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By Brad Case in Bases, Machinery Installation and Best Practices, Shims, Soft Foot June 4th,
2010
Soft foot is a common issue when aligning rotating equipment. It is a major cause of
repeatability problems in shaft alignment measurements. In addition to alignment quality and
repeatability problems, it can be a cause of machinery vibration, reduce life in electric motors,
and cause internal clearance problems in gearboxes and pumps.
But if the proper precautions are taken, soft foot can be minimized and controlled.
The term soft foot is the common term used for the improper contact between a machine
casing, and the baseplate used to support it. It may be either an angular or parallel soft foot, but
often it is a combination of the two.
It is often compared to a straight-backed wooden chair, where one leg, being shorter, does not
contact the floor, causing a rocking motion in the chair when you are seated in it. While this is a
good mental image, soft foot in machinery is a little more complex. While an angular soft foot
might make contact with a baseplate or foundation, it does not make a UNIFORM amount of
contact. Once base bolts are tightened, the foot tends to bend to conform to the baseplate to
which it is mounted.
CAUSES OF SOFT FOOT CONDITIONS
Excessive tension on machine feet due to jack bolts warping the machine feet.
it can cause the same type of problem. Once you tighten the bolt where the soft foot is, you
change the relative position of the shaft. In other words, the position of the shaft changes
between tight and loose. If you have used laser alignment tools, you might have noticed that
there is sometimes a foot that causes a noticeable change in the vertical or horizontal readings as
you tighten a particular bolt. Often, this is the location of the soft foot condition.
Notice that the relative position of the shaft centerline changes due to changes in the position of
the soft foot.
In addition, unless you tighten and loosen the bolts in sequence, the position of the shaft
centerline in relation to the stationary machine can change. As an example, if you tighten the
inboard left foot first one time, and the inboard right foot the second time, you may take
measurements in different shaft centerline locations. Using the straight-backed chair analogy, not
tightening in a known sequence causes the movable machine to rock into different positions.
STEPS TO MINIMIZE AND CONTROL SOFT FOOT
Confirm that base plates and foundations are installed and leveled to specifications.
Make sure that baseplates and machine feet are clean, deburred and free from dents in the areas to which
machinery will be mounted.
Use clean, flat shims. If you must cut thicker shims from steel stock, be sure they are clean, flat and
deburred.
Once the machine components are placed on the baseplate, rough align, and perform a gross soft foot check
of both the movable and stationary machines.
o
Check one foot at a time, on at least three corners of each foot, with a 0.005 shim or feeler gauge.
Correct by shimming with the minimum number of shims possible. If an angular soft foot
condition exists, cut one shim in half, leaving the tab in place, to make it easier to reposition.
Do not attempt to cut several shims to step the shim thicknesses under a particular foot. While
this might seem like a good idea to increase the amount of contact area, it becomes much more
complicated to reposition several shims each time.
Once gross soft foot has been corrected, tighten each bolt, using a bolt torque pattern similar to the diagram
below. The starting point can be any foot, as long as the same pattern is followed EACH TIME the feet are
loosened and tightened.
Once all bolts are tight, loosen one foot, and recheck for soft foot with a 0.002 shim or feeler gauge.
Repeat the process of checking each foot at three corners, to identify angular soft foot. Shim to correct as
needed. Then retighten the foot and move to the next one. Repeat this process until all feet have been
checked and shimmed as needed.
Tighten foot bolts using 3 passes and following the same bolt torque pattern on each pass. 1 st pass tighten to
hand tight. 2nd pass tighten the bolts, using a wrench, to around 50% tightness. 3 rd pass, complete tightening
the bolts. This will minimize the effect of any remaining soft foot.
Additional soft foot checks can be done using laser alignment tools that have soft foot check capability or
with dial indicators. But be mindful that soft foot can not only be in the machine foot it can also be in the
baseplate to which the machine is mounted. In other words, when you loosen the foot bolt, the machine foot
may not move, but the base or support underneath it might. This can happen when the foot of the machine
you are aligning is thicker than the base or riser onto which it sits. In the example below, if the motor feet
are tightened, the base may bend upward to contact the thicker motor foot.
If the base moves up to contact the motor foot, you may not be able to measure it with a laser alignment
tool, or a dial indicator, but it might still cause a soft foot response in the movement of the motor. A shim or
feeler gauge is preferred to determine and correct this type of soft foot.
Using two offset readings along with fixture setup and machine dimensions, the relative position
of the movable shaft is determined by performing calculations or by graphing/plotting. See 3.3.6
and 3.3.7 for detailed reverse dial calculation and graphing procedures.
While some fixtures are designed to permit reverse rim alignment with the shafts un-coupled,
others require that the shafts be coupled during the alignment process.
Many fixtures accommodate reverse rim alignment with the indicators mounted either at the
same location along the shaft circumference (as shown above) or 180 degrees opposite one
another, that is, in a cross dial arrangement.
Maximize the distance between the dial indicators for the geometry of the machine being
aligned. As a general rule, the plungers should be positioned at least 100 mm apart.
Ensure that fixtures are mounted at a position where rotation is possible. It is desirable to
have 360 degrees of rotation.
Before obtaining alignment measurements, determine dial indicator bar sag and ensure
that dial indicator readings are valid and repeatable.
Reverse-Rim dimensions
To accurately determine the position of the movable shaft using reverse rim calculations or
graphing procedures, the relative position of the dial indicators and the front and rear feet of the
movable machine must be determined.
These dimensions should be determined using a standard tape measure. Each dimension should
be measured to the nearest 1/8 (1-2mm).
The B Dimension
The B Dimension is the distance from the movable side indicator to the front foot bolt center.
This dimension is measured parallel to the shafts. Especially on larger machines, it is sometimes
helpful to use a string or straight edge to transfer the position of the movable dial plunger to the
machine base prior to measuring this dimension.
The C Dimension
The C Dimension is the distance between front and rear foot bolt centers. This dimension is
measured parallel to the shaft.
The set up in figure 3.49 doesnt affect the sign of the dial indicator readings
(horizontally and vertically)
When using the set up in figure 3.50 and zeroing at 12:00 or 3:00 the sign of the movable
dial indicator value DIM has to be reversed.
When using the same set up as in figure 3.50 but instead zeroing at 6:00 or 9:00 the sign
of the stationary dial indicator value (DIS) has to be reversed.
Obtaining a set of as-found readings is considered optional in some facilities, but is highly
recommended here. For most alignment tasks, it is desirable to obtain and document a complete
set of as-found readings along with the A, B, and C dimensions. As-found readings are used for a
variety of purposes:
Documenting alignment conditions prior to removing equipment from service for repair.
Better communication between different personnel involved with the alignment task.
Figure 3.52
2. Set both dial indicators to the positive sag value.
NOTE: For example, if the amount of sag for a fixture is determined to be -10 mils (-0.254 mm),
the dial would be set to read + 10 mils (+0.254 mm) at the 12:00 position.
Figure 3.53
3. Rotate both shafts (if possible) to 6:00.
Figure 3.54
4. Record the DIS and DIM dial indicator TIR values.
To determine vertical angularity from the two reverse rim offsets, use the following rule:
Consider the following reverse rim 6:00 total indicator readings (TIRs).
Figure 3.57
2. Set both dial indicators to zero.
3. Rotate both shafts to 3:00.
Figure 3.58
4. Record the DIS and DIM dial indicator TIR values.
To determine horizontal angularity from the two reverse rim offsets, use the following rule:
Consider the following reverse rim 3:00 total indicator readings (TIRs).
Many different equations may be used for various reverse rim calculations. The
information presented here applies to a reverse rim dial setup such as that shown
below. The equations presented are used to calculate the position of the movable
machines front and rear feet from DIS and DIM offset values.
Calculations apply to both the vertical and horizontal planes of misalignment. However,
they are typically applied primarily to the vertical plane. As presented earlier,
Figure 3.60
The position of the movable machines front feet is determined using the following
equation:
Figure 3.61 Front feet equation
The position of the movable machines rear feet is determined using the following
equation:
Figure 3.62 Rear feet equation.
where:
A = the distance between the stationary and movable dial indicator plungers.
B = the distance from the movable dial indicator plunger to the movable machines front
feet bolt center.
C= the distance between the movable machines front and rear feet bolt centers.
Positive results mean the foot is high (vertical) or to the right (horizontal.)
Negative results mean the foot is low (vertical) or to the left (horizontal.)
The stationary side offset (S) is +12 mils (0.305 mm), or 12 mils high.
The movable side offset (M) is +17.5 mils (0.444 mm), or 17.5 mils high.
Figure 3.63 The front feet are 25.2 mils (0.64 mm) too high; shims need to be removed.
Rear Foot Position Calculation
Figure 3.64 The rear feet are 51.6 mils (1.31 mm) too high; shims need to be removed
This line represents the stationary shaft center and is drawn across the page midway
down the graph dividing the page. It is helpful if this line is on top of one of the bold
lines.
Always use the largest scale possible. Measure the distance from the stationary indicator
plunger to the centerline of the rear feet of the movable machine. Standard graph paper is
about 260 mm. The largest horizontal scale will be the machine distance divided by the
page width. Note your horizontal scale.
5. Make a small vertical line on the extreme left of the horizontal line.
This mark represents the point along the length of the stationary indicator plunger and is
labeled: DIS.
6. Using the proper scale, make a second vertical line to the right of the first on the horizontal
line.
This line represents the point along the length of the movable indicator plunger and is
labeled: DIM.
7. Make a third small vertical line representing the point along the length of the front feet of the
movable machine (FF).
8. Make the fourth vertical line representing the point along the length of the rear feet of the
movable machine (RF).
Upon completion of the steps above, the graph will look similar to the one shown below. For this
example, the A, B, and C dimensions all equal 100 mm.
Plotting Offsets
After setting up the graph, the next step is to plot the offsets in the planes of the dial indicators on
the stationary side (DIS) and movable side (DIM). To plot the offsets, perform the following
steps:
1. Determine the vertical scale.
The vertical scale is typically 1 hundred of a mm (0.01) per division. In cases of gross
misalignment where the offsets will not fit on the page, a larger scale, such as 2-3
hundreds per division, is sometimes required.
Use the horizontal line representing the stationary shaft centerline as the reference. All
points above this horizontal line are positive (+) and all points below the line are negative
(-).
If the movable shaft is above the horizontal stationary shaft reference line, the shaft is too
high.
If the movable shaft is below the horizontal stationary shaft reference line, the shaft is too
low.
6. When interpreting the graph to determine the movable shafts front and rear feet positions in
the horizontal plane, view the graph the way you view the machine, that is, standing behind the
movable machine facing the stationary machine. Also, observe the following rules:
If the movable shaft is above the horizontal stationary shaft reference line, the shaft is
positioned to the right.
If the movable shaft is below the horizontal stationary shaft reference line, the shaft is
positioned to the left.
To correct misalignment involves a number of different procedures. The sequence of steps in the
correction process varies slightly according to the specific alignment conditions of the machine.
Before Correcting Misalignment
Measure misalignment.
When it comes to actually moving the machine, that is, SOLVING the PROBLEM, several
questions are often asked:
Correcting misalignment involves initial and final corrections. Initial corrections are made to
minimize the amounts of misalignment and improve the accuracy of alignment measurements.
Prior to making any moves, look at the horizontal and vertical positions of the movable machine.
In general, you will start the correction process by making initial corrections in the plane where
the misalignment is worse and then make final corrections.
Making Corrections
If
Misalignment is 0.5 mm
or less
Misalignment is greater
than 0.5 mm
Misalignment is greater
than 0.5 mm
Then
In this example, the horizontal misalignment is over twice the vertical misalignment. Therefore,
an initial horizontal adjustment will be made; then, final vertical and horizontal corrections will
be made.
Figure 3.68Positive values at the feet mean that the movable machine is high, therefore you
will remove shims. Negative values mean that the movable machine is low, so you will add
shims.
Positive values at the feet mean that the movable machine is away from you; therefore it
should be moved towards you.
Negative values at the feet mean that the movable machine is towards you; therefore it
should be moved away from you.