ChockingWe provide the design service and implementation of regrouting and chocking solutions to large reciprocating compressors, crushing, stamping and rotating machinery, on concrete and steel foundations. Our methods eliminates both the need to disassemble machinery and the need to hire expensive cranes or lifting equipment.

Foundation Repair & StrengtheningWe repair and strengthen sinking, cracked, and damaged foundations and structures utilising state of the art technology. This includes design and implementation of insitu structural refurbishment solutions to large machinery foundations and static structures found in heavy industrial facilities.

Contact us for brochures on Insitu Machine Regrouting & Chocking and Foundation Repair & Strengthening.


1/13 Blackly Row Cockburn Central

Perth, Western Australia AUSTRALIA 6164

P +618 9412 6666 F +618 9412 6600

E [email protected] W www.esi-alphatec.com

Proudly Celebrat ing Y E A R S25

laser alignment - esi · pdf fileks-jackscrew are inserted between the foundation and the...

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