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60403a
88880006877 +01

MILLWRIGHT 16403A 3.0 AD

Millwright

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0888800068778 $4.68

Advanced Alignment

rt

Machine Levelling

Fourth Period

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Advanced Alignment
Rationale
l4/hy is it important

for you to leurn this skill?

Aligning two or more machine shafts that are coupled together is a very important skill to
have in the millwright trade. Thermal growth and process forces from flowing media tend
to misalign aligned machines when they are started and placed under load. Using the
Essinger procedure, along with graphs, calculations and design d,ata, it is possible to
misalign a machine when it is cold and not running so that it runs aligned at operational
temperatures. The desired end result is to have very little maintenance caused by
alignment problems.

Outcome
Wlten you huve completed this module, you

will be able to:

Align and then purposely misalign

a multiple chain of cold, non-rotating machines to a

very high degree of accuracy so that the rr-rachines are aligned when running and loaded.

Objectives

fJ

1.
2.
3.

Revierv safety, rim and face and cross dial shaft alignment.
Explain the various techniques used to measure machine thennal and process
movement.
Demonstrate graphical solutions for solving multi-machine shaft alignment.

lntroduction
You need to develop the skill of analyzing and solving machine shaft to shaft alignment
problems. Alignment solutions are developed and applied by logical thinking and by
follou,ing the strict guidelines set out in the shaft alignment modules.
The procedures followed (such as rim and face, cross-dialing and reverse dialing) use dial
indicators to measure the degree of misalignment over specific distances to determine the
required corrective moves through the formulae or the graph methods. The initial result is
a set or a train of machines that are coupled together in nearly perfect shaft alignment
when they are not running.
When the machines are energized and put online a number of things happen that result in
the shafts moving out of their ideal alignment planes. In other words, the shafts become
rnisaligned. This misalignment is detrimental to the life of the machine.

Thermal Growth or Shrinkage

Two factors that cause a machine to move off its centreline are lhermal grou,th or
shrinkage caused by the expansion and contraction ofmetal due to temperature changes.
Significant temperature changes may take place u'ithin a machine after it is started and
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O 2007. Her Majestv the Queen in right ofthe Province ofAlberta

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placed under load. The temperature may rise due to friction or to hot materials such as
steam rnoving through the machine. An example of thermal shrinkage occurs on
centrifugal pumps made of stainless steel and designed to circulate very cold brines or
thermal antifreeze fluids. The reduction in pump tenrperature when the pump is operated
causes tlre tnetal to shrink. The Inost accurate rnethod of determinitrg the thermal growth
of a rnachine is to directh' measure the growth from a fixed daturn point using optical.
rnechanical or laser measuring instruments.

Moment of Force
Another factor that can move a machine off its centreline axis is a moment of force. A
moment of force pushes against a machine to force or displace it off of its principal axis
ofrotation. such as the force created by high-pressure steam entering one side ofaturbine
pushing it sideways. Using engineering design data and formulas. it is possible to
calculate the degree of misali-enmerrt due to therrnal grouth and nrornents of force. Once
the amounts of movement of the machines are calculated it rnakes sense to perform cold
corrective trloves that are opposite to (or counteract) the thentral growth and rnornents of
force tnovetlents. The required cold corrective rnoves result in rnachine shafts and
couplings being purposely misaligned when not operating. As the machine repositions
(frorrr temperature change or moment of force). you want the shafts and couplings to
move into almost perfect alignment.
For this intentional misalignment of cold rnachines to be successful it is imperative that
the machine foundation is sound. A crack or fracture in a critical location within the
foundatiorr could alter machine shaft positions due to foundation shifts. These shifts may
be caused by'hydraulic pressures or seasonal shifting ofthe subsoils adjacent to the
foundation.

A cold, purposely misaligned tlachine alignment can be checked by predicting the cold
su'eep readings. These readings are taken from cross dial aligment graphs (vertical and
horizontal). If the cold misaligned sweep readings from the unit match the predicted
readings from the graphs it is safe to assume that the machines have been successfully
misaligned. At this point the machine should be started and placed under normal load. As

the n.rachines heat up they exhibit a lou'er vibration level as they come into alignment.

This is good. but u'hat happens if the vibration levels steadily increase? At some high
vibration lirnits it is advisable to shut the rnachine down before it fails. At this noint it
rnal' be necessary to perform a hot aligrunent, u'hich lneans to inspect the aligrunent just
after the machine has been shut dou,n. The hot aligmnent inspection rnay reveal that the
machines did not move in the directions that were anticipated.

A good rnethod of hot alignment inspection is the most reliable industry standard, rvhich
is called rhe Essinger Tooling Ball alignment procedure. The Essinger method can be
used to check and track transient lrlovements u'hile the machines are hot and running.
Transient movelnents are machine lrovements that are not non.nal or predictable.
Several otlrer methods have been developed to check hot alignrr-rents. One basic method is
called hot machine olignntent in.sltection, uhich means that the inspection is performed
on the machine as quickly as possible after the machine is shut down. The brackets and
dials are mounted and a set of su,eep readings are quickly, taken. These sweep readings
change constantly because the n-rachine is cooling down.

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Objective One
Llthen

you have completed this objective,you will be uhle to:

Review safety, rim and face and cross dial shaft aligrunent.

Safety
Obtain a safe work pennit and n'ork order, then lock out the equipment that is to be
aligned and make ceftain that an information tag is placed on the locked out energy panel.
On some higher voltage panels, a racking out or electrical disconnect procedure rnust be
followed. Racking out, locking out and tagging the control or source panel prevents
personal injury due to an unplanned, unwanted equipment start-up.
The tag should have the following information:
r the reason for the lockout.
r the date and
e the narne ofthe person responsible for the lockout.

Keep in mind that the energy source is not always electricilv; it may be petroleurn fuels
or stearn. In the case ofnatural gas, diesel or gasoline powered engines, it is necessary to
isolate or disable the unit so it cannot start when it is rolled over during aligrunent checks.
Steam lines entering a turbine must be closed and chained or locked in the closed
position. In some cases, a slip blind can be installed after the valve.

In an industrial complex that controls machine operation thlough the use of

proqrarnmable logic controllers (PLCs) or distributive control (DC) systerns. it may be
necessarv to request the control roorn operator to disable the unit. The operator may also
issue a safe u'ork permit that requires motor control centre (MCC) panel lockout for a
specific machine. The last inspection before starting an alignment procedure is to try to
test-start the unit being worked on at the local command station.
Care must be taken when preparing special types of process equiprnent for shaft
alignment. An example of this u'ould be a steam turbine driving a dynamic colt'lpressor.
In this case, both the turbirre and the colnpressor must be blocked in (r'alves closed),
isolated. bled off and locked. The reason for compressor isolation and lockout is to
prevent a reverse flow of gas through the compressor, which would result in the unit
running backwards at high speeds.

Hydraulically driven equipment must be isolated and bled off

so that no shaft rotation,

other than alignment rotation, takes place. The equipment must be isolated by locking the
valves in a closed position and bleeding off trapped oil to the reservoir. Accumulators
should be depressurizedby bleeding the high-pressure oil to the resen'oir. In cases where
large presses are used, it rnay be necessary to block with wood to prevent drift due to
gravity. The reverse flow of oil through a pump can result in the purnp turning in reverse
and driving an electric motor.

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G 2007, Her Majes$ the Queen in right ofthe Province ofAlbena

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The procedure to lock out valves on a turbine/corlpressor unit is shown in Fieure

Compressor

l.

TurbinelCampressor
Clcse and lock
sleam thrc{lle valves

1500$ Ste am Inlet

Compressor Valves
nl^-^
g)>ul u d;
^^J
utuJU -.^^^,,"^
lu
iJ,
lockoul vaive actuaiof.

1, Close all compressor

d:scharger.valves

d*ry

$team Supply Valves

Close all steam supply valves
and chain and lock hand wheels.

--' '. sf,

ffii
2. Shul ofiand
lock oLtt pcwer

3. Close and iack out

hanC wheels and chaln

Siearn Supply Valve

Hand \{heel

Figure I - Valves to lockout on turbine/compressor unit.

(Photographed at Agrium Redwater Fertilizer Operations)
Pneumatic motors that require shaft alignment must also be isolated and locked out. The
lines to and frorn the motors must be depressurized so that the potential for an accidental
start is eliminated.

Coupling guards and safety shields must be reinstalled after the alignment is completed.
Guards prevent accidents that could be caused by human contact with rotating shafts and
couplings. Shields prevent accidental burns from high heat sources such as engine
exhaust pipes.

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C 2007. Her Majeso.the Queen rn right of the province of Albe(a

Objective Two
ll/hen 1,ou huve completed this objective. you will be able to:

Explain the various techniques used to measure machine thermal and process lrovement.

Spindle Shaft (Drive Shaft) Goupling Atignment

You may be required to align an externallv mounted electric motor to an internally
mounted gear drive unit, as in the case of a cooling torver fan drive assembly. One way to
do this is to use two dial indicators; one mounted on the face of the inboard coupling at
the 12 o'clock position and the second dial on the face ofthe outboard coupling at the 12
o'clock position. See Figure 2 for arrangement of the dials.
Dial
lr

- Rnr

Li(

= 90"

L-..,

I
L:B

ry

- 1trn
- /tK,

n
u;,

Caupling

- 4nr

Coupling

a
Coupling

x----n*
Figure 2 - Cooling fan drive.
The spindle shaft alignment rnethod is used to negate the effects of bar sag over long
distances. This method of alignment will correct for angular and offset misalignment in
both the vertical and horizontal planes. The rnethod works on the assurnption that all of the
n.risalignment is angular and the correction takes place at the two coupling centrelines. The
amount of angular misalignrnent is measured at both couplings and then. using sirnilar
triangles. is projected back to the motor feet u'here the calculated shirn move is added or
removed from Sl and S: locations. This shim move u'ill then result in the motor shaft
centreline being coaxial rvith the gearbox shaft centreline.

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Use the following steps to calculate the shim one and two and side to side moves.

Step One
The following is a solution for Sr and S: using "A" dial readings and dirnensions.

S, TIR\
Lre = De
L,^

' =:qx
DA
S, TIRA
L.^ = D^
S,

TIRo

L"^

Sz-DA
==axTIR^

Step Two
Use the follorr,ing formula to solve for

and 32 using

"B" dial readings and dimensions.

S, TIRB
L,- = De
T .^

=:]g^TIRB
'Du

S,

S, TIRB
=
Lru DB
T

=3xTIR'

S,-DB

Step Three
Combine the "A" and "B" dial fbrrnulae solutions by adding the "A" and "B" dials
together in a final formula.

II
"tt

"rB

xTlR.- +
xTlR.
DA
Du
TI
":t vTlR. - -tu xTIR^
S.-D.\*D"D
=
S, =
'

The spindie shaft coupling alignrnent method assumes all of the rnisalignment is angular
and will be corrected at the flexible coupling centrelines. The formula uses similar
triangles to determine the amount of shims required at Sr and 32 to bring the motor shaft
centreline into alignment with the gearbox shaft centreline.

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O 2007. Her Malesq the Queen in right of the Province of Alberta

Using the values from Figure 2:

ri
60 )+:x-4=-24mils
^ =-x
s,
'1010
15
90
^5__x,)+_x
-10
10

4='2lmrls

The values for S1 and Sz from the combination "A" and "B" readings are the required
shim moves. A positive answer means that shims must be added; a negative answer
means that shims must be removed. A positive side-to-side move means that the machine
should be shimmed to the right-hand side by the value calculated. Always view the
MTBS frorn the fixed rnachine to determine the left and right sides. The amount of sag on
the "A" and "B" dials is minimal as they are both taking face-coupling readings.

Thermal Growth
Thermal growth describes small movements that occur in all types of industrial
equipment due to temperature changes. The temperature change within a machine causes
the metal to grow or shrink by a fixed amount that is linked directly to the coefficient of
expansion for that specific metal (see Table 1).

Linear Expansion per

Unit Length per'G

Linear Expansion per

Unit Length per "F

Aluminum

0.0000223

0.00001244

Brass

0.0000187

0.0000104

Metal

r>

Bronze

0.0000'184

0.0000102

Carbon Steel

0.0000114

0.00000633

Cast lron

0.00001 18

0.00000655

Table 1 - Heat expansion coefficients.

ty

@ 2007, Her

Majesq the Queen rn ri,eht of the Province of Alberta

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The formula for deterrnining thermal growlh is the change in length is equal to the
original length times the change in temperature times the coefficient of expansion for that
parlicular material.

AL:LoxATxa
Where:

AL: change in length (change of centreline height)

: original length (distance from base to shaft centreline)
AT : change in temperature (average temperature change)
u : coefficient ofexpansion (obtained from chart)

Lo

Most expansion and contraction within machines is due to temperature changes. The
causes ofthese ternperature changes depend upon the design ofthe machine. Possible
causes of rise in temperature include adding heat from steam, heat from compression, heat
from reaction, heat from electrical load and possibly heat from friction (or the removal of
heat for the same reason). Examples of cooler temperature machines are refrigeration
pumps, brine solution circulation pumps and rl'it.rter giycol cooling tower pumps.
You must be able to recognize and determine thermal growth problems and be able to
soive thern. lf not recognized and compensated for, thermal growth can result in shorter
machine life.
Thermal gror.lth affects machine centrelines and therefore tends to create misalignment at
the couplings.

Example of a Thermal Growth Problem

Given an electric motor driving a brine pump, create mathematical solutions for thermal
growth at all shim locations. Use this information to create a graphical solution to the
problem. Use the values given in Figure 3.
Elec{rlc Molor
MTBS Ca$on $teel

Srine Purnp

Carbcn Sleel

c
*1oo'r

-110"F

- so"F

r3o"

{*s0"F

r@

o
rg

120'r
110"

3o'F

$-*

.\

:< {
L,

Ambient
Temperature

=72"7

Lr

}r L."
I
x'

X=
|
|

10"

- {arr
- Alr

I -4"
,'"^u

Figure 3 - Dimensions and temperature for thermal grou'th brine pump alignment.

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2n07. Her Majesn the Queen in right ofthe Pror rnce ofAlbena

l_

NOTX

Assume that the pump and motor were perfectly aligned when cold
and not running.
The first step is to determine the amount of thermal growth at the 4 shirnming locations.
You are only concerned rvith the thermal expansion betrveen the base and the shaft
centreline. Any expansion above the shaft centreline will not affect the shaft alignment.
Tl.re temperature of the components u,'ill not be consistent from the base to the shaft
centreline so an average temperature is required to be able to find the average thermal
groMh. The more temperature readings that can be taken at the individual shim locations
will result in a more accurate average; four readings is usually adequate. A quick
approxirnation can be obtained with only.' one temperature reading taken at the shaft
centreline. Add this temperature to the ambient temperature and divide by trvo. This will
result in an average ternperature which assumes that the base is at ambient temperature.
The amount of thermal growth can be calculated in metric or imperial units, but because
you usually shirn with irnperial shirn stock, you wiil calculate the thermal growth in
thousands of an inch or rnils.
For convenience, round to the nearest degree ofternperature and round to the nearest
thousandth of an inch for shim illoves.

NOTE

You can perform these calculations in metric or in imperial. but do not

mix the two systems when calculating thermal growth.

Thermal Growth at St
Average temperature

130 + 120

+110 + 90

= I l2.5oF

Round to 1 13'F

AL:LoxATxa
LL :24" x (l l3 - 72) x 0.00000633
The shaft centreline

0.006"

will rise 6 rniis at the S1 location.

Thermal Growth at Sz
Average telxperature

: 110+100+90+80

= 95oF

AL:LoxATxu
LL

: 24" x (95 - 72) x 0.00000633 : 0.003"

The shaft centreiine w'ill rise 3 mils at the S. location.

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2007. Her Majesn rhe Queen in right of the Provrnce of Albena

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Thermal Growth at 33
9O

Average

temperature

+'7)
= 81oF

AL:LoxATxa
LL:24 X (81 - 72) X 0.00000633 :0.001"
The shaft centreline will rise

I mil

at the S. location.

Thermal Growth at St
Averagetemperature

3'0

!^72 = 5loF
2

AL:LoxATxo
LL : 24 x (51 - 72) x 0.00000633 :
The shaft centreline

-0.003"

will shrink or lower

3 mils at the Sa location.

The previous mathematical calculations predict the thermal growth of the motor. The
solution indicates that the shaft centreline ra'iil rise up by 0.006" at the S1 location and
will rise up by 0.003" at the 52 location. Do not remove shims at these locations to
compensate for thermal grorvth. More information is needed before starting any shirn
rnoves. The thermal changes to the purnp must be considered and compared to the
electric motor growth within a graphical representation of the problem.
The brine pump centreline thermal growth at the S: location indicates a rise of 0.001" and
a downward move of 0.003" at the S+ location. At this point. all of the necessary
information is available and requires analyzing. Construct a graphical representation of
the problem and then analyze it.

After constructing the graph, study it and develop some conclusions based on the
inforrnation contained in the graph.

It is wise to leave the pump bolted down because moving it could result in piping strain.
Piping strain is the cause of unwanted distortion of the pump housing due to improper
pipe fit-ups. As the suction and discharge flanges are tightened, the pipes pull the pump
housings out of shape and alter the shaft centreline position, disturbing alignment and
adding internal stress to internal rotating parts. This is not good. Once the pipes fit without
strain it is a good idea to leave the purnp alone and make adjustments on the rnotor.
A shim rnove under the motor feet is the best solution.
From the graphical representation in Figure 4, one solution is to have the /rol motor
centreline #l and the hot pump centreline #2 become one and the same. To accornplish
this, remove 0.001 " at both S 1 locations and add 0.006" shims at both 32 locations. Keep
in mind that this solution u'il1 only work if the unit u,as precisely aligned when cold. In
other words, the unit had to be precision aligned to within specs before atternpting to
offset the alignment to compensate for thermal growth. Once the offset shim moves are
made on the motor it becomes necessarv to oredict u'.hat the "A" and "B" dials read when
cold and offset.

IS
I

60+0Japj.0. docx

2007. Her Ma,iestl the Queen in right olthe Province of Alberta

t
C{
l,
T1

ll

il

ll

c0

\
tl

(/,r-=
Figure 4 - Graph showing required shim move to align motor to pump.
11
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O 2007. Her Majest) the Queen in right of the Province of Albena

NOTE

If there is no sag "A" dial cold should read -12 mils TIR
"B" dial cold should read 7 mils TIR
The above readings for "A" and "B" dials are taken from where line
nurrrber three crosses "A" and "B" dial nlanes. These are TIR values.

Combination Misalignment and Thermal Growth Correction

It is possible to align

a unit when

it is cold and offset for thermal growth by rnaking only

one set of shim moves. The data in Fisure 5 is used in the sample calculations.

Given: Complete the Thermal Offset Alignment.

Gear Box
(cast iron)

Electric Motor
(cast steel)

122',F

140'F

156'F

140" F

Base Temp.

is72'F
,l

X=

15"

No Bracket Sag

Top

+6

I e ,/

B\

urar
rr t unit
\
)

L.U.

h.

Top

\3y_/

K.b.
+3

/T) *'
\ utit )

Re

\ggj-l
+10

Bottom

Bottom

Figure 5 - Data given for thermal growth example.

12
l

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1007. Her N'tajesn the Queen in ri-eht olthe Province of Alberta

Combination Problem
,

Thermal growth at

51

156
Average ternperature

+ 7)
2

AL-LoxAtxa
LL:12"
rnotor

x (114 -72)x 0.00000633:0 003"

.,,
t will
rise 3 mils at 51

Thermal growth at

52

1)) t- 7)
Average temperature
2

AL:LoxATxo,
AL

l2 x(97

72) X 0.00000633:0.002"

rnotor Q will rise 2 rnils at S,

Thermal growth at

53

140

Averagetemperature-

t,

+ 72

=lU6"F

AL=LoxATxa
AL=

12

x (106

The gearbox

Thermal growth at

-72)x

0.00000655:0.003"

will rise 3 rnils at 53

Sa

A'erage remperarure :

r!=

o6oF

AL=LoxATxo
LL =

12" x (106

-F
The gearbox shafl

72) x 0.00000655

t will rise.i

: 0.003"

mils at

Sr

4 :::::
M:t:

a at

O 2007, Her Ma;esq the Queen in right of rhr'Province of Albena

6it403ap3.0.docx

:a

Analyze the graph in Figure 6 and determine required shim moves.

t/J--=
Lf) z--:

O|r)

{(t")

-)[.C)[N]OrOr-

c)
- l-l-:-:'
-,u

: ! :] d]

\OE
\\,-r1-99

\ cJt

\c\
1 {Jt-'

to&-:
!, vE

t'O$

-1 9N-

lal :::]U

l"
IX

.'

tv[
\oN.
--.98...i og.
....izN,
\.2\
lct
to\
\6&
lS4
r:L>

-i-a-li

...1....i.-.

te

l'1L

....tr
:--i-:':

i :.'...:..:$
i..i..:.r r "S

l
ln*
l*

(Jir

i&

:.N

I-

U)

6ii

.'...'i...i.-!!l

.li-.i*ii-i--

.c

iCI

-,!'-r f.--a-:-n-\-..

-i.^i

c\l

i.Y

':.

,:,]...,

..i....:...:.i

I
d

r -r -- r^-l(-)

cv

*f i

C7:
'=

r.i f-

=\
'-:.^
,- c*

:il F
ir,,..

v(,ll

\\

5m
LO

{
4
tJt

lrl

tl

-i- rn

_
-

ertt
t&l

tvl

ra!,

ll

a.

*.'T

l-J--t"r.i

s-i

f.*
ll

_s

:*T

Nrr-r

U)r-=
Figure 6 - Graph shon,ing required shim move to align motor to gearbox.

t4
I

60403api.0.docx
O 2007. Her Majestl the Queen in right of the Province of Alberta

From the graph in Figure 6, you can see that the gearbox raises up 0.003" at the 53 and Sa
locations; leave the gearbox bolted down. The hot gearbox centreline is represented by
line 2. Linel represents the original cold rnisalignment present at the coupling. Line 3 is
the hot motor centreline. In other words, the motor moved frorn line 1 up to line 3 when it
was started and loaded. Line 3 shows a fair degree of angular misalignment of the hot
motor centreline as compared to line 2, which represents the hot gearbox centreline.

To correct this misaligrunent of the motor, 0.003" shim removal is required at both S1
locations and 0.001 inch shim addition is required at S: locations. These shim adjustments
lower the drive end of the motor and raise the non-drive end enough so the centrelines of
the motor hot and the centreline of the gearbox hot are common.
This section helps you determine what the dials should read when the correct shim
adjustments are completed. Line 4 represents the cold motor offset centreline. To
establish the S1 position for line 4, subtract or remove 0.003" shims from the intersection
of the line 1 and S r plane. To establish the 52 position for line 4, add 0.00 I "to the
intersection of the line 1 and Sz plane. Where line (4) crosses A and B dial planes, these
values indicate that the correct dial reading for the cold offset motor A dial reads'0.002"
TIR and dial B reads -0.00025".

!t

The previous example is a guideline to show you how to align a motor to a gearbox cold,
taking into account the thennal growth of both units and the amount of original
misalignment present. Once the alignment is complete it must be confirmed by some
feedback loops. First, the cold offset rnisaligned machines result in dial readings that are
not zeros. The readings expected are predicted from line 4 where line 4 crosses the A and
B dial plane lines. Secondly, upon stafi-up the unit vibration should be a little high until
the motor and the gearbox reach operating temperatures. At this point very low
acceptable vibration readings indicate *'hether the procedure is successful. lfthe
vibration level continues to increase to higher levels after start-up, it is safe to conclude
that the procedure u'as not successful and the unit must be realigned and rechecked for
mechanical integrity.

Mechanical integrity is a term that describes the mechanical condition of a machine.

Good mechanical integrity means that the machine is in excellent condition; poor
integrity means that the machine has a number of mechanical faults.

Hot Alignment Methods

Hot alignment is a tenn that describes a number of ways of checking the alignment of one
or more shafts in relationship to each other once the rnachines have been put online
(started and loaded) and a thennal equilibrium has been reached. Thermal equilibrium
means that the machine has reached its ruming temperature throughout and no more
heating or cooling will take place. In other words, the unit has reached an operating
temperature throughout and there will be no more metal thermal growth.

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O 2007. Her Majestl'the Queen in right of the Province of Albena

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."

The quick hot alignmenr check is a very poor method that can give enoneous results. This
is because the hot running unit is shut down, isolated and prepared for a conventional dial
or laser procedure. This method is poor for the following reasons.
e Shutdowns are costly and unpopular with operating personnel.
. The equipment cools down very quickly, which results in ever-changing
alignment readings.
r The media that had been flowing through the machine stops flowing; as a result,
hydraulic effects cease and moments of force are eliminated.
. Couplings sornetimes have to be disconnected, u'hich this takes up valuable time.
o Close proximity to high temperature casings can result in burns to personnel.
The traditional hot alignment method is not reliable and rarely works.

Online Hot Alignment Checks

Online hot alignment means that you can track the alignment changes of two or more
shafts in relation to each other by some specific procedures. The procedures do not
require the unit to be unloaded or shut dorvn. The procedures require some permanent
measuring devices to be mounted on the machines being monitored. The most common
methods are the optical tool method, the laser beam and target method, water stand and
proximity probes, Dodd's bars and transducers and the Essinger tooling ball method.
data. The methods vary greatly in
cost, complexity and ease of use. None of the rnethods are applicable to every situation.
Review the rnerits ofeach system and choose the system that best fits the need.

All of these methods provide reliable online alignment

Precaution
With the exception of instrumented couplings, all of the methods listed belorv use cold
coupling alignment readings as baseline from which to calculate (or plot) hot coupling
aiignment. An instrumented coupling has alignment probes built into the coupling.
Regardless of the method used, it is vital that the cold baseline data be taken at the same
tirne the cold coupling alignment data is taken-

For example, reliable results cannot be obtained by taking coupling data in the cool of the
morning and hot alignment baseline data in the blazing afternoon sunshine. Take the data
sirnultaneouslv.

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Optical Methods of Determining Machine Movements

Optical methods (Figure 7) use very precise surveying techniques to determine machine
movements, from which shaft alignment information can be obtained. To use the optical
method, the coupling alignment is performed in a conventional manner. Once the alignment
is satisfactory, the vertical and horizontal baseline data are obtained with the aid of
precision levels and transits. 'fhis baseline data is taken off flat-machined split joint
surfaces. When the equipment is put online and brought to equilibrium. this same optical
instrumentation is used to detennine the movement of each of the machines with respect to
the baseline data. From this data. runnins alisnment can be plotted or calculated.

. Cold alignment is the benchmark.

. Movement is referenced to line af sight.
. Optical levels and jig transits are used
to determine vefical and horizontal
machine movements.

Figure 7 - Hot check by optical means.

Some companies employ in-house specialists to conduct hot alignment checks by optical
methods and some use one of the several commercial firms rvho offer these services.

Lasers
Several variations of laser rnonitoring (Figure 8) are available. Machines are ty'pically aligned
a conventional manner using dial indicators or lasers; another laser/reflector system is used
to rnonitor the movement of one machine casing with respect to the adjacent casing.

in

. Cold alignment is the benclrmark.

. Laser system is used to monitor
relat:ve machine movemenls.

. Data is analyzed and recorded

by computer system.

Figure 8 - Hot check by laser systems.

From this data, coupling alignment can be determined by plotting or by calculations.

In some systems, the laser equipment is mounted perrnanently upon the equipment. In
other systems, brackets are used to permit the lasers to be installed and/or removed
during operation.

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Proximity Probes with Water-Cooled Sfands

With this method (Figure 9), water-cooled stands are attached to the foundation near the
couplings and outboard bearing housings. These stands are support electronic proxirnity
probes, which monitor the movement of the coupling, shafts and/or machine casings
relative to the foundation.

. Cold alignment is the benchmark.

. Machine movements are referenced

to water cooled stands.

C.W.

. Prcximiiy probes detect machine movements;

data is monitored and/or recorded.

Figure 9 - Hot check by water-cooled stands and proximity probes.

With the above method, coupling alignment is done as per norrnal plant standards, at
which time baseline proximity probe readings are taken. Equipment movements are
monitored via these probes as the equipment is brought online and comes to equilibrium.
While the machines are changing alignment due to increases in operating temperatures,
the readings given by the probes are monitored and recorded. Movenrent of the
equipment relatit,e to the proximity probes provides data from rvhich to determine
running aligrunent of the equipment.

Dynalign (Dodd) Bars

This method (Figure l0) of continuous. online monitoring uses proximitl' probes fastened
to pemanently rnounted brackets on the coupled machines. The brackets are arranged in a
fashion sirnilar to that ofindicator brackets used in the reverse alignntent ntethod, except
that the brackets are mounted to the housings, not the shafts. Vertical and horizontal dara
from four probes supply information about the relative movement of the machine casings.

. Cold alignment rs the benchmark.

. Relaiive machine movements are referenced
to bars affixed to opposite machine.
. Proximity probes detecl machine movements;
dala is monilored and,lor recorded.
Figure 10 - Hot check by Dynalign (Dodd) bars.
With this method, cold alignurent is done in the as per plant standards and baseline data is
read off the probes. Output from the probes is then monitored and/or recorded. Data is
sufficient to plot graphically, calculate mathematically, or indicate where the equiprnent
has moved during thermal growth changes
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Benchmark Gauges (Acculign Sfeet Tooling Ball Method)

This systern (Figure I 1) monitors the movement of bearing housings or machine casings
with respect to the equipment foundation. With this system, permanent benchmarks are
mounted on the equipment and the foundation. Once the n.rachine is aligned, benchmark
gauges are used to detertnine baseline measurements between the foundation-mounted
benchmarks and those mounted on the equipment. when the machines are brought
online, benchmark gauge readings are again taken to detennine the relative movement of
the equipment.

. Cold alignment is the benchmark.

, lVlachine movements are referenced

to foundation.

. Movernents are measured bv dioital

benchmark gauge.
. Alignment analyzed by PC program.

Figure 11 - Hot check by benchmark gauges.

Running alignment of the coupling is normally calculated by a personal cornputer (PC)
software program, but can also be detennined by graphical methods.

Instrumented Cou plings

Instrumented coupling system (Figure 12) electronic probes are built into the couplirrg
spacer. Power is supplied to the probes by a stationary transformer. The signals from the
probes are retrieved in a similar manner. This arrangement provides online, continuous
monitoring of coupling alignment as well as axial movement of the coupled shafts.

'

dffirh

W IJ:

Base data is by coupling caljbration.

, Proxinrity probes within the coupling

detect misalignment.

. Signals and power are transmitted

by stationary transformer.

Figure 12 -Hot check by instrumented couplings.

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Satisfactory and long-lasting alignment is achieved by paying attention to details

throughout the design, fabrication and installation of the equipment. The following are
minimal requirements:
o rotating equipment that is properly designed and well-made,
a well-designed and properly executed system into which the equipment is
integrated (this rneans choosing the right online monitoring equipment and
installing it according to suggested engineering specifications),
a
knowledgeable, careful and experienced craftsmen,
a
proper training of craftsrnen and supervisory personnel,
a
appropriate tools,
a
standards and/or specifications detailing alignment requirements and
a
a system to assure that job specifications are followed.

Characteristics of Online Monitoring

AIJ online monitoring methods require a cold accurate aligmnent to be performed initiaily
before installing special online monitoring devices. The initial cold aligrunent gives the
necessary reference measurements needed betu,een the machine shafts and the
instruments. Most online methods are very susceptibie to unwanted accidental instrument
movement. For example, the optical system requires the precise iocation of the telescope
on a tripod or base. lf the base is not protected by a house with windows the tripod may
be accidentally moved. The result is that all the readings are inaccurate and the procedure
must start over from the initial cold alignment start point. Lasers are also vulnerable to
accidental external movements of stationary pennanent mounts. The permanent mounts
must be of rigid design with little or no thermal growth. Water-cooled units made from
titanium or Invar (high nickel steel) are the preferred types.

Proxirnity probes are fitted to special constant temperature water-cooled stands that are
secured to the same base. The danger or downside ofthese stands is that they are very
susceptible to accidental movement from external forces, such as personnel contacting
them. Over tirne, vibration can cause mechanicai looseness because of cracks in the
stand.

Another problern that can cause all reference measurements to be lost is a rvorker who
unknowingly removes the stands while making a repair. After the repair is completed the
stand is reattached to the rnachine, but all reference rneasurements are lost because the
stand is mounted in a slightly different location.
Dynalign or (Dodd) bars are susceptible to cracks due to vibration after a period of time.
Once a crack develops, all the reference lneasurements are lost and the online monitoring
gives false information. Benchmark gauges are also susceptible to accidental external
forces and shifts or cracks in the foundation.
One industry standard used to check multiple machine coupling alignment is the machine
tooling ball (benctmark system), which is an online mounting system. It is very reliable
and relatively easy to use. The next section deals with this system.

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Online Monitoring of Coupling Alignment

Benchrnark gauges are used to take very accurate measurements between matching sets
of benchmarks. The benchmarks are stainless steel 8 - 18 metal that has been machined
to form a ball on one end rvith some type of fastener on the other end. These benchmarks
are mounted permanently to the machine and the rnachine base so that measurements can
be taken between the balls at any tirne desired.

Common Styles of Benchmarks

Common styles of benchmarks are discussed in this section.
Weld-On Benchmarks
Figure 13 is an example of a rveld-on benchmark. This benchmark is on a fla! nonthreaded base that is welded directly to the equiprnent and has the same 95o useful limits
as other benchmarks. The base is '/a inch in diameter. The measurement from the base to
3! inch.
centreline of the ball is

Useful Limits in Which

Figure l3 - A weld-on benchmark.

Threaded Benchmarks
Figure 14 is a simple benchmark that is useful for a wide range of non-critical
applications that do not require the long-term protection afforded by other benchmarks. A
threaded benchmark is a one-piece construction of 18 - 8 stainless steel and is screwed
into a tapped hole and secured with a locknut. The stainless steel locknut is fumished
with the unit.
.:

k
(,,Q'l

l.

J/O

3/B-16 NC

to I

Usefui Limils in Which

Use Benchnark Gauge

(remov*ble locknut)

----J

Figure 14 - Threaded benchmark.

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in right of the Province of Alberta

60.103ap3.0.docr

zl

Covered Benchmarks
Covered benchmarks (Figure 1,5) are recommended for general turbo machinery rvork
(turbine-related equipment). These are one-piece construction oftype l8 - 8 stainless

\.

steel and are furnished with a %" x l6 NC carbon steel stud for mounting directly into a
tapped hole. Altematively. the stud can be removed for mounting directly on a '.{" x l6
NC male thread, or the base of the benchmark can be welded directly to the equipment. If
threaded fasteners are used. it is recornrnended that the assernbly be bonded in place rvith
epoxy to avoid inadvertent movement. The protective cover is nrade of moulded plastic,

rvlrich offers good mechanical ploperties and excellent corrosion resistance. To mount
this benchmark in concrete, use a benchrnark mount suclr as that shown in Figure 16.
Properly tnounted, this protected, stainless steel benchmark affords alignment reference
for the life of the equiprnent.
23,'o"

to Rerrrove Cap

3iB

- 16 NC

-i

Uselul Limits in Which to ,/

use Benchm6lla $6uqg -----l

Figure 15 - Covered benchmark.

Benchmark Mounts
Benchmark mounts (Figure 16) provide an excellent rneans of mounting covered
benchrnarks to concrete or lnasonry structures or foundations. The units include a
concrete anchor, '11" - 16 NC stud, and a heavy rnounting ll'asher. This mount is installed
in a5l3 inch diameterby 2tla inch deep hole. Epoxy cement rnay be applied upon
assemblv to enhance rnechanical intesritv. The benchmark is not included.

--r-- -

t\
I

2118"

I1/4"

t 3/8 "k

l;[-

318-16 NC $tud

Figure l6 - Benchmark mount.

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Masonry Benchmarks

o/ro

The masonry benchmark in Figure 17 is made with a

inch diarneter base which can be
bonded by epoxy directly into a'l3 inch diameterby | 'la deep hole. This is especially
useful for non-critical applications requiring placement of benchmarks in concrete. It is
made of one-piece construction of type l8 - 8 stainless steel and has the same 95o useful
limits as other benchrnarks. The dimension from the base to the centreline of the ball is I
-/a lnCh.

,-)n

to ,
*--,/

Useful Limits in Which

use Benchmark Gauge

?5'

Epoxy

.(9/16',:

Figure 17 - Masonry benchmark.

Benchmark Protectors
Benchrnark protectors (Figure 18) are recommended for use u'hen the benchmark must be
placed in a location in which it is subject to mechanical damage. These protectors are
made of galvanized pipefittings and come complete with four concrete anchors and
screws for mounting. Anchors require holes '/z inch diameterby I'la inch deep. The
benchmark is accessible by unscrewing the cap and pipe nipple. The floor flange need not
be removed to take benchmark gauge readings.

Dimensions are approximid!g

Mounts with fcur concrete
anchors (furnished}.

a.)

A1/'\
q/2

Figure l8 - Benchmark protector.

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60403ap3.0.docx

NOTE
Once benchmarks have been mounted in strategic locations they
should be protected from external forces that can move the ball.

Mounting Benchmarks
Mount all benchmarks as close
Figure 19.

as

possible to the shimming planes, as shown in

fiirim*m

S*" tu'linimunt
"120. l,4inimum

9C* L.4inin:um

I'n4inirrun't

60'Mininr*m
12S"

?il'

Figure l9 - Showing end views of the benchmarks and gauges installed.

NOTE
Benchmark gauges are only used for a short time to take accurate
readings and then they are stored in their wooden cases.

11'

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Basic Benchmark Gauge Set (ltem 1M for Metric Units)

Benchmark gauges (Figure 20) are specifically designed for conducting online checks for
turbine-related alignment. The basic benchmark gauge set consists of a telescoping
column with an electronic dieital readout. six extensions. a 25-inch (625-mm) standard
and an inclinometer.

,
uy\"

.,Fd1

*try
"='tt'S

lnclinonreter

I
I

Indicator

Tooling
Ball

df

,r,...

f,t

Spring Lcaded
Telescoping
Sleeve

Dial lndicator Mounted

in Bar Assembly

Essinger Bar $et Up

Standard

Inclinometer to
Measure Bar Angle

Essinger Bar Kit

Figure 20 - Essinger benchmark gauges.

The benchmark gauge is spring-loaded with spherical seats at either end to match the
spherical benchmarks that are mounted on the equipment. The gauge is self-supporting
when placed between pairs of benchmarks. The range of the benchmark gauge, u,ithout
extensions, is 25 inches to 30 inches (625 mm to 750 mm).

The six extensions give the tool a range of 25 inches to 60 inches (625 mm to
1500 rnm) in increments of 0.001 inch (0.01 mrn). The standard and the extensions are
constructed of lnvar. The low coefficient of thermal expansion of this material greatly
reduces measure[lent errors resulting from thermal expansion of the tool. The standard
and the extensions are manufactured to an overall accuracy of 0.001 inch (0.025 mm) in
length.

,I

The exposed portions of the tool, including spherical seats, are made of stainless steel.

:=

25
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O 2007, Her Majes4'the Queen in flght of the Province of Alberta

Working Example of Benchmark Procedure

a high degree of accuracy. The machine must be locked out (not
running or turning over) and must be of ambient temperature.

Align the machine to

Once the machine is aligned, fasten the benchmarks to the machine and the base. as close
as possible to all shimrning planes. It becomes difficult to mount the balls so the included
angle between the base and the benchrnark gauge is 45o. Oil lines, instrument gauges and

other equipment sometimes get mounted in the benchrnark tool pathway, which forces
you to choose a slightly different angle of approach. This nerv angle may require
installing new tooling balls in the base or on the machine housing.

If bearing housings are readily accessible, benchmarks are located

as in Figure

2lA.

Where they are not readily accessible, an alternate such as that shown in Figure 21B may
have to be used.

B.

A.

Figure 21 - Benchmark procedures.

The benchmarks can be attached to the machine by drilling and tapping holes in the
machine bearing housings. The fasteners screrved into the drilled and tapped holes should
be installed with a permanent thread-locking compound so they do not vibrate loose. The
benchmarks rnounted in the base may be cemented in. bonded in rvith epoxv. or welded
or threaded to the base structural steel. All of the benchmarks should be protected from
external accidental contact, which can bend or distort them and change the benchmark
gauge reading.

--

Using an electrical or rnechanical benchmark gauge, measure the distances betu,een pairs
of benchmarks. The angles and measurernent readings are taken and recorded for each
position. The benchmark gauge set includes an inclinorneter, which uses a pendulum to
fileasure the benchmark gauge angles in relationship to level base.

NOTE
Remember that an acceptable cold alignment must be completed first.

to
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i;ri: .,;: :,

l1r1

Self-Test
1.

Why misalign a set of machines at the coupling rvhen perforrning an alignment?

a) to be within coupling specifications
b) to account for coupling wear
c) to offset for thermal growth
d) to correct for seasonal foundation mover.nents

2.

Is it possible for two coupled rnachine shafts to share a common centreline in the

vertical and horizontal nlanes?

a)
b)
3.

If

yes
no

a motor and pump have a vertical mount (shafts up and down, not horizontal) do

they require precision alignment, like horizontal units?

a)
b)
1.

yes

no

lncreases in ternperature and pressure cause a rnachine shaft to change its position

slightly.

a)
b)
5.

6.

false

What is a moment of force caused by a flowing media?

a) A force generated in the same direction as the flowing media.
b) A force on the housing generated in the same direction as the media travel.
c) A hydraulic force caused by pressure pulsation.
d) The windage force created at the coupling.

ls it possible to predict accurate A and B cross dial sweep readings once the rrachine
has been offset for thermal srowth?

a)
b)
7.

true

yes

no

What is the value of the information collected when you perform a hot aligmnent
check?

a)
b)
c)
d)
8.

Lt\

It deterrnines machine foundation integrity.

It indicates soft foot conditions.

It reveals improper coupling spacing.
lt reveals relative shaft positions.

When shafts are not aligned u,ith each other in the vertical and horizontal planes
when running. what is the most corlmon result or syrnptom?
a) Bearings develop oil whirl.
b) Bearings wear until they align themselves.
c) Vibration levels increase.
d) Alignment nleasurements change.

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Majest] the Queen rn right of the Province olAlberta

9.

Why must you acquire a safe work permit after receiving an alignment orientated
u'ork order?
a) Management requires it.

b)
c)
d)

OH&S requires

a copy.

You require it for your records.

It is a requirement for personnel safety.

10. The purpose of a millwright racking out a breaker rvithin the local M.C.C. before
performing an alignment is:
a) to prevent rnachine shaft rotational drift.
b) to prevent machine shaft rotation.
c) to prevent accidental starts/runs.
d) to prevent breaker contact arcing.
1

1. Why must all energy sources connected to a machine be blocked off, locked and
tagged before alignments are commenced?
a) to prevent uncontroiled process media from flowing
b) to prevent unskilled workers from being trapped inside
c) to prevent unusual sequence ofalignment events
d) to prevent an unwanted high-speed roilover, either foru'ard or ret'erse

!;

12. The procedure to chain some valves in the closed position is required before
perfonning an alignment (assume the valves are chained. locked and tagged). Why?
a) It gives you peace of mind.
b) lt protects fellow u,orkers.
c) It prevents energy flowing.
d) lt is a form oflockout safety required.
13. After locking out a breaker at the M.C.C. and placing the information tag on the
lockout device, what should you do at the machine before commencing with a
coupling alignment?
a) Check that all tools are available.
b) Remove the coupling guard.
c) Rope offthe area.
d) Try the local cornmand station.
14. To align a turbo compressor you must have the stearr lines blocked and bled off as
well as having the valves chained, closed and locked. Should dynamic compressor
piping also be isolated and bled offand locked out?
a) No. it is not necessary.
b) Dynarnic units isolate autornatically.
c) The compressor state does not matter.
d) Yes, it should be done because backflows energize the unit.

15. When aligning an electric motor to a hydraulic pump the system including the
accumulators should be bled off and then isolated because:
a) an increase in temperature could cause the pressure safety to open.
b) high-pressure trapped oil could backflou'through the pump.
c) other components in the system rnight be energized.

d)

no system pressure is required.

a:a::,a.:aaa:::::.a.a:::,::.

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:i''

I ::rl:i::::,:::ii:l ll::

16. What can happen to millwrights perforrning shaft aiignment on a pump if accidental
reverse flow ofoil through a hydraulic system occurs?
a) Nothing will happen because there is no shaft movement.
b) The pump rnight run forrvard and injure them.
c) The purnp might motor backwards and injure thern.
d) The dial brackets and alignment tools attached to the shafts can catch on
clothing and injure the worker if the pump motors backwards.
1

7. Lasers can cause serious eye injury due to:

a)
b)
c)
d)

direct viewing.
indirect viewing.
amplification through targets.
flashes caused by dust parlicles.

18. What is meant by bucking in alaser unit mounted on a rnachine?

a) It is a laser self-check for accuracy.
b) It is mounting the laser bearn centrally within the base.
c) It is a method used to check the machine housing for accuracy.
d) It is setting the laser to a benchmark location.
19. Do laser beam targets hat,e a set of direct mechanical microrneters?
a) No, they are not necessary.
b) Yes, they alu'ays require checking by constant feedback.
c) Yes, because laser beams can fail.
d) Yes, because lasers are not self-centring.

20. Do laser beams sag due to gravity?

a)
b)

yes

no

21. Drive shaft coupling alignment can be used to check:

a)
b)
c)
d)

drive shatls for straightness.

u'ear in the couplings.
alignment of the motor shaft to the gearbox shaft.
degree ofshaft levelness.

22. Drive shaft (or spindle shaft) alignment

a)
b)
c)
d)

uses two dials mounted:

one inboard and one outboard.
one on the rim inboard. the other on the face inboard.
both on the rims, one inboard and one outboard.
both on the same plane, one inboard, one outboard, both on the face.

23. When using the formulae to calculate the required shim moves for a spindle shaft,

positive value means that shims should be:

a)
b)

removed.
added.

24. What is the purpose of online coupiing monitors?

a)
b)
c)
d)

to align shafts when cold

to align shafts when hot
to provide a quick hot alignment check
to check alignment while the machines are running

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-v

Self-Test Answers
1.
2.
3.
4.
5.
6.
7.
8.
9.

c) to offset for thermal gron'th

a) yes
a) yes
a) true
b) A force on the housing generated in the same direction as the media travel.
a) yes
d) It reveals relative shaft positions.
c) Vibration levels increase.
d) It is a requirement for personnel safety.
10. c) to prevent accidental starts/runs.
I 1. d) to prevent an unr.l,'anted high-speed rollover, either foru'ard or reverse
12. d) lt is a form ofiockout safety required.
13. d) Try the local command station.
14. d) Yes, it should be done because backflows energize the unit.
I 5. b) high-pressure trapped oil could backflow through the pump.
16. d) The dial brackets and alignment tools attached to the shifts can catch
on clothing and injure the worker if the pump motors backwards.

fi. a)
18. b)
19. b)
20. b)
21 . c)
22. d)
23. b)
24. d)

direct viewing.

It is mounting the laser beam centrally u,ithin the base.

Yes, they always require checking by constant feedback
no
alignment of the motor shaft to the gearbox shaft.
both on the same plane, one inboard, one outboard, both on the face.
add

to check alignment while the machines are running

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