Our process begins by completely removing all the segments from the caster and involves comprehensive measurement and analysis of pads, pins, keepers, saddles, and segment repair stands relative to plan specifications. Recommendations are made for shimming practices and a best-fit center for proper caster alignment is calculated.
Our practice has proven to be 10 times faster than conventional surveying and has received numerous recognitions from AIST Operating Committees.Related Resources Project Details
Working in a collaborative manner with the technology and expertise of Falk PLI, ThyssenKrupp was able to achieve precision equipment installation and alignment without the costs and delays associated with third party checks. This allowed contractors and equipment OEM’s to address concerns in “live time” instead of waiting for a report on conditions. Whether it is a new mill installation or routine maintenance, our practices are more efficient and reliable than traditional mill surveys.
Falk PLI remains the preferred supplier of alignment services and works with AMNS to develop maintenance best practices.
Over the course of 4 months, Falk PLI worked under the direction of Fluor and in coordination with equipment OEM Andritz to expedite the setting of equipment. Our “sell off” process enables all parties to verify the mechanical setting of the equipment relative to onsite monument control within 24 hours and avoids the delay and costs associated with third party checks. Onsite project management and staff support allowed for quick turnaround of reports while maintaining QA/QC practices.Related Resources Project Details
As part of a $200M modernization to the mechanical, electrical, and automation systems, Falk PLI provided a complete laser scan and 3D pointcloud of the plate mill operation. The resulting information accurately documented as-found conditions aiding in design efforts. A unique challenge of the project was maintaining operations while constructing a new foundation and downcolier in an adjacent building, requiring a comprehensive understanding of mill stability and an integrated process to ensure construction site control.Related Resources Project Details
The challenge – how to safely, quickly, and accurately measure crane rail structures that are 50’ above ground. Conventional survey requires shutdown of the operations and man-lifts in order to take measurements. Our methodology measures from the ground and a crane mount then combines data into a 3D coordinate system. The quantity and quality of data gathered by laser scanning expands the information available to make adjustments to rails and girders as well as entire support structure often uncovering the root cause of crane failure.Related Resources Project Details
Over the course of the project, the Falk PLI team mobilized on 3 different occasions for a total of 225 hours to support the equipment setting. We were able to significantly reduce the total number of hours needed by establishing good site control at the onset of the project, utilizing the efficiency of the laser tracker, which has the ability to measure multiple pieces for process equipment from one set-up, and coordinating with all contractors. By using a single source for alignment services this project stayed ahead of schedule.
$750M transformational investment. Falk PLI worked with Alcoa, Danieli, Walbridge Industrial, and Heavy Lift to perform all the necessary industrial measurements required for precision equipment alignment and installation.Related Resources
The above slitter animation shows the deflection of the roll based on 3 coils representing varying strengths and chemistries. Using laser tracker technology, Falk PLI mounted nests and the SMR to the recoiler and measured deflection. While equipment is designed to move, is the movement predictable and within design tolerances? While the onset of AHHS will continue to push the design parameters of processing equipment, Falk PLI is working to help our clients get capital upgrade performance on a maintenance budget.Related Resources Project Details
With the rotor pulled out of the lower casing, Falk PLI’s crew was able to measure and report: casing split line elevation, diaphragm alignment and elevation, bearing diameter and profiles, and bore diameter and profiles. Using the laser tracker to obtain our measurements, we were able to quickly and accurately gather a large amount of data, provide detailed analysis relative to turbine centerline and provide shimming recommendations. Traditional measurement methods would have been limited to horizontal and vertical deviations.Related Resources Project Details
Our team worked with the pump OEM to determine ideal points to monitor for pump housings and bearings. Starting from a cold state through full operation, we recorded the 3D movement of 11 designated points and correlated data with the temperature reading of the pump. By plotting the movement of the pump over time and temperature, we were able to simulate the operating conditions for future modifications and new pump installation.Related Resources Project Details
Falk PLI used the basis 3D laser scanning to generate custom reports for ComEd including: 3D pointcloud for autocad analysis, 2D drawings of areas surveyed, and detailed tables itemizing structures. This information is used by the engineers in the office for component replacement and documentation for an emergency outage. As a result of this work, laser scanning is becoming a key methodology for future substation upgrade projects to avoid the scheduling of outages for the sole purpose of collecting data.Related Resources Project Details