LESSON

CENTRIFUGAL COMPRESSOR
ALIGNMEMNT

LECTURE
SUB - OBJECTIVE
At the end of the lesson the Trainee will be able to demonstrate an understanding of
Centrifugal Compressor Maintenance.

1.0

INSTALLATION

Proper installation will contribute to trouble-free operation with minimum

maintenance. This chapter furnishes detailed procedures for ensuring a successful
installation. Certified outline and connection drawings, issued by Elliott Company,
provide important installation details. Study these drawings closely and refer to them
for mounting dimensions, electrical and piping connections, etc. The instructions in
this chapter, along with the information shown on the certified drawings, should be
thoroughly understood before installing the PAP.
Successful installation requires specialized knowledge and skills. For this reason,
Elliott Company recommends an Elliott Service Representative be retained to
supervise with the PAP installation and first start-up. Installation site conditions vary
greatly and sometimes make it necessary to deviate from the procedures in this
manual. A service representative can suggest alternate procedures to better suit
specific field or service conditions and thereby provide the best possible installation.
Regardless of the procedure, quality materials and workmanship are an absolute
necessity for a successful installation.
2.0

FOUNDATION

The primary function of the foundation is to provide a permanently rigid, non-warping

support for the PAP. The following must be considered when designing the
foundation:
1.

2.
3.
4.
5.

Refer to the unit outline drawing for equipment mounting

surfaces, mounting pad locations, equipment weight distribution,
lifting locations, main piping connections and other necessary
information.
Construct a foundation of ample size and proportion to
support all of the equipment.
The foundation should be designed so outside vibrations are
not transmitted to it. Use vibration damping materials between floor
beams and the foundation if necessary to isolate the foundation.
Design the foundation to avoid resonant frequencies of 40 to
50% of operating speed, rotor critical speeds and two times operating
speed.
Allow concrete foundations to cure for approximately 28 days
before loading. This strengthens the foundation and reduces the
shrinkage rate.

ADVANCED COURSE
LESSON 9 PAGE 1

MECHANICAL MAINTENANCE
MACHINE ALIGNMENT

3.0

MOUNTING THE COMPRESSOR ON THE FOUNDATION

The mounting arrangement used for PAP compressors consists of a specially

designed vibration isolating pad called a Jackmount. These Jackmounts (Fig 9-1)
positioned under each of the four PAP baseplate mounting pads. This arrangement
permits setting the PAP directly on the floor or a concrete slab foundation.
Each Jackmount consists of a bolt, washer, two nuts and a rubber-backed steel
support pad. The PAP is leveled by adjusting the nuts at the bottom of the mounting
pads. This adjustment is maintained by tightening the lock nuts against the washers
and baseplate mounting pads

Fig. 9-1 Jackmount.

Note: Use any horizontally machined surface on the baseplate for a reference plane
when leveling the PAP.

MECHANICAL MAINTENANCE
MACHINE ALIGNMENT

ADVANCED COURSE
LESSON 9 PAGE 2

4.0

SHAFTALIGNMENT

Proper shaft alignment is essential for smooth, trouble-free operation. Equipment

vibration and heavy bearing and coupling wear can be caused by improper
alignment.

Two types of shaft misalignment must be determined and corrected to within certain
tolerances:
1.
2.

Angular displacement fig. 9-2 is a form of misalignment

where shaft centerlines intersect but are not parallel.
Parallel Offset Fig. 9-2 is a type of misalignment which
occurs when shaft centerlines are parallel to each other but do not
intersect.

When making the initial alignment, allowances must be made for thermal growth
(expansion) which occurs when the compressor gear case and the driver change
from ambient to normal operating temperature. This is necessary to ensure collinear
shaft alignment Fig. 9-3 during normal operation. (Collinear alignment occurs when
shaft centerlines are parallel and intersect).
To determine the approximate thermal expansion of the compressor gear case;
measure the distance from the bottom of the gear case support feet to the shaft
centerline. Multiply this distance, in inches (alternately, in millimeter) by the thermal
expansion coefficient of 0.0000067 inch per degree Fahrenheit (alternately, 0.000012
mm per degree Celsius) times the temperature change in degrees Fahrenheit
(alternately, degrees Celsius).
4.1

THERMAL EXPANSION FORMULA:

Distance in inches x 0.067 inch x 10-4 x temperature change in F = Thermal Growth

In
inches
(Distance in mm x 0.012 mm x 10-3 x temperature change in C = Thermal Growth in
in
millimeters
4.2
1.
2.
3.
4.
5.

PRE-ALIGNMENT CHECKS
Be sure compressor gear case is level and square in
relationship to the driver.
Ensure the gear case and driver rest firmly on the baseplate,
with equal loading at each hold down bolt.
Tighten all equipment hold down bolts.
Ensure compressor inlet and discharge piping (and turbine
inlet and exhaust piping, when turbine driven) are disconnected.
Check drive coupling run-out (face and rims).

Note:
Perform the initial alignment checks with the equipment at ambient
tempeature. Make alignment checks and corrections in proper sequence; angular
misalignment must be correct first, parallel misalignment second.

ADVANCED COURSE
LESSON 9 PAGE 3

MECHANICAL MAINTENANCE
MACHINE ALIGNMENT

Fig. 9-2. Types of Shaft Misalignment.

Fig. 9-3. Shaft Alignment.

4.3

CHECKING AND CORRECTING ANGULAR MISALIGNMENT

CAUTION: Supply lubrication to all bearings before rotating or moving compressor

drive gear shaft or driver shaft.
1.
2.
3.
4.

Move drive gear shaft to the normal axial operating

position(toward the driver).
Move the driver shaft to the normal axial operating position (if
motor driven); place motor on magnetic center. If turbine driven; shift rotor
toward drive gear).
Measure the distance between the two shaft ends (with an
inside micrometer). Take measurements at four location 90 apart, as shown
in Fig. 9-3.
Make adjustments, by shifting and shimming the driver, to
obtain equal distance (within .001 inch or 0.02 mm) between the coupling
faces at each 90 location.

MECHANICAL MAINTENANCE
MACHINE ALIGNMENT

ADVANCED COURSE
LESSON 9 PAGE 4

NOTE: Refer to the certified outline drawing or coupling manufacturers specifications

for required hub spacing.
4.4

CHECKING AND CORRECTING PARALLEL MISALIGNMENT

1.
2.

Match mark rims of both coupling halves so that the

shat position are known at all times during the
alignment check.

Tighten all hold down bolts and mount a dial indicator (of
known accuracy) on one of the coupling hubs. Position the indicator contact
point on the rim of the opposite coupling hub. Rotate the shaft so the
indicator contact point is at the top of the rim.
3.
Align the match marks on the coupling rims and set the dial
indicator on zero.
4.
Rotate both shafts simultaneously, keeping the match marks
together. Record the indicator readings at 90, 180, 270 and 360
locations. The indicator should read zero at 360 (starting point).
Note: Repeat step 4 several times to ensure accurate indicator readings.
5.

6.

4.5

Loosen driver hold down bolts and correct the vertical

parallel misalignment by adding or removing shims between the driver
support feet and the baseplate.
Correct the horizontal parallel
misalignment by moving the driver laterally.
Tighten the hold down bolts and recheck the horizontal and
vertical parallel alignment. Continue to make these adjustments until the
parallel and angular alignment is within .001 inch (0.02 mm) total
indicator reading.
HOT ALIGNMENT CHECK

A hot alignment check must be made after the PAP has operated at full load for
several hours and operating temperatures have stabilized. This check shows
alignment adjustments required to bring shafts into collinear alignment during
operation.
The purpose of the hot alignment check is to determine the relative change of the
shaft end positions as the equipment changes from ambient to operating
temperature. It is generally impractical, if not impossible, to determine the relative
shaft positions by indicating the rotating shaft ends with dial indicators. For this
reason, most hot alignment checks are based on the assumption that the equipment
casings and bearing housings expands uniformly in a radial direction form the shaft
center and maintain this relationship to the shaft center, regardless of the operating
temperature. Experience indicates this to be a valid assumption when applied to
rotating machinery designed in approximate symmetry about the shaft. An accurate
mechanical alignment check (based on this assumption) can be readily accomplished
by measuring the movement of the driven machine, as the equipment changes from
ambient to stabilized operating tempeature.
With the equipment at ambient temperature; mount a dial indicator (having minimum
indicating range of 0.1 inch (2.5 mm) on the top of the coupling end bearing housing
of the driven machine (Indicator A, fig. 9-4). Adjust the dial indicator to the
approximate mid range of the total travel. Place the indicator contact point on top of
the coupling end bearing cap (driver). This dial indicator will measure the amount of
vertical thermal expansion of the driver in relationship to the driven machine when
both have reached normal operating temperature.

ADVANCED COURSE
LESSON 9 PAGE 5

MECHANICAL MAINTENANCE
MACHINE ALIGNMENT

Mount another dial indicator on the side of the coupling end bearing housing of the
driven machine (indicator b, fig. 9-4). Adjust the dial indicator so the contact point
rests against the side of the coupling end bearing cap of the driver. This dial indicator
will detect any horizontal equipment movement caused by piping expansion or
foundation deflections which might occur at normal operating temperatures.
With the equipment at ambient temperature; set dial indicator A to reflect the vertical
thermal expansion allowance made during the initial (cold) alignment. Set dial
indicator B at zero.

Fig. 9-4. Hot Alignment Check

Note: If the driver shaft was initially set .006 inch (0.15 mm) lower than the driver
machine shaft; set indicator a to read minus.006 inch (-0.15 mm)
Start the PAP in accordance with the applicable routine start-up procedure given in
Chapter 3 and apply full load. Operate the PAP for one or two hours (or until
operating temperatures have stabilized). Readings of zero on both dial indicators
verify collinear shaft alignment Fig. 9-3 at normal operating temperatures. A reading
other than zero on indicator B indicates piping strains, foundation or baseplate
deflections, that must be corrected before putting the PAP into regular service.

MECHANICAL MAINTENANCE
MACHINE ALIGNMENT

ADVANCED COURSE
LESSON 9 PAGE 6

If indicator a does not read zero at normal operating tempeature; the PAP must be
shut down and the alignment corrected by the amount shown on the indicator.
EXAMPLE:
Indicator A reading is plus .002 inch (+0.05 mm); the driver must be lowered by
removing .002 inch (0.05 mm) shims from under each support. Indicator a reading is
minus .003 inch (-0.08 mm); the driver must be raised.003 inch (0.08 mm) by adding
shims under each support.
The primary advantage of using this method of checking hot alignment (or any
variation of this method using the same principles) is that the relative shaft positions
can be accurately determined at normal operating temperature without shutting down
the equipment. Experience shows that regardless of how quickly an alignment check
is made after shutting down the PAP, the immediate heat loss is enough to produce
erroneous alignment readings.
In most cases, thermal expansion has minimal affect on angular shaft end alignment.
Therefore this method of checking hot alignment does not allow for angular change.
Mounting the indicators on a vertical plane will indicate any adjustments that may be
necessary to provide correct angular alignment.
Other suitable methods are available for checking the hot alignment and may be used
when practical. In cases where the hot alignment is questionable, it is advisable to
use an alternate method to verify collinear shaft end alignment during operation.

ADVANCED COURSE
LESSON 9 PAGE 7

MECHANICAL MAINTENANCE
MACHINE ALIGNMENT