Shaft Alignment

Author: Ugo Simeoni

V2.0 December 2008
 Course Objectives

Understand the reason to perform shaft alignment

Understand how to set the machine skids soft foot

Understand how to set the machine Distance Between Shaft Ends

(D.B.S.E.)

Understand how to read an alignment specification

Understand how to perform fine alignment with dial gauges

Course Introduction

Why is shaft alignment important?

A gas turbine shaft bearing is damaged caused from
shaft misalignment

The customers turbine is down for repair for 30 hours

When the turbine is running the customer makes

$41,000.00 per hour

How much money did the customer loose?

$1,230,000.00
 Machines Alignment

Machines are misaligned when their rotational centerlines are not collinear when
the machines are operating under normal conditions.
 Effects of Misalignment

Premature bearing, seal, shaft and coupling failures

The breaking or crancking of shaft at, or close to the inboard

Excessive vibration

High bearing and coupling temperatures

High power consumption

 Performing Shaft Alignment

The shaft alignment is performed when any of the following occur:

After machine skids positioning on foundations

Repair or installation of the major component

Process pipe connections

Important Steps

The first action to be taken is to

have ready the Check List for
Units Alignment Execution that
could be found in the Installation
Check List Package developed for
the specific Job Site. Also the RIC
8952047 “Alignment Execution
procedure for turbo-compressors
and turbo-generators” must be
available in site.

Strictly follow the sequence

indicated in the check list.

In case the check list is not

available, an abstract of it could
be also found in the document RIC
8952047.
 Check List – Step 1
Before to start the alignment activities, installation only!

Check the soft foot on every anchorage point
• Position a magnetic base with dial guage (fig.1) close to the foundation bolt
• Tighten the nut at a value of 80Kgm for GT skid and 120Kgm for
compressor/motor skids
• Verify that the maximum soft foot is equal or less than 0,05mm

Fig. 1
 Check List – Step 1

Correct the soft foot

• Remove or add more shims between the spherical washer and the skid
plate (fig. 2)
• Remove or add more shims under the plate (fig. 3)

Repeat the step 1 unless the correct value has been found
How does dial gauge work ?

0 mm 0 mm

0,8 mm

tip

start start

Remember that in our example, dial gauge is set at +5mm

Compressing spring’s dial gauge  positive variation
Realising spring’s dial gauge  negative variation
Overview

soft foot

Axial and
radial
moving Shims”
BOLTS

Up&down
moving
bolt
 Check List – Step 2
Set the Distance Between Shaft Ends (D.B.S.E.), installation only!

Check the design values D.B.S.E. from the following drawings:

• Coupling Assembly Drawing
• Foundation Drawing
• Alignment Specification

The cross check of the D.B.S.E. in all 3 documents should be the same

Measure the real value using an inside micrometer

Correct the value of the D.B.S.E. moving the skids/units in order to be exactly
at the design value
 Example D.B.S.E.

Open document SOS9982409

Values reported:
• Distance Between Shaft Ends at cold 800 +/- 0.25 mm

• Coupling installed with a pre-stretch of 0 mm

Gas Turbine Compressor

D.B.S.E.

D.B.S.E. may be 799,75mm or 800,25mm

 Check List – Step 4
Only for Gas Turbine!

Remove the gas turbine from the third point

(shipping pin) before starting the alignment

N.B.: a detailed procedure could be found in GE manual EM5315 downloadable at

the methods portal home page
http://insideapp.ps.ge.com/int258/site/Methods/
 Alignment Definitions
Radial – Parallel (rim)
Radial alignment is the relative position of the machines to be coupled on the
vertical and horizontal planes.

Axial – Angular (face)

Axial alignment is the relative position between the perpendicular planes to the
axes of rotation of the two machines to be coupled.
Misalignment

….. usually Both are Always Combined

Alignment at cold conditions
Alignment at load conditions
Alignment Specification

Now that the soft foot and the
D.B.S.E. Has been checked we
must start to understand the
alignment specification values.

Download from EDM the

alignment specification specific
for your Job Number (the one in
the figure is an example).

Decide which method of alignment

you would use:

Double Radial (Rim) alignment

(called also Reverse alignment)

Radial (Rim) + Face alignment

As Ge O&G we always
recommend to use the Rim and
Face alignment, and therefore in
this course we will explain this
method.

Record the specification value on

the alignment form (MEST 1003,
see next page).
 Alignment Specification /2

The values of the radial reading depend by the side where the special tool is
assembled

A1 A1
DRIVEN DRIVER DRIVER DRIVEN
D D

A2 A2
 MEST 1003

The Alignment form MEST 1003 must

be filled for any group of machines.

WRITE HERE THE SPECIFICATION VALUES

WRITE HERE THE ALIGNMENT VALUES BEFORE

THE OVERHAULING

WRITE HERE THE FINAL ALIGNMENT VALUES

 Example
For the following train

Gear Box Generator

Gas Turbine

You should fill in a MEST 1003 for the alignment between gas turbine and gearbox
and a MEST 1003 for the alignment between gearbox and generator.
Alignment Special Tool
 Preparation of the readings

To perform the alignment both shafts need to be turned and therefore it is
necessary, in order to eliminate the run-out of the disk, to mark the dial gauges
reading position as showed below:

270°
0 90°

180°

IMPORTANT: While you do the alignment, first rotate the disk of 90° clockwise, then rotate the
alignment fixture of 90° clockwise in order to have the radial gauge matching the sign 0°. Set
the dial gauge to +5.00mm in order to have the full travel of the dial gauge available during
the readings.
 Radial Reading
A Example
0 Readings in mm

DRIVER DRIVEN (z)+ 1,32 R + 1,32 (Y)

+ 2,64 (X)

The readings of the radial misalignment should be read for every 90° rotation of the shafts.
The values should be recorded on the apposite form.
The value of radial misalignment on the vertical plane will be equivalent to half of the reading
made on the dial gauge after a rotation of 180°.

V= X V= + 2,64
V= + 1,32 mm
2 2
In this example the driver shaft is higher than the driven of 1,32mm (see the + sign). If the sign
was – it means that the driver shaft was lower than the driven.
 Radial Reading
A
Example
0 Readings in mm

DRIVER DRIVEN (z)+ 1,32 R + 1,32 (Y)

+ 2,64 (X)

The value of radial misalignment on the horizontal plane will be equivalent to half-difference
in the reading made on the dial gauge after a rotation of 90° (y) and 270° (z).

y-z +1,32 – (+1,32)

h= h= h= 0
2 2
In this example the driver shaft and the driven shaft are aligned on the horizontal plane. Note
also that the sum of the horizontal readings is equal to the vertical one.
Radial Reading
 Axial Reading
A1 Important Note: always remember to check
DRIVER DRIVEN the distance (D) between the two dial gauges
D
as showed in the diagram.
A2

For the axial misalignment two dial gauges must be

used due to the fact that, during rotation of the two
flanges, axial displacement of one of the two elements
to be coupled may occur.
By using two dial gauges, any displacement along this
axis is nullified, while displacement on the faces of two
flanges to be coupled remains unaltered.
 Axial Reading
A1
DRIVER DRIVEN It is important to always remember that
D
the A1 dial gauge is the one closest to
A2 the radial gauge

0 180° (X)

270° (z) A1 90° (Y) 90° (Y) A2 270° (z)

0
180° (X)

Readings in mm
 Axial Reading
The value of the axial misalignment on the vertical plane will be given by the
algebraic half-difference in the readings (considered with their sign) made on dial
gauges A1 and A2 after a 180° rotation.

A1(x) – (+/- A2(g))

A0=
2

0 180° (g) 0

270° A1
(z) 90° (Y) 90° (h) A2 270° (f) A0
0
180° (X) ()
Readings in mm
 Example Axial Reading
Let’s simulate now a axial reading on the vertical plane. For this we will do a
rotation of the disk and the tool of 180°.
-0,02
0 180° (g) 0

270° (z) A1 90° (Y) 90° (h) A2 270° (f) A0

0
180° (X) +0,045
+0,07
Readings in mm

By using the formula we will have:

+0,07 – (-0,02) +0,09

A0= A1(x) – (+/- A2(g)) A0= A0= A0= +0,045
2 2 2
If the result has a negative sign the flanges are open at the bottom. If the result has a positive
sign the flanges are closed at the bottom.
 Example Axial Reading
The value of the axial misalignment on the horizontal plane will be given by the
algebraic half-difference in the readings (considered with their sign) made on dial
gauges A1 and A2 after a 90° and 270° rotation.

0 180° (g) 0

270° (z) A1 90° (Y) 90° (h) A2 270° (f) () A0 ()

0
180° (X)

Readings in mm

A1(z) – (+/- A2(f))

A0= =
2
A1(y) – (+/- A2(h))
A0= =
2
 Example Axial Reading

Let’s simulate now a axial reading on the horizontal plane. For this we will do first a
rotation of the disk and the tool of 90°.

0 180° (g) 0

270° (z) A1 90° (Y) 90° (h) A2 270° (f) A0 -0,01

-0,04 -0,02 0
180° (X)

By using the formula we will have:

A1(y) – (+/- A2(h)) -0,04 – (- 0,02) -0,02

A0= = A0= = A0= = -0,01
2 2 2
 Example Axial Reading
Let’s simulate now a axial reading on the horizontal plane. For this we will do now a
rotation of the disk and the tool of 180°.

0 180° (g) 0

270° (z) A1 90° (Y) 90° (h) A2 270° (f) +0,05 A0

+0,02 -0,08
0
180° (X)

By using the formula we will have:

A1(z) – (+/- A2(Y)) +0,02 – (- 0,08) +0,10

A0= = A0= = A0= = +0,05
2 2 2
 Example Axial Reading
Now, that we have completed the radial readings and the axial readings let’s see
what we will write on the alignment form:

0 0

+ 1,32 R + 1,32 +0,05 A0 -0,01

+ 2,64 +0,045

NOTE: the algebraic sum of the values read on the horizontal plane (90° and 270°) will be the
same, except for minor errors, as the value read on the vertical plane (180°).
 Alignment Corrections
Once the reading has been taken it should be evaluated the movement to be done
on the unit in order to meet the specification values. It has to be said that the first
correction to be done is the AXIAL displacement. Once the axial alignment has been
corrected we will proceed to adjust the radial alignment.
Alignment corrections
 Alignment Corrections
A

y1
y2
Driver D
S

Example data:
1230 900 Driven
• Diameter D: 300 mm
• A = Axial Error measured G E
• S = shims to be added/removed
• y1 and y2: vertical movement of the shaft

Specification values (only vertical plane): Measured values (only vertical plane):

0 0 0 0

A R A R

- 0,04 + 0,15 + 0,04 + 1,23

 Alignment Corrections
Example data:
A
• Diameter D: 300 mm
• A = Axial Error measured
• S = shims to be added/removed
• y1 and y2: vertical movement of the shaft
y1
y2

Driver D
S

1230 900 Driven

G E
ERROR values (only vertical plane): Axial Error
0 0 S= xE
D
A R
S= 0,08 x 900
300
0,08 + 1,08

S = 0,24 mm
 Alignment Corrections
Now we have found the amount of shims that needs to be added on y2 feet for
having the axial value as per specification. Note that we could not add +0,24 due to
the fact that the minimum shim thikness is 0,05 mm. Therefore we will add 0,25mm
(S) on y2 feet.

Example data:
• Diameter D: 300 mm
A
• A = Axial Error measured
• S = shims to be added/removed
• y1 and y2: vertical movement of the shaft
y1
y2
Driver D
S

1230 900 Driven

G E

S = 0,24 mm S = 0,25 mm
 Alignment Corrections
As you can understand, from the figure above, if we add 0,25 mm on feet y2 than
the flange will move down and then the radial reading will change. For calculating
of how much the radial readings will be affected from this correction let see below:

Example data:
• Diameter D: 300 mm
• A = Axial Error measured y1
• S = shims to be added/removed y2
• y1 and y2: vertical movement of the shaft
Driver D
S

1230 900 Driven

G E

S
S = 0,25 mm Y1&Y2 = xG
E
 Alignment Corrections

Example data:
• Diameter D: 300 mm A
• A = Axial Error measured
• S = shims to be added/removed
• y1 and y2: vertical movement of the shaft
y1
y2
Driver D
S

1230 900 Driven

G E

0,25
Y1 & Y2 = x 1230 Y2 & Y1 = 0,34 mm
900

Now remember that the value y1 must be multiplied by 2 in order to have the value of the
radial reading on the vertical plane. In this example the value to be considered is 0,68 mm.
 Alignment Corrections
Example data:
• Diameter D: 300 mm
• A = Axial Error measured A
• S = shims to be added/removed
• y1 and y2: vertical movement of the shaft

y1
y2
Driver D
S

1230 900 Driven

G E

In theory now we have that:

we need to add to 0,25 mm on the y2 feet for correcting the axial value and by doing this the
radial value will change from +1,23 to +1,91 ( 1,23+0,68=1,91 mm). So to complete to correct
the radial we will need to add from all 4 feet of the unit the following shims:

1,91 – 0,15 = 1,76 mm / 2 = 0,88 mm 0,90 mm

 RE-CAP
Example data:
• Diameter D: 300 mm
• A = Axial Error measured
• S = shims to be added/removed A
• y1 and y2: vertical movement of the shaft

y1
y2
Driver D
S

1230 900 Driven

G E

For correcting the axial we need to add 0,25 mm on the back feet
For correcting the radial we need to add 0,90 mm on all the 4 feet
Now that we have the amount of the shims we could proceed with the adjustment and then
to take a new reading to validate our calculation