Shaft Alignment Training Course 11/27/2011

Shaft Alignment Training

Course
NATCOM Training Classes

Nov. 29 – 30th, 2011

Presented by Nader S. Farah

Alignment Course Outlines

Alignment Fundamentals – An
Introduction
Introduction To Shaft Alignment
What Is Misalignment?

Pre-alignment Checks and Soft Foots

Determining The Alignment State.

1
Shaft Alignment Training Course 11/27/2011

Alignment Course Outlines

Shaft Alignment Mathematics.

Understanding Dial Indicators.
Soft Foot checks and Corrections.
Dynamic and Thermal Movement.

Alignment Course Outlines

The Rim – Face Dial Indicator Method.

The Reverse Dial Method.
Laser Alignment.

Moving The Machine.

2
Shaft Alignment Training Course 11/27/2011

Alignment Fundamentals – Introduction

Why Alignment Is So Important?
We are all under great pressure to increase
uptime, reduce costs, and improve product
quality, no matter what your role in the
organization we can all contribute to these
goals. One way you can help is to perform
precision shaft alignment on your rotating
machinery.

Alignment Fundamentals - Introduction

Why Alignment Is So Important?

The fact is that misalignment is the root

cause of the majority of machine
breakdowns: bearing failures, and
damaged seals, shafts and couplings.

50% of machine failures are due to

misalignment.

3
Shaft Alignment Training Course 11/27/2011

Alignment Fundamentals - Introduction

Bearing Damage
Rolling element (anti-friction) bearings are
precision components designed to operate
with:
Clean lubricant.
Reasonably constant
temperature.
Axial and radial forces / loads within
design guidelines.

Alignment Fundamentals - Introduction

Do You Know?
If you increase the You reduce the
load on a bearing bearing life to the
by just 20 % half (1/2).
If you increase you reduce the life to
the load to the one seventh (1/7) of
double on a its design life.
bearing,

4
Shaft Alignment Training Course 11/27/2011

Alignment Fundamentals - Introduction

Seal Damage
Seals are high cost items, often costing up
to a third of the total pump cost.
Seals do not tolerate
misalignment:
 Face rubbing.
 Elevated temperatures.
 Ingress of contaminants.

All The above, quickly damage seal.

Alignment Fundamentals - Introduction

Seal Damage
Misalignment also causes seals to fail
prematurely due to the increased load. The
life of the seal can be reduced to 30-50% of
design life.

5
Shaft Alignment Training Course 11/27/2011

Alignment Fundamentals - Introduction

Seal Damage
When seal fails
Seal will fail with little or no warning.
Lubricant leakage.
Lubrication problems.
New Seal and bearing will have to be replaced.
The total cost of parts, labor and downtime
can make this a very expensive failure.
Production will stop.

Alignment Fundamentals - Introduction

Coupling Damage
The impact of misalignment
on couplings varies greatly
according to the type of
coupling used.
The forces and friction are
detrimental to all couplings,
however the signs of damage, and
the nature of the damage can vary.

6
Shaft Alignment Training Course 11/27/2011

Alignment Fundamentals - Introduction

Coupling Damage
The rubber or plastic sleeve between the
two hubs in flexible couplings can wear – in
fact you will often find a small pile of rubber
or plastic under the coupling when you
move the coupling guard.

Alignment Fundamentals - Introduction

Coupling Damage
There is a common misconception

7
Shaft Alignment Training Course 11/27/2011

Alignment Fundamentals - Introduction

Coupling Damage
It is very important to understand that:
The life of the coupling will be
reduced if there is misalignment.

Bearings, seals and shafts will still be

under increased load and thus likely
to fail prematurely.

Alignment Fundamentals - Introduction

Gear Coupling Damage
In gear couplings, misalignment
results in increased wear on the
mating teeth.
Under sever misalignment
conditions; the load on the teeth will
be concentrated to the end of the
gear tooth flank.

8
Shaft Alignment Training Course 11/27/2011

Alignment Fundamentals - Introduction

Gear Coupling Damage
Misalignment can also cause lubrication
problems, resulting in metal to metal
contact and therefore greatly increased
wear.

Alignment Fundamentals - Introduction

Energy Consumption
Misaligned machines can also consume more
energy.
It is generally considered that a
misaligned machine will consume up to
15% more energy.
Large studies have documented savings
of between 3% and 8% when machines
are aligned.

9
Shaft Alignment Training Course 11/27/2011

Alignment Fundamentals - Introduction

Product Quality
Misalignment can also result
in reduced product quality in
many industries.

By reducing vibration levels, and aligning

rolls and other items, product quality can
be maximized.

Alignment Fundamentals - Introduction

Conclusion
The rotational forces that result from
misalignment generate vibration, these
forces can damage the coupling, seals,
shaft and bearing, but the vibration can
damage other components – even
machines located within close proximity.

10
Shaft Alignment Training Course 11/27/2011

Detecting Misalignment

Alignment Fundamentals - Introduction

Detecting Misalignment
There are basically three ways to determine if
a machine is misaligned:
1. you can look at the maintenance records
and alignment records.
2. You can monitor various physical parameters
such as vibration and temperature.

11
Shaft Alignment Training Course 11/27/2011

Alignment Fundamentals - Introduction

Detecting Misalignment
3. Other physical signs include loose or broken
hold-down bolts, loose shim packs or,
excessive oil leaks at bearing seals, and loose
or broken coupling bolts.

Alignment Fundamentals - Introduction

Detecting Misalignment
First if a machine has not been “precision”
aligned, that is, it was aligned “by eye” or
only using a straightedge, then it is VERY
likely that will be misaligned.

12
Shaft Alignment Training Course 11/27/2011

Alignment Fundamentals - Introduction

Detecting Misalignment
Issues like lubrication, imbalance, resonance
and misalignment should be considered
when a machine fails.
when a machine is put back into
service, it should be “precision”
balanced and “precision” aligned,
and the lubrication program
should be maintained.

Alignment Fundamentals - Introduction

Detecting Misalignment
Due to the nature of misalignment, there are at
least two physical signs that shafts are not
aligned:
The machine will vibrate in
characteristics ways.
The coupling may get hot which can
be detected with non-contact
temperature guns or thermal imaging
cameras.

13
Shaft Alignment Training Course 11/27/2011

Alignment Fundamentals - Introduction

Detecting Misalignment
Vibration analysis has been successfully
used for many years to detect
misalignment.
Depending upon the nature and severity of
the misalignment (and the nature of the
coupling and size/speed of the machine),
vibration measurements can help us detect
misalignment and assess the severity.

Alignment Fundamentals - Introduction

Detecting Misalignment
Vibration analysis has been successfully
used for many years to detect
misalignment.
Depending upon the nature and severity of
the misalignment (and the nature of the
coupling and size/speed of the machine),
vibration measurements can help us detect
misalignment and assess the severity.

14
Shaft Alignment Training Course 11/27/2011

Alignment Fundamentals - Introduction

Detecting Misalignment

Alignment Fundamentals - Introduction

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

15
Shaft Alignment Training Course 11/27/2011

Alignment Fundamentals - Introduction

Misalignment
If the pump was uncoupled and you turned
its shaft, it would rotate around a straight
line. This is the pump’s “rotational center”.
The same is true for the
motor – it’s shaft also
has a “rotational
centerline”.

Alignment Fundamentals - Introduction

Misalignment
Ideally, the motor and pump
(in this example) will be
mounted so that the two
rotational centerlines are
aligned perfectly

In this case the shafts are said to be

“collinear”.

16
Shaft Alignment Training Course 11/27/2011

Alignment Fundamentals - Introduction

Misalignment
What happens if is that the two components
do not come together perfectly.
It might look OK to the
naked eye, so the
components are
coupled together and
the machine is run that
way.

Alignment Fundamentals - Introduction

Misalignment
You will see an offset and angle introduced
in the vertical direction, and then you will
see a different offset and angle introduced in
the horizontal direction. The result is two
shafts that are misaligned.

17
Shaft Alignment Training Course 11/27/2011

Alignment Fundamentals - Introduction

Misalignment – Closer Look
Think about what is happening
to the shaft, and the bearings,
and the seals, and the
coupling?
With every rotation the shaft has to flex –
it is forced to stay within the bearings. That
puts strong radial and axial forces on the
coupling, bearings, seals and shaft.

Alignment Fundamentals - Introduction

Misalignment – Closer Look
Let’s take a closer
look at the impact of
bending the shaft.
For every half-
rotation (180 degrees
rotation), the shaft
must flex to an exact
opposite curve.

18
Shaft Alignment Training Course 11/27/2011

Alignment Fundamentals - Introduction

Misalignment – Closer Look
The coupling may be designed to
cope with some misalignment,
but the other components are
not.
The misalignment will lead to excessive
bearing wear, leaking seals, increased power
consumption, and depending upon the
application, reduce product quality.

Types of Misalignment
Types of Misalignment
Offset Misalignment
If one component is higher than the
other, or to one side, there will be an
offset. This is called “offset
misalignment”, or sometimes “parallel
misalignment”.

Angular Misalignment
It is called “angular misalignment” (or “gap
misalignment”) when the two shaft centerlines
meet at an angle.

19
Shaft Alignment Training Course 11/27/2011

Types of Misalignment
Types of Misalignment
Combined Misalignment
In reality, shaft misalignment is a
combination of both offset and
angular – it will almost never be just
angular or offset (parallel)
misalignment.

Alignment Conventions and

Common Terms

20
Shaft Alignment Training Course 11/27/2011

Alignment Conventions and Common Terms

Stationary & Movable Machines
The first is the concept of
“stationary” and “movable”
components.
Although the motor and pump all have feet
that can be moved, components like pumps,
fans, and compressors are typically very
difficult to move so they are considered
“stationary”.

Alignment Conventions and Common Terms

Clock Position
All clock positions are referenced when
you are standing behind the movable
component.

21
Shaft Alignment Training Course 11/27/2011

Alignment Conventions and Common Terms

Positive Offset
Offset is described as positive when the
movable component is higher, and when the
movable components is to the right (when
viewed from behind the movable
component).

Alignment Conventions and Common Terms

Positive Angularity
Angularity is described as positive when the
gap at the coupling is open at the top (at
12:00) or on the right hand side (at 3:00).

22
Shaft Alignment Training Course 11/27/2011

Specifying Misalignment

Specifying Misalignment
Specifying Misalignment
Before we consider how to align a machine,
we need to consider how to specify the
amount of misalignment. If we are to align a
machine, we need some kind of target so
that we know when the job is done.

23
Shaft Alignment Training Course 11/27/2011

Specifying Misalignment
Specifying Misalignment
One of the keys is to have a
target to aim for – so that you
know when the job is done.
Given the variety of machine
sizes and speeds, how do you
know if a machine is precision
aligned?

Specifying Misalignment
Specifying Misalignment
There are basically three ways to specify the
amount of allowable misalignment:
1- The corrections required at the feet.

2- The total indicator reading (TIR).

3- The offset, angle (or gap) at the
point of power transfer (the coupling).

24
Shaft Alignment Training Course 11/27/2011

Specifying Misalignment
Corrections at Feet
One traditional way to specify alignment
targets is to specify maximum foot corrections.
For example;
“the alignment is done when you
require less than 3 mils correction”.

Specifying Misalignment
Corrections at Feet
1- It can result in totally alignment states
for machines of different sizes.
2- It makes a huge difference when the
correction required at the front and back
feet are in the same direction or in the
opposite directions.

25
Shaft Alignment Training Course 11/27/2011

Specifying Misalignment
Corrections at Feet
Example 1; 3 mils of movement are required at
the front and rear feet.

According to the “Correction @ feet” Rule this

machine doesn’t require alignment.

Specifying Misalignment
Corrections at Feet
Due to the direction of movement required
(one up, the other down), and the ratio of the
distance between the front and rear feet to
the distance between coupling and the front
feet, the alignment is terrible (6 mils out),
even though only 3 mils could be considered
to be “within tolerance”.
See Next

26
Shaft Alignment Training Course 11/27/2011

Specifying Misalignment
Corrections at Feet

Different machines sizes can result in

totally different alignment states .

Specifying Misalignment
Corrections at Feet
Example 2;
* There is no offset at the coupling
* The angularity is small – it is aligned quite well.
However, because of the size of the machine, and the
ratio of distances (between the feet versus the
distance between the front feet and the coupling),
the offset at the rear feet is quite large – well outside
the 3 mil limit. The aligner would go to work to
correct the situation, even though it is already ok.
See Next

27
Shaft Alignment Training Course 11/27/2011

Specifying Misalignment
Corrections at Feet

Before Alignment

After Alignment

Specifying Misalignment
Total Indicator Reading
As we will soon see, angularity is calculated
by taking the difference between the two TIR
values and dividing by the distance between
them.

If the “tolerance” is based on the TIR values

only, we are ignoring the angularity.

28
Shaft Alignment Training Course 11/27/2011

Specifying Misalignment
Total Indicator Reading
The same TIR readings
from dial/laser heads
2” (5mm) apart
represents quite a
different situation than
if the dial/heads were
10” (25 mm) apart.

Specifying Misalignment
Offset & Angularity (GAP)
The most common way to specify
alignment targets is to specify to
offset and angularity at the point
of power transmission – (at the
center of the coupling).

the vertical offset (VO), vertical angle

(VA), horizontal offset (HO) and
horizontal angle (HA).

29
Shaft Alignment Training Course 11/27/2011

Specifying Misalignment
Offset & Angularity (GAP)
The offset is simply specified as a
displacement in mils or mm.
Knowing the location of the center
of the coupling relative to the
position of the laser heads or dial
indicators the offset can be
calculated and compared to the
target.

Specifying Misalignment
Offset & Angularity (GAP)
If you have thermal offset values, or other
dynamic movement information (based on
the amount the shafts will move when the
machine is running – explained later).

These offsets will be added to the

tolerance values to arrive at the final
targets.

30
Shaft Alignment Training Course 11/27/2011

Specifying Misalignment
Offset & Angularity (GAP)
Angularity can be described in one of two
ways;
1. The rise-over-run of the shaft.
2. Coupling gap.

Both angles are equal.

Specifying Misalignment
Offset & Angularity (GAP)
When angularity is specified as “coupling
gap”, it is defined based on a particular
diameter of coupling.
Multiply the stated gap tolerance (from
tables) by the ratio of the actual diameter to
the reference diameter.
See next

31
Shaft Alignment Training Course 11/27/2011

Specifying Misalignment
Offset & Angularity (GAP)
𝑺𝒕𝒂𝒕𝒆𝒅 𝒈𝒂𝒑 𝒕𝒐𝒍𝒆𝒓𝒂𝒏𝒄𝒆 𝑮𝒔

𝑮𝒂𝒑 𝒕𝒐𝒍𝒆𝒓𝒂𝒏𝒄𝒆 @ 𝒎𝒆𝒂𝒔𝒖𝒓𝒆𝒎𝒆𝒏𝒕 𝒑𝒐𝒊𝒏𝒕 𝑮𝒕

𝒅𝒓
𝒅𝒂

𝑆𝑡𝑎𝑡𝑒𝑑 𝑔𝑎𝑝 𝑡𝑜𝑙𝑒𝑟𝑎𝑛𝑐𝑒 𝐺𝑠 𝑓𝑟𝑜𝑚 𝑡𝑎𝑏𝑙𝑒𝑠 𝐺𝑎𝑝 𝑡𝑜𝑙𝑒𝑟𝑎𝑛𝑐𝑒 @ 𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑚𝑒𝑛𝑡 𝑝𝑜𝑖𝑛𝑡 𝐺𝑡

𝜃= =
𝑑𝑟 𝑀𝑒𝑎𝑠𝑢𝑟𝑒𝑚𝑒𝑛𝑡 (𝑎𝑐𝑡𝑢𝑎𝑙)𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑑𝑎

Actual gap is compared to Gt

Specifying Misalignment
Offset & Angularity (GAP)
You can think of the
tolerances as a cone - the
motor’s shaft centerline can
exist anywhere within the
cone.

32
Shaft Alignment Training Course 11/27/2011

Specifying Misalignment
Offset & Angularity (GAP)
1. The cone doesn’t come
to a point because we
allow a certain amount of
offset.

2. As shaft speeds, the

cone shrinks.

Specifying Misalignment
Offset & Angularity (GAP)
The relationship between the misalignment
and the damage that can be done to the
machine is the machine speed. If the
machine speed is greater, the damage will
be greater.

33
Shaft Alignment Training Course 11/27/2011

Specifying Misalignment
Offset & Angularity (GAP)

Specifying Misalignment
Spacer Coupling – Jackshaft
Conventions and Tolerances
Spacer coupling are designed to
cater for larger amounts of
misalignment.
Whereas flexible couplings can tolerate a
certain amount of misalignment, due to their
length, spacer coupling are frequently used
where alignment changes may be anticipated.

34
Shaft Alignment Training Course 11/27/2011

Specifying Misalignment
Spacer Coupling – Jackshaft
Conventions and Tolerances
The offset is taken up with the spacer shaft,
and the angles at the two coupling interfaces
are very smaller.

Specifying Misalignment
Spacer Coupling – Jackshaft
Conventions and Tolerances
The alignment condition and tolerances
are described differently for spacer shafts.
Rather than an offset and angle, it can be
specified as two angles in both horizontal
and vertical.

35
Shaft Alignment Training Course 11/27/2011

Specifying Misalignment
Spacer Coupling – Jackshaft
Conventions and Tolerances
The other way the tolerance can be specified
is as two offsets, in both vertical and
horizontal direction.

Specifying Misalignment
Spacer Coupling – Jackshaft
Conventions and Tolerances

36
Shaft Alignment Training Course 11/27/2011

Specifying Misalignment
Spacer Coupling – Jackshaft
Conventions and Tolerances
Tolerances are available
from a number of
sources. You can see that
the allowable offset and
angularity is reduced for
higher speed machines.

Specifying Misalignment
Spacer Coupling – Jackshaft
Conventions and Tolerances

37
Shaft Alignment Training Course 11/27/2011

Specifying Misalignment
CSI Tolerances

Specifying Misalignment
CSI Tolerances

1 𝑚𝑟𝑎𝑑 = 0.0753 𝑑𝑒𝑔𝑟𝑒𝑒

38
Shaft Alignment Training Course 11/27/2011

Pre-alignment checks

Pre-alignment Checks
Plan and Review Maintenance History.
Why The Machine Is Not Aligned?
Pipe Strain.
Bent Shaft or Coupling Run-out.
General Preparation for Safety.
General Preparation on Site Clean Up.
General Preparation on Site Shims.
General Preparation on Site Jacking Bolts.

39
Shaft Alignment Training Course 11/27/2011

Soft Foot Checks & Correction

Base plate
Soft foot is the condition where the
machine case distorts as the hold – down
bolts are tightened. This condition arises
when poor contact is being made at the feet
of the machine and the base plate or frame.

Soft Foot Checks & Correction

Pipe / Conduit Strain
It also occurs when excessive pipe or
conduit strain exists. It is very common
and very important.

40
Shaft Alignment Training Course 11/27/2011

Soft Foot Checks & Correction

Internal Misalignment and Clearances.
The act of tightening the bolts would not
put any strain on the machine case, and
thus the internal air gaps or other
clearances would not be changed.

There would be no internal

misalignment. There would
be no strain on the shaft.

Soft Foot Checks & Correction

Soft Foot Checks
Soft foot correction is a step done before
alignment.
We test soft foot by loosening each
hold-down-bolt, one at a time while
monitoring the foot for any lift.
If values exceeds 0.05mm, soft
foot correction is needed.

41
Shaft Alignment Training Course 11/27/2011

Soft Foot Checks & Correction

Soft Foot Checks
If soft foot is detected, we have to assess
the nature of the soft foot by studying
which feet appear to be soft and what its
profile of the gap under the feet

We then add shims to the

gaps so that they are filled
and all of the feet make
flat contact.

Soft Foot Checks & Correction

Different Types of Soft Foot
Rocking Soft Foot.

Angled Soft Foot.

Squishy Soft Foot.

Induced Soft Foot.

42
Shaft Alignment Training Course 11/27/2011

Soft Foot Checks & Correction

Rocking Soft Foot
There are three foot conditions that will
result in the “Rocking Soft Foot”;

1. Short Foot.

2. High Foot.

3. Even Feet.

Soft Foot Checks & Correction

Rocking Short Parallel Foot
Leg is too short; or one base plate mounting
pad is lower than the other three (it’s not
coplanar), or because there are a fewer
shims or missing shims under the feet,
incorrect shims were used.

43
Shaft Alignment Training Course 11/27/2011

Soft Foot Checks & Correction

Rocking High Foot
The “high” foot” situation is again similar,
however the high foot condition exists
because the air gap under the diagonally
opposed feet are pointing outwards, again
causing the machine to rock.

Soft Foot Checks & Correction

Rocking Even Feet
The “even foot” situation is similar to the
short foot case, however in reality we have
two short feet, diagonally opposite each
other.

44
Shaft Alignment Training Course 11/27/2011

Soft Foot Checks & Correction

Bent Foot
The “bent foot” soft foot
condition exists when the
bottom of the foot is not
parallel with the base. This is
likely because the foot itself is
angled, but could be because
the base plate is bowed or
the foot pad is not parallel
(coplanar).

Soft Foot Checks & Correction

Squishy Foot
The squishy foot condition exists when the act
of tightening the hold down bolts causes the
material under the foot to compress.
Too many shims.
Bent shims.
Dirt shims.
Rusted – paint - dust

45
Shaft Alignment Training Course 11/27/2011

Soft Foot Checks & Correction

Squishy Foot
Summarize shims under foot to
maximum of four shims.
Clean shims thoroughly .
Clean working area and under foot before
putting shims.

Soft Foot Checks & Correction

Induced Soft Foot

Pipe strain.
Conduit strain.
Some other external force is
exerted on the machine.
Severe misalignment.

46
Shaft Alignment Training Course 11/27/2011

Soft Foot Checks & Correction

Induced Soft Foot
0.05 mm soft foot caused the shaft and
coupling to be dragged by 0.2 mm.
The motor body has become distorted
putting stress on the bearings , the shaft
needs to go through the bearings which
are designed to allow.
Shaft will always be
under fatigue.

Soft Foot Checks & Correction

Measuring Soft Foot
Prepare a form that has
the foot number
marked, and it has
space for writing down
the soft foot readings,
the feeler gauge
readings, and the shim
values.

47
Shaft Alignment Training Course 11/27/2011

Soft Foot Checks & Correction

Rocking Soft Foot Correction
If the two highest readings are
diagonally opposite each other
then you have the rocking soft
foot condition.
1. Measure each foot, check the
profile, and determine how much is
required in the conventional way.
2. You can use shortcut proposed by Pedro Casanova of
Ludeca, Inc.
3. You can use the “80% rule”.

Soft Foot Checks & Correction

Casanova Method
This method works whether you have a
“short foot”, ”high foot” or “even” rocking
soft foot condition.

48
Shaft Alignment Training Course 11/27/2011

Soft Foot Checks & Correction

Rocking S.F. Correction - Casanova Method
1. Loosen the hold down bolts on the two
feet with the soft foot condition, and
leave the other two feet tight.
2. Perform a reverse soft foot
check on one of the feet (with
laser system or dial indicator),
you tighter it. The dial indicator
will give you a reading.

Soft Foot Checks & Correction

Rocking S.F. Correction - Casanova Method
3. Shims that foot with the reading amount.
For example, if the reading was 10 mil, add a
10 mil shim. Do not tighten the bolt- leave it
loose.

49
Shaft Alignment Training Course 11/27/2011

Soft Foot Checks & Correction

Rocking S.F. Correction - Casanova Method

4. Now do the same thing on the other foot

that was soft (diagonally opposite the foot
you just tested).
Tighten the bolt, record the value, and shim
it.

Soft Foot Checks & Correction

Rocking S.F. Correction - Casanova Method
5. After completing this procedure, you
should repeat the normal soft test to ensure
that the soft foot has been corrected. For
example, the test will reveal if one or both of
the soft feet were bent.

50
Shaft Alignment Training Course 11/27/2011

Soft Foot Checks & Correction

80% Rule
The 80% rule can also be
used to determine the size
of the shims to place under
diagonally opposite feet.
It assumes that the same amount is required
under both feet, and like the previous
method doesn’t take into account the profile
of the gap under the feet.

Soft Foot Checks & Correction

80% Rule
1. Add the amount of the two
highest feet lifted. in our
example 22 mils.

2. Add the amount of the two lowest feet

lifted . In our example it’s 2 mils.

3. Compute the difference. In our example

20 mils.

51
Shaft Alignment Training Course 11/27/2011

Soft Foot Checks & Correction

80% Rule
4. multiply by 80%. In our example 16 mils.

5. Shim half of this amount under the two

highest feet. 8 mils.

Soft Foot Checks & Correction

Feeler Gauge
If the soft foot readings do not indicate that
a rocking soft foot condition exists (or if the
short-cut did not work), you must use feeler
gauges in order to measure the profile of
the gap under the foot. .

52
Shaft Alignment Training Course 11/27/2011

Soft Foot Checks & Correction

Examples

Soft Foot Checks & Correction

Examples

53
Shaft Alignment Training Course 11/27/2011

Soft Foot Checks & Correction

Examples

Soft Foot Checks & Correction

Examples

54
Shaft Alignment Training Course 11/27/2011

Soft Foot Checks & Correction

Examples

Soft Foot Checks & Correction

Examples

55
Shaft Alignment Training Course 11/27/2011

End of Session

Understanding Dial Indicators

Accuracy
What is the reading?
Is it 12:00 or 6:00?
What if the gauge is under the shaft.
It’s very easy to misread the dial.

56
Shaft Alignment Training Course 11/27/2011

Understanding Dial Indicators

Watching Needle Travel During Reading
For this reason, it is very important that you
watch the face of the dial during the test to
see which way the needle travels.

Understanding Dial Indicators

Fully Extended Plunger – Completely
Forced Plunger

The plunger is fully extended, or

forced into dial body.

57
Shaft Alignment Training Course 11/27/2011

Understanding Dial Indicators

Bar Sag Test
Determine bar sag before data acquisition.

Understanding Dial Indicators

Total Indicator Reading
When we perform the offset
readings we set the dials at
12:00 position, then either
zero the gauge or set it to the
bar sag reading, then rotate
to the 6:00 position at the
end of test we have a
reading. This is called “ Total
Indicator Reading” TIR.

58
Shaft Alignment Training Course 11/27/2011

Understanding Dial Indicators

Hysteresis
Plunger does not move smoothly, or the
needle does not return to its original
position.

Understanding Dial Indicators

Clock Position
It is important that you understand where
12:00 and 6:00 are located and also 3:00
and 9:00 position.

59
Shaft Alignment Training Course 11/27/2011

Trigonometry

Shaft Alignment Mathematics

Trigonometry
In this section we will explain
the terms “Angularity” ,
“Offset” and “Slope”, and
discuss a few mathematical
(Trigonometry) rules that will
often be used.

60
Shaft Alignment Training Course 11/27/2011

Shaft Alignment Mathematics

Equal Triangles

Different offsets and angles can form

different triangles

Shaft Alignment Mathematics

Equal Triangles
A triangle can be described in a number
of ways, but for our application it is the
best to describe the angle in the terms of
the “rise over run”.
RISE

RUN

61
Shaft Alignment Training Course 11/27/2011

Shaft Alignment Mathematics

Equal triangles
Multiple right – angled triangles, all with the
same angle, but with different rise and run.
Ratio between rise and run is the same for
all triangles
Rise 2 Rise 3
Rise 1
𝜃
Run 1
Run 2
Run 3

𝑅𝑖𝑠𝑒1 𝑅𝑖𝑠𝑒2 𝑅𝑖𝑠𝑒3

= =
𝑅𝑢𝑛1 𝑅𝑢𝑛2 𝑅𝑢𝑛3

Shaft Alignment Mathematics

Equal Triangles

Rise 2
Rise 3 Rise 3
𝜽 Rise 2
Rise 1 Rise 1
𝜽 𝜃
Run 1 Run 1
Run 2 Run 2
Run 3 Run 3
𝑹𝒊𝒔𝒆𝟏 𝑹𝒊𝒔𝒆𝟐 𝑹𝒊𝒔𝒆𝟑 𝑅𝑖𝑠𝑒1 𝑅𝑖𝑠𝑒2 𝑅𝑖𝑠𝑒3
= = = =
𝑹𝒖𝒏𝟏 𝑹𝒖𝒏𝟐 𝑹𝒖𝒏𝟑 𝑅𝑢𝑛1 𝑅𝑢𝑛2 𝑅𝑢𝑛3

62
Shaft Alignment Training Course 11/27/2011

Shaft Alignment Mathematics

Equal Triangles

Rise 1

Run 2 𝜽
𝜽
Rise 2
Run 1
𝑹𝒊𝒔𝒆𝟏 𝑹𝒊𝒔𝒆𝟐
=
𝑹𝒖𝒏𝟏 𝑹𝒖𝒏𝟐

Shaft Alignment Mathematics

Equal Triangles Rise 2
Run 2

If you know “Rise2 𝜽

Rise 1
and Run2”, then we 𝜽
can know the Run 1

horizontal angularity.
𝑹𝒊𝒔𝒆𝟏 𝑹𝒊𝒔𝒆𝟐
=
𝑹𝒖𝒏𝟏 𝑹𝒖𝒏𝟐

63
Shaft Alignment Training Course 11/27/2011

Shaft Alignment Mathematics

Equal Triangles
We have two triangles. The triangle made
between two shafts, and the triangle made
by the two offset points

Shaft Alignment Mathematics

A Triangle From Two Offsets
The method known as rim and face. It uses
a measurement on the face of the coupling,
from which we can compute the angle.

64
Shaft Alignment Training Course 11/27/2011

Shaft Alignment Mathematics

A Triangle From Two Offsets
The reverse dial method uses two offsets
come from two dials. We know distance
between dials and the difference between
two offsets, then we could have Rise and
run.

The Face – Rim Dial indicator Method

65
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

Equal Triangles
Face and Rim describes the angle in the
terms of the “rise over run”.
RISE
RUN

RISE

RUN

66
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

They call it:
Face – Rim Method.
Rim and Face or Face and Rim Method.
Face – Peripheral Method.

Rim measurements will run

on one of the coupling rim.
Face measurements will be
run on one of the coupling
face

The Rim – Face Dial Indicator Method

The rim readings

provides the offset RISE
between the rotational
centerlines.
RUN

RISE

The Face readings

provides the angularity RUN
between the shafts
centerlines.

67
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

What if only one shaft is rotated?
Although this method can be used with only
rotating one shaft. But we prefer to rotate
the two shafts for the following reasons:

Potential run-out problems.

Rim and face irregularities.

The Rim – Face Dial Indicator Method

Accuracy Issue – Setup Problems
If the diameter is less
than 8” the accuracy will
be compromised.

To solve this problem use

extension brackets as shown.

68
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

Accuracy Issue – Setup Problems
If the space between couplings is insufficient
use:
The back of the coupling to insert the
face dial, readings signs should be
taken into account in this
measurement.
Use extension bracket fixed
on the other shaft for the face
dial measurements.

The Rim – Face Dial Indicator Method

Accuracy Issue – Axial End - Float
If the machine has
plain/ sleeve bearings,
the shaft may axially
float or move. The face
readings will fail the
validity test.
If you cannot stop the axial shaft
movement, use another method.

69
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

General Alignment Arrangements .
Check the appropriate tools
for lifting the machine.
Check the machine jacking
bolts
Check the machine tightening
bolts .

Check the soft foot and fix

it first.
Secure your machine before any start.

The Rim – Face Dial Indicator Method

Rim – Face Measurement Procedure.
We will consider two cases:
1- If the two shafts rotate simultaneously during
measurement.
2- If one shaft rotates while the other is still
during measurement.

We shall use methodical steps for avoiding any

mistakes during the whole alignment job.

70
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

Rim – Face Measurement Procedure.
Now position the dials on
the 12:00 position and zero
dials and compensate for
the bar sag instead of
calculation later.
Rotate the dials to the
3:00, 6:00, 9:00 positions
and record the readings
at each position.

The Rim – Face Dial Indicator Method

Alternative method of measurement
In this method we collect the horizontal and vertical
measurements separately.
Start from 12:00 position. Zero the dials
and rotate to 6:00 position. Take the
readings
Start from 3:00 position. Zero the dials
and rotate to 9:00 position. Take the
readings

71
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

Validity Rule
Validity Rule
(12:00 + 6:00) Readings = (3:00 + 6:00)Readings
00.0 00.0

0.19 F -0.09 -0.06 R 0.18

0.10 0.12

As Found Reading

You should rotate the dials back to the 12:00

position and check if they read zero or not.

The Rim – Face Dial Indicator Method

Rim – Face Measurement Procedure
Better to repeat the test to check readings and
signs (+/-). Check dials and brackets carefully.

Record the “As Found” readings of the dial

indicators.
12:00 12:00 12:00

9:00 F 3:00 9:00 R 3:00 9:00 S 3:00

6:00 6:00 6:00

As Found Reading

72
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

Rim – Face Measurement Procedure.

Determine the “Bar Sag” of

your bracket, by measuring
the arm length of the bracket
and make a simulator test to
determine the bar sag value.
Record the value in negative
sign.

The Rim – Face Dial Indicator Method

If two shafts rotate simultaneously.
First we will consider we have a machine that was
aligned perfectly in both horizontal and vertical
planes.

73
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

If two shafts rotate simultaneously.
V

Suppose we made
an offset between
the two machines in
both horizontal and H
vertical planes (H
&V).

The Rim – Face Dial Indicator Method

If two shafts rotate simultaneously.

Now we will
create an ɵV
angularity
between the two
machines in both
horizontal and ɵH
vertical planes
(𝜽𝒉 & 𝜽𝒗 ).

74
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

If two shafts rotate simultaneously.

You are called to ɵV

make alignment
for the machines,
considering that
both shafts ɵH
rotates.

The Rim – Face Dial Indicator Method

If two shafts rotate simultaneously.

First we have to
determine the
movable machine
(the machine that will
be moved to align the
other stationary
machine).

75
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

If two shafts rotate simultaneously.

Now we will specify our virtual clock by looking

from the movable machine to the stationary.

The Rim – Face Dial Indicator Method

If two shafts rotate simultaneously.

Once you specified the MOV and STAT machines,

Bracket will be fixed on the STAT machine so that dial
indicators measure on the MOV machine’s shaft.

76
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

If two shafts rotate simultaneously.

Determine the rotation direction, preferable to be in

the same direction as machine rotates. For example
C.C.W. Keep readings according to clock positions.

The Rim – Face Dial Indicator Method

If two shafts rotate simultaneously.
We need to define the offsets names according to
their location and angles.
As the right
machine is the
movable machine,
then we will
extend the
centerline of the
left machine to
the right machine.

77
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

If two shafts rotate simultaneously.
Look now as there is an angularity exists, offset
change on location to another.
C M
s
Offset is different
at center (Power
transmission F R
plane), at front and
rear feet for both
vertical and
horizontal planes.

The Rim – Face Dial Indicator Method

If two shafts rotate simultaneously.
VC VM VF VR

We will denote
s
to offsets
referenced to
their position
C M F R
and plane.

HC HM HF HR

78
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

If two shafts rotate simultaneously.
Vc VM VF VR
VC Vertical displacement at power
transmission plane.
VM Vertical displacement at rim dial s
indicator position.
VF Vertical displacement at front foot
position.

VR Vertical displacement at rear foot

position. C M F R
HC Horizontal displacement at power
transmission position.

HM Horizontal displacement at rim dial

indicator position.

HF Horizontal displacement at front

foot position.

VR Horizontal displacement at rear

foot position.
Hc HM HF HR

The Rim – Face Dial Indicator Method

VC VM VF VR

We will denote
s
to distances
referenced to LR
the position C M F R LF
from rim dial LC
indicator
plunger.

HC HM HF HR
LC Distance from “RIM” dial plunger to center @(power transmission).
LF Distance from “RIM” dial plunger to MOV machine front feet center.
LR Distance from “RIM” dial plunger to MOV machine rear feet center.

79
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

If two shafts rotate simultaneously.
Vertical Plane.

The Rim – Face Dial Indicator Method

If two shafts rotate simultaneously.
Vertical Direction Equations.
𝑶𝒇𝒇𝒔𝒆𝒕 𝒂𝒕 𝒇𝒐𝒐𝒕 = 𝑨𝒏𝒈𝒖𝒍𝒂𝒓𝒊𝒕𝒚 × 𝑫𝒊𝒔𝒕𝒂𝒏𝒄𝒆 𝒕𝒐 𝒇𝒐𝒐𝒕 − 𝑫𝒊𝒂𝒍 𝒐𝒇𝒇𝒔𝒆𝒕

80
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

If two shafts rotate simultaneously.
Vertical Direction Equations.
𝑹 𝟏𝟐: 𝟎𝟎 − 𝑹 𝟔: 𝟎𝟎 + 𝑩𝒂𝒓 𝒔𝒂𝒈
𝑽𝒆𝒓𝒕𝒊𝒄𝒂𝒍 𝑫𝒊𝒔𝒑𝒍𝒂𝒄𝒆𝒎𝒆𝒏𝒕@𝒅𝒊𝒂𝒍 𝑹 𝒐𝒇 𝑴𝑻𝑩𝑴 𝑽𝒎 =
𝟐
𝑭 𝟔: 𝟎𝟎 − 𝑭 𝟏𝟐: 𝟎𝟎
𝑽𝒆𝒓𝒕𝒊𝒄𝒂𝒍 𝑨𝒏𝒈𝒖𝒍𝒂𝒓𝒊𝒕𝒚 𝒐𝒇 𝑴𝑻𝑩𝑴 𝑨 = /𝑫
𝟐

𝑽𝒆𝒓𝒕𝒊𝒄𝒂𝒍 𝑴𝒐𝒗𝒆𝒎𝒆𝒏𝒕 𝒔𝒉𝒊𝒎𝒔 @ 𝒇𝒓𝒐𝒏𝒕 𝒇𝒆𝒆𝒕 𝒐𝒇 𝑴𝑻𝑩𝑴 𝑽𝒇 = 𝑳𝒇 × 𝑨 − 𝑽𝒎

𝑽𝒆𝒓𝒕𝒊𝒄𝒂𝒍 𝑴𝒐𝒗𝒆𝒎𝒆𝒏𝒕 𝒔𝒉𝒊𝒎𝒔 @ 𝒓𝒆𝒂𝒓 𝒇𝒆𝒆𝒕 𝒐𝒇 𝑴𝑻𝑩𝑴 𝑽𝒓 = 𝑳𝒓 × 𝑨 − 𝑽𝒎

𝑽𝒆𝒓𝒕𝒊𝒄𝒂𝒍 𝑴𝒐𝒗𝒆𝒎𝒆𝒏𝒕 @ 𝑪𝒆𝒏𝒕𝒆𝒓 𝑪𝒐𝒖𝒑𝒍𝒊𝒏𝒈 𝑷𝒍𝒂𝒏𝒆 𝑽𝒄 = (− 𝑳𝒄 × 𝑨) − 𝑽𝒎

+ means add shims

- means remove shims.

The Rim – Face Dial Indicator Method

81
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

If two shafts rotate simultaneously.
Horizontal Plane.

The Rim – Face Dial Indicator Method

If two shafts rotate simultaneously.
Horizontal Direction Equations.
𝑹 𝟑: 𝟎𝟎 − 𝑹 𝟗: 𝟎𝟎
𝑯𝒐𝒓𝒊𝒛𝒐𝒏𝒕𝒂𝒍 𝑫𝒊𝒔𝒑𝒍𝒂𝒄𝒆𝒎𝒆𝒏𝒕@𝒅𝒊𝒂𝒍 𝑹 𝒐𝒇 𝑴𝑻𝑩𝑴 𝑯𝒎 =
𝟐
𝑭 𝟗: 𝟎𝟎 − 𝑭 𝟑: 𝟎𝟎
𝑯𝒐𝒓𝒊𝒛𝒐𝒏𝒕𝒂𝒍 𝑨𝒏𝒈𝒖𝒍𝒂𝒓𝒊𝒕𝒚 𝒐𝒇 𝑴𝑻𝑩𝑴 𝑩 = /𝑫
𝟐

𝑯𝒐𝒓𝒊𝒛𝒐𝒏𝒕𝒂𝒍 𝑴𝒐𝒗𝒆𝒎𝒆𝒏𝒕 @ 𝒇𝒓𝒐𝒏𝒕 𝒇𝒆𝒆𝒕 𝒐𝒇 𝑴𝑻𝑩𝑴 𝑯𝒇 = 𝑳𝒇 × 𝑩 − 𝑯𝒎

𝑯𝒐𝒓𝒊𝒛𝒐𝒏𝒕𝒂𝒍 𝑴𝒐𝒗𝒆𝒎𝒆𝒏𝒕 @ 𝒓𝒆𝒂𝒓 𝒇𝒆𝒆𝒕 𝒐𝒇 𝑴𝑻𝑩𝑴 𝑯𝒓 = 𝑳𝒓 × 𝑩 − 𝑯𝒎

𝑯𝒐𝒓𝒊𝒛𝒐𝒏𝒕𝒂𝒍 𝑴𝒐𝒗𝒆𝒎𝒆𝒏𝒕 @ 𝑪𝒆𝒏𝒕𝒆𝒓 𝑪𝒐𝒖𝒑𝒍𝒊𝒏𝒈 𝑷𝒍𝒂𝒏𝒆 𝑯𝒄 = − 𝑳𝒄 ) × 𝑩 − 𝑯𝒎

+ means move towards 3:00

- means move towards 9:00
STAT MTBM

82
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

Example

83
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

Considering the following dimensions:

“Lf” = 1200 mm “Lr” = 2400 mm
“Lc” = 50 mm “D” = 100 mm

The Rim – Face Dial Indicator Method

Readings was as shown and Sag was found to be

0.2 mm.

0.00 0.00 0.00

-0.06 R 0.18 0.19 F -0.09 0.00 S 0.00

0.12 0.10 -0.2

As Found Reading

84
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

0.00 0.00 0.00

-0.06 R 0.18 0.19 F -0.09 0.00 S 0.00

0.12 0.10 -0.2

𝑹 𝟏𝟐: 𝟎𝟎 − 𝑹 𝟔: 𝟎𝟎 + 𝑩𝒂𝒓 𝒔𝒂𝒈
𝑽𝒆𝒓𝒕𝒊𝒄𝒂𝒍 𝑫𝒊𝒔𝒑𝒍𝒂𝒄𝒆𝒎𝒆𝒏𝒕@𝒅𝒊𝒂𝒍 𝑹 𝒐𝒇 𝑴𝑻𝑩𝑴 𝑽𝒎 =
𝟐
(𝟎) − 𝟎. 𝟏𝟐 + −𝟎. 𝟐
𝑽𝒎 = = −𝟎. 𝟐𝟐
𝟐
𝑭 𝟔: 𝟎𝟎 − 𝑭 𝟏𝟐: 𝟎𝟎
𝑽𝒆𝒓𝒕𝒊𝒄𝒂𝒍 𝑨𝒏𝒈𝒖𝒍𝒂𝒓𝒊𝒕𝒚 𝒐𝒇 𝑴𝑻𝑩𝑴 𝑨 = /𝑫
𝟐

𝟎. 𝟏𝟎 − 𝟎. 𝟎𝟎
𝟐 𝟎. 𝟎𝟓
𝑨 = =
𝟏𝟎𝟎 𝟐𝟎𝟎

The Rim – Face Dial Indicator Method

(𝟎) − 𝟎. 𝟏𝟐 + −𝟎. 𝟐
𝑽𝒎 = = −𝟎. 𝟐𝟐
𝟐 Considering the following dimensions:
“Lf” = 1200 mm “Lr” = 2400 mm
𝟎. 𝟏𝟎 − 𝟎. 𝟎𝟎
𝟐 𝟎. 𝟎𝟓 “Lc” = 50 mm “D” = 100 mm
𝑨 = =
𝟐𝟎𝟎 𝟐𝟎𝟎

𝑽𝒆𝒓𝒕𝒊𝒄𝒂𝒍 𝑴𝒐𝒗𝒆𝒎𝒆𝒏𝒕 𝒔𝒉𝒊𝒎𝒔 @ 𝒇𝒓𝒐𝒏𝒕 𝒇𝒆𝒆𝒕 𝒐𝒇 𝑴𝑻𝑩𝑴 𝑽𝒇 = 𝑳𝒇 × 𝑨 − 𝑽𝒎

𝑽𝒆𝒓𝒕𝒊𝒄𝒂𝒍 𝑴𝒐𝒗𝒆𝒎𝒆𝒏𝒕 𝒔𝒉𝒊𝒎𝒔 @ 𝒓𝒆𝒂𝒓 𝒇𝒆𝒆𝒕 𝒐𝒇 𝑴𝑻𝑩𝑴 𝑽𝒓 = 𝑳𝒓 × 𝑨 − 𝑽𝒎

𝑽𝒆𝒓𝒕𝒊𝒄𝒂𝒍 𝑴𝒐𝒗𝒆𝒎𝒆𝒏𝒕 @ 𝑪𝒆𝒏𝒕𝒆𝒓 𝑪𝒐𝒖𝒑𝒍𝒊𝒏𝒈 𝑷𝒍𝒂𝒏𝒆 𝑽𝒄 = (− 𝑳𝒄 × 𝑨) − 𝑽𝒎

𝟎.𝟎𝟓
𝑽𝒇 = (𝟏𝟐𝟎𝟎 × ) − (−𝟎. 𝟐𝟐) = 𝟎. 𝟓𝟐 𝒎𝒎
𝟐𝟎𝟎

𝟎.𝟎𝟓
𝑽𝒓 = 𝟐𝟒𝟎𝟎 × − −𝟎. 𝟐𝟐 = 𝟎. 𝟖𝟐 𝒎𝒎
𝟐𝟎𝟎

𝟎.𝟎𝟓
𝑽𝒄 = (− 𝟓𝟎 × ) − −𝟎. 𝟐𝟐 = 𝟎. 𝟐𝟎𝟕𝟓 𝒎𝒎
𝟐𝟎𝟎

85
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

The Graphical Method
This method will allow
you to see where the
movable machine is
positioned to the
stationary machine and it
will be more obvious to
how it should be removed

The Rim – Face Dial Indicator Method

The Graphical Method – vertical Plane.

Set up a graph with two different scales.

86
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

The Graphical Method – Vertical Plane.

Draw a line represents the “STAT” machine

centerline.

The Rim – Face Dial Indicator Method

The Graphical Method – vertical Plane.
1200

Vm Vf Vr

2400

Draw the planes of Vm, Vf, and Vr according to

scale.

87
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

The Graphical Method – vertical Plane.
1200

Vm Vf Vr

0.05 10.4units x 0.05= 16.4units x 0.05=

0.52 mm 0.82 mm
2400

Draw the displacement point at “Vm” plane

and draw the angle “A”.

The Rim – Face Dial Indicator Method

If one shaft only rotates.
If the shaft of the “STAT” machine is fixed while
the shaft of the “MTBM” is rotating.
Fix the bracket on the MTBM and take
measurements on the “STAT” machine
hub .
At this case reverse the signs of the “Rim”
dial readings, while keep the “Face” dial
readings as it is. Follow the same steps as
described before.

88
Shaft Alignment Training Course 11/27/2011

The Rim – Face Dial Indicator Method

Summary
Face and Rim readings are easy to be understood.
You can look at rim readings to know the offset.
You can look at the face reading to know the
angularity.
The rim – face method can be inaccurate if the
face diameter is less than 8”.
Is useful when it is not possible to rotate both
shafts.
The face – Rim method could be inaccurate if you
have shaft end play.

End of Session

89
Shaft Alignment Training Course 11/27/2011

The Reverse Dial Method

Introduction
They call it:
The Reverse Dial Method.

The Dial reverse Method.

The Indicator Reverse

Method.
The Double Dial Method.

The Reverse Dial Method

Introduction
In this method we use two dials and take two
offset readings.
From these readings we compute angularity and
offset at the point of power transmission plane.

90
Shaft Alignment Training Course 11/27/2011

The Reverse Dial Method

Introduction

There are a number of

commercial products that
allow you to set up the
dials and brackets so that
you can perform accurate,
repeatable tests.

The Reverse Dial Method

Introduction
The angularity is computed by dividing the
two offsets by the distance between the
points where the measurements were taken
(i.e. where the dials are located).

91
Shaft Alignment Training Course 11/27/2011

The Reverse Dial Method

Introduction
If this distance is small, 4” [10 cm] or less, the
results achieved may lack accuracy. If
possible, setup the dials with as large gap
between them as possible.

The Reverse Dial Method

Introduction
There are two common
setups. In this first case
the two dials are on the
same side of the shaft.
The other case the two
dials are in opposite
sides of the shaft.

92
Shaft Alignment Training Course 11/27/2011

The Reverse Dial Method

Introduction
The absolute value of the readings will be
the same, but the sign will be different. So
when it comes to the calculations and the
graphical method, you will have to take
these differences into account.

The Reverse Dial Method

Reverse Dial Procedure
For simplicity, we will use the following
configuration where the dials are attached
by brackets on opposite sides of the shaft.

93
Shaft Alignment Training Course 11/27/2011

The Reverse Dial Method

Introduction
Set up the dials as shown and take readings
at 90 degree intervals.
Label the dial touching the stationary
machine as the “stationary dial”, and its
reading will be “DIS”. The dial touching the
movable machine is the “movable dial” and
its reading will be “DIM”.

The Reverse Dial Method

Introduction

12:00 12:00

9:00 DIS 3:00 9:00 DIM 3:00

6:00 6:00

94
Shaft Alignment Training Course 11/27/2011

The Reverse Dial Method

Reverse Dial Procedure
The dials are set to the 12:00 position, and
the dials are zeroed.

The Reverse Dial Method

Reverse Dial Procedure
The dials and shaft are rotated to the 3:00,
6:00 , 9:00 and back to 12:00 positions. You
check that readings are zero when you are
back to 12:00 position.

12:00 12:00

9:00 DIS 3:00 9:00 DIM 3:00

6:00 6:00

95
Shaft Alignment Training Course 11/27/2011

The Reverse Dial Method

Reverse Dial Procedure
These readings are called “as found”
readings.. It’s important to have a record of
the original alignment state so that you can
show the improvement made and justify the
action taken.
12:00 12:00

9:00 DIS 3:00 9:00 DIM 3:00

6:00 6:00

The Reverse Dial Method

Validity Rule
Validity Rule
(12:00 + 6:00) Readings = (3:00 + 6:00)Readings
00.0 00.0

0.19 F -0.09 -0.06 R 0.18

0.10 0.12

As Found Reading

You should always check the reading

against the validity rule.

96
Shaft Alignment Training Course 11/27/2011

The Reverse Dial Method

Compensate for Bar Sag
You must start with the recorded values and
subtract the bar sag readings from these
readings. Given that the bar sag reading is
negative, you can simply add positive value
of the bar sag readings to the recorded rim
readings

The Reverse Dial Method

Compensate for Bar Sag - Example

0.00 0.00 0.00

-6.0 DIS -10.0 0.0 SAG 0.0 -6.0 DIS -10.0

-16.0 -30.0 +14.0

As Found SAG Reading Compensated

Reading Reading

97
Shaft Alignment Training Course 11/27/2011

The Reverse Dial Method

Performing The Calculation
We must compute the
offset and angularity
(at the point of power
transfer) so that we
can determine how
the current alignment
state.

The Reverse Dial Method

When dials are in opposite direction.
VC VM VF VR
M
D
LR
s
CM F R LF
LC

HC HF
D Distance Between two dials. HM HR
LC Distance from “RIM” dial plunger to center @(power transmission).
LF Distance from “RIM” dial plunger to MOV machine front feet center.
LR Distance from “RIM” dial plunger to MOV machine rear feet center.

98
Shaft Alignment Training Course 11/27/2011

VC VM VF VR

M
D

LR
s
C M F R
LF
LC

HC HF
HM HR

The Reverse Dial Method

When dials are in opposite direction.
Vertical Offset
𝑴 𝟏𝟐: 𝟎𝟎 − 𝑴 𝟔: 𝟎𝟎 + 𝑺𝒂𝒈 𝑴
𝑽𝒆𝒓𝒕𝒊𝒄𝒂𝒍 𝒐𝒇𝒇𝒔𝒆𝒕 @𝒅𝒊𝒂𝒍 𝑴 𝒐𝒇 𝑴𝑻𝑩𝑴 𝑽𝒎 =
𝟐

𝑺 𝟏𝟐: 𝟎𝟎 − 𝑺 𝟔: 𝟎𝟎 + 𝑺𝒂𝒈 𝑺
𝑽𝒆𝒓𝒕𝒊𝒄𝒂𝒍 𝑶𝒇𝒇𝒔𝒆𝒕 @ 𝒅𝒊𝒂𝒍 𝑺 𝒐𝒇 𝑺𝑻𝑨𝑻 𝑽𝒔 =
𝟐

99
Shaft Alignment Training Course 11/27/2011

The Reverse Dial Method

When dials are in opposite direction.
Horizontal Offset
𝑴 𝟑: 𝟎𝟎 − 𝑴 𝟗: 𝟎𝟎
𝑯𝒐𝒓𝒊𝒛𝒐𝒏𝒕𝒂𝒍 𝒐𝒇𝒇𝒔𝒆𝒕 @𝒅𝒊𝒂𝒍 𝑴 𝒐𝒇 𝑴𝑻𝑩𝑴 𝑯𝒎 =
𝟐

𝑺 𝟑: 𝟎𝟎 − 𝑺 𝟗: 𝟎𝟎
𝑯𝒐𝒓𝒊𝒛𝒐𝒏𝒕𝒂𝒍 𝑶𝒇𝒇𝒔𝒆𝒕 @ 𝒅𝒊𝒂𝒍 𝑺 𝒐𝒇 𝑺𝑻𝑨𝑻 𝑽𝒔 =
𝟐

The Reverse Dial Method

When dials are on the same side of the shaft.
We alter (-) the stationary side values
Vertical Offset
𝑴 𝟏𝟐: 𝟎𝟎 − 𝑴 𝟔: 𝟎𝟎 + 𝑺𝒂𝒈 𝑴
𝑽𝒆𝒓𝒕𝒊𝒄𝒂𝒍 𝒐𝒇𝒇𝒔𝒆𝒕 @𝒅𝒊𝒂𝒍 𝑴 𝒐𝒇 𝑴𝑻𝑩𝑴 𝑽𝒎 =
𝟐

𝑺 𝟏𝟐: 𝟎𝟎 − 𝑺 𝟔: 𝟎𝟎 + 𝑺𝒂𝒈 𝑺
𝑽𝒆𝒓𝒕𝒊𝒄𝒂𝒍 𝑶𝒇𝒇𝒔𝒆𝒕 @ 𝒅𝒊𝒂𝒍 𝑺 𝒐𝒇 𝑺𝑻𝑨𝑻 𝑽𝒔 = −
𝟐

100
Shaft Alignment Training Course 11/27/2011

The Reverse Dial Method

When dials are on the same side of the shaft.
We alter (-) the stationary side values
Horizontal Offset
𝑴 𝟑: 𝟎𝟎 − 𝑴 𝟗: 𝟎𝟎
𝑯𝒐𝒓𝒊𝒛𝒐𝒏𝒕𝒂𝒍 𝒐𝒇𝒇𝒔𝒆𝒕 @𝒅𝒊𝒂𝒍 𝑴 𝒐𝒇 𝑴𝑻𝑩𝑴 𝑯𝒎 =
𝟐

𝑺 𝟑: 𝟎𝟎 − 𝑺 𝟗: 𝟎𝟎
𝑯𝒐𝒓𝒊𝒛𝒐𝒏𝒕𝒂𝒍 𝑶𝒇𝒇𝒔𝒆𝒕 @ 𝒅𝒊𝒂𝒍 𝑺 𝒐𝒇 𝑺𝑻𝑨𝑻 𝑽𝒔 = −
𝟐

The Reverse Dial Method

When dials are in the same direction.
VC VM VF VR
M
D
LR
s
CM F R LF
LC

HC HF
D Distance Between two dials. HM HR
LC Distance from “RIM” dial plunger to center @(power transmission).
LF Distance from “RIM” dial plunger to MOV machine front feet center.
LR Distance from “RIM” dial plunger to MOV machine rear feet center.

101
Shaft Alignment Training Course 11/27/2011

VC VM VF VR

M
D

LR
s
C M F R
LF
LC

HC HF
HM HR

The Reverse Dial Method

Computing the vertical angularity - Equations
VC VM VF VR
M
D
LR
s
CM F R LF
LC

HC HF
HM HR
𝑽𝒎 − 𝑽𝒔
𝑽𝒆𝒓𝒕𝒊𝒄𝒂𝒍 𝑨𝒏𝒈𝒖𝒍𝒂𝒓𝒊𝒕𝒚 𝒐𝒇 𝑴𝑻𝑩𝑴 𝑨 =
−(𝑫)

102
Shaft Alignment Training Course 11/27/2011

The Reverse Dial Method

Computing the horizontal angularity - Equations
VC VM VF VR
M
D
LR
s
CM F R LF
LC

HC HF
HM HR
𝑯𝒎 − 𝑯𝒔
𝑯𝒐𝒓𝒊𝒛𝒐𝒏𝒕𝒂𝒍 𝑨𝒏𝒈𝒖𝒍𝒂𝒓𝒊𝒕𝒚 𝒐𝒇 𝑴𝑻𝑩𝑴 𝑩 =
−(𝑫)

The Reverse Dial Method

Computing the vertical movement (shims) - Equations
𝑽𝒆𝒓𝒕𝒊𝒄𝒂𝒍 𝑴𝒐𝒗𝒆𝒎𝒆𝒏𝒕 𝒔𝒉𝒊𝒎𝒔 @ 𝒇𝒓𝒐𝒏𝒕 𝒇𝒆𝒆𝒕 𝒐𝒇 𝑴𝑻𝑩𝑴 𝑽𝒇 = 𝑳𝒇 × 𝑨 − 𝑽𝒎

𝑽𝒆𝒓𝒕𝒊𝒄𝒂𝒍 𝑴𝒐𝒗𝒆𝒎𝒆𝒏𝒕 𝒔𝒉𝒊𝒎𝒔 @ 𝒓𝒆𝒂𝒓 𝒇𝒆𝒆𝒕 𝒐𝒇 𝑴𝑻𝑩𝑴 𝑽𝒓 = 𝑳𝒓 × 𝑨 − 𝑽𝒎

VC VM VF VR
M
D
LR
s
CM F R LF
LC

HC H HF HR
M

103
Shaft Alignment Training Course 11/27/2011

The Reverse Dial Method

Computing the horizontal movement - Equations
𝑯𝒐𝒓𝒊𝒛𝒐𝒏𝒕𝒂𝒍 𝑴𝒐𝒗𝒆𝒎𝒆𝒏𝒕 𝒔𝒉𝒊𝒎𝒔 @ 𝒇𝒓𝒐𝒏𝒕 𝒇𝒆𝒆𝒕 𝒐𝒇 𝑴𝑻𝑩𝑴 𝑯𝒇 = 𝑳𝒇 × 𝑩 − 𝑯𝒎

𝑯𝒐𝒓𝒊𝒛𝒐𝒏𝒕𝒂𝒍 𝑴𝒐𝒗𝒆𝒎𝒆𝒏𝒕 𝒔𝒉𝒊𝒎𝒔 @ 𝒓𝒆𝒂𝒓 𝒇𝒆𝒆𝒕 𝒐𝒇 𝑴𝑻𝑩𝑴 𝑯𝒓 = 𝑳𝒓 × 𝑩 − 𝑯𝒎

VC VM VF VR
M
D
LR
s
CM F R LF
LC

HC H HF HR
M

The Reverse Dial Method

Computing the Vertical and horizontal movement at the
power transmission Plane- Equations
𝑽𝒆𝒓𝒕𝒊𝒄𝒂𝒍 𝑴𝒐𝒗𝒆𝒎𝒆𝒏𝒕 @ 𝑷𝒐𝒘𝒆𝒓 𝑻𝒓𝒂𝒏𝒔𝒎𝒊𝒔𝒔𝒊𝒐𝒏 𝑷𝒍𝒂𝒏𝒆 𝑽𝒄 = −𝑳𝒄 × 𝑨 − 𝑽𝒎

𝑯𝒐𝒓𝒊𝒛𝒐𝒏𝒕𝒂𝒍 𝑴𝒐𝒗𝒆𝒎𝒆𝒏𝒕 @𝑷𝒐𝒘𝒆𝒓 𝑻𝒓𝒂𝒏𝒔𝒎𝒊𝒔𝒔𝒊𝒐𝒏 𝑷𝒍𝒂𝒏𝒆 𝑯𝒄 = −𝑳𝒄 × 𝑩 − 𝑯𝒎

VC VM VF VR
M
D
LR
s
CM F R LF
LC

HC H HF HR
M

104
Shaft Alignment Training Course 11/27/2011

End of Session

Dynamic and Thermal Movement

Introduction
A great deal many people go to a lot of
effort to align machines to an appropriate
tolerance, believing that the machine will
run smoothly, with reduced stress on the
shaft, seals bearings and coupling.

Unfortunately, the machine may not be

running as smoothly as they think!

105
Shaft Alignment Training Course 11/27/2011

Dynamic and Thermal Movement

Introduction
Virtually all machines undergo a change due
to:
Metal heats and expands.
Dynamic rotational forces try to move the
machine.
Process fluids or gases begin to flow –
often at high temperatures and pressures
and considerable weights.

Dynamic and Thermal Movement

Introduction
There are tests you can perform, and
calculations you can make that will give
you an indication of how the machine
will change when running.

106
Shaft Alignment Training Course 11/27/2011

Dynamic and Thermal Movement

Off-Line to Running OL2R
For example, thermal calculations may tell
you that the pump shaft will lift 0.5 mm and
the motor shaft lift 0.25 mm. You would
then align the machine (when cold) with the
motor shaft (0.25 mm) higher than the
pump shaft
This movement is often described as “Off-
Line To Running” and is abbreviated to
“OL2R”

Dynamic and Thermal Movement

Which Machines Will Be Effected?
Machines with speeds of 1200 RPM or
greater or above 150 KW.
Machinery that undergo a change in casing
temperature:
A) Electric motors and generators.
B) Steam turbines.
C) Gas turbines.
D) Internal combustion engines.

107
Shaft Alignment Training Course 11/27/2011

Dynamic and Thermal Movement

Which Machines Will Be Effected?
3- Gearboxes and other speed changes.

4- Pumps and compressors where the fluid

or gas changes in temperature by 27oC.
5- Machinery with piping attached to the
case where expansion or contraction could
place distortion forces on the case.

Dynamic and Thermal Movement

Thermal Effect
Different materials expand by different
amount. For example, aluminum expands
more than concrete.
Temperature , material volume and
coefficient of expansion can be used to
determine the amount of expansion.
Change in (Length) = Length x Coff. Of expansion x Change in temperature.

108
Shaft Alignment Training Course 11/27/2011

Dynamic and Thermal Movement

Thermal Effect

Dynamic and Thermal Movement

Thermal Effect (Example)
For Example if the distance from the base
to the shaft axis was 20 inches (500mm),
the material was mild steel, and the
temperature rose from ambient (21oC) to
(70 oC), the height of the shaft would rise
by 11 mils (0.275 mm).

20 * 0.0000063 * 90 = 11 mils

109
Shaft Alignment Training Course 11/27/2011

Dynamic and Thermal Movement

Thermal Effect
The temperature change on the machine is not
even due to:
Construction.
Cooling.
Contact with process liquids and gases or
lubricants.
Therefore the change in position may not be as expected,
and the change may not be equal at each end of the
machine.

Dynamic and Thermal Movement

Manufacturer’s Supplied Offset
Manufactures of certain rotating
equipment will provide offsets based on
their own experience and calculations.

Manufacture’s will provide offset data

based on anticipated temperature and
possibly other changes

110
Shaft Alignment Training Course 11/27/2011

Dynamic and Thermal Movement

Internal (System) and External Sources
Affecting Heating and Machine Expansion
Lubricants Sun light
Coolants Ambient temperature
Process gases Support structures.
Process liquids Foundation.
Alignment
Pipe works.
Balance

Dynamic and Thermal Movement

Mechanical Effect
Pipe strain
Oil wedges.
Gear Clearances.
Looseness.
Foundation Movements.

111
Shaft Alignment Training Course 11/27/2011

Dynamic and Thermal Movement

Pipe Strain
Perhaps due to hot fluid and gases, pipe
strain places potentially destructive forces
on a machine. The forces can distort the
frame, misalign the bearings, generally make
difficult to collect repeatable alignment
readings.

Dynamic and Thermal Movement

Oil Wedges
When machines with journal “fluid film”
bearings go from off-line to running, the shaft
will move from the bottom of the bearing to
ride on the film. This movement is normally
predictable, and thus the resultant offset can
be built into the alignment targets

112
Shaft Alignment Training Course 11/27/2011

Dynamic and Thermal Movement

Jacking Fluid
With larger machines, steam turbines for
example, jacking oil may be required in order
to turn the shaft. The shaft may be lifted 2-4
mils (0.05-0.1mm). The pressure can then be
left on or taken away when alignment
measurements are collected.

Dynamic and Thermal Movement

Dealing With Dynamic Movement
Four ways to compensate for dynamic
movements:
1- Use manufacturers offset data.
2- Perform calculations to compensate for temperature
changes.

3- Take alignment readings while the machine is still hot.

4- Take temperature measurements while the machine
is running.

113
Shaft Alignment Training Course 11/27/2011

Dynamic and Thermal Movement

Temperature Compensation
You can take temperature
measurements and assess the
temperature gradients so that you
can arrive at cold alignment targets
that will compensate for
expansion/contraction that will occur
when running.
Change in (Length) = Length x Coff. Of expansion x Change in temperature.

Dynamic and Thermal Movement

Take Hot Reading
If you were to collect the alignment
readings just after the machine stopped
running, the machine would still be hot and
thus the materials would not yet have
contracted to their ambient temperature.

In reality it’s very difficult to achieve this

for safety issues.

114
Shaft Alignment Training Course 11/27/2011

Dynamic and Thermal Movement

Hot Reading - Multiple Tests
One way to improve the results is to
perform multiple tests, five minutes apart
for example. The readings will change in
each test, but if perform three or four
tests, you can extrapolate back to the time
when the machine was running.

Dynamic and Thermal Movement

Hot Reading - Multiple Tests
1 2
3 4

This method doesn’t take mechanical effect into account.

115
Shaft Alignment Training Course 11/27/2011

Dynamic and Thermal Movement

Hot Reading - Multiple Tests
Ex. Shaft1 dropped 0.25 mm in 15 min. and the other
shaft2 dropped 0.5 mm and the first test was take 15 min.
after machine was stopped. Then we could adjust the first
set of readings by (0.25 and 0.5 mm). Considering change
in temperature is linear.

Dynamic and Thermal Movement

Monitoring The Movement of The Shaft or
Bearing
There are a number of different types of
approaches:
1. Measure the movement of the machine cases relative to
their base plate or some remote reference point.

2. Measure the movement of one case relative to the other.

3. Measure the movement of one shaft relative to the other.

116
Shaft Alignment Training Course 11/27/2011

Dynamic and Thermal Movement

Using Laser Heads To Measure Relative Movement

Special brackets are usually provided

(Purchased) that allow the standard
alignment laser heads to be mounted on the
machine.

Dynamic and Thermal Movement

Using Laser Heads To Measure Relative Movement

As the machine comes up to normal

operating temperature, the brackets and
thus laser heads will move along with the
point on the machine where they have
been mounted, they will monitor both
vertical and lateral movement.

117
Shaft Alignment Training Course 11/27/2011

Dynamic and Thermal Movement

Using Laser Heads To Measure Relative
Movement
The laser heads should be mounted to the
machine as close to the centerline of the
shaft as possible.

Dynamic and Thermal Movement

Using Laser Heads To Measure Relative
Movement
If the laser heads were mounted at a
distance from the shaft (for ex. On the
case), they will not only measure the
change in shaft position, they will measure
the expansion and contraction of the
whole case body.

118
Shaft Alignment Training Course 11/27/2011

Dynamic and Thermal Movement

Issue To consider
Depending upon the size of machine, the
relative movement between the two cases
could be quite large it’s possible therefore,
the laser beam to drift outside the target
area of the detector.

Dynamic and Thermal Movement

Issue To consider
The machine may operates at high
temperatures, which could damage the laser
detectors..

The machine will vibrates, thus the

readings should be averaged.

119
Shaft Alignment Training Course 11/27/2011

Dynamic and Thermal Movement

Manufacturer’s Offset Data
You are given foot values, you would
calculate the alignment corrections in the
normal way (i.e. do you cold alignment
calculations) and then adjust the feet
positions by the suggested amounts.

Dynamic and Thermal Movement

Manufacturer’s Offset Data

The information from the manufacture

could come in three forms. The most
common form is an “offset and angular”
value., you could also be given
adjustments at the feet or dial indicator
TIR adjustments.

120
Shaft Alignment Training Course 11/27/2011

Dynamic and Thermal Movement

Manufacturer’s Offset Data - Predicted Dial
Indicator Values
You may be given” Predicted dial indicator
values”. The assumption is that you are using
the reverse-dial method.
You would simply adjust the measured dial
indicators values, in much the same way as
you compensate for bar sag measurements.

Dynamic and Thermal Movement

Manufacturer’s Offset Data – Offset and
Angularity
The most common information provided is the
offset and angle. If you are using graphical method
to determine final foot positions, you would add
one step to compensate for this offset data.

121
Shaft Alignment Training Course 11/27/2011

Dynamic and Thermal Movement

Manufacturer’s Offset Data – Offset and
Angularity Using Graphical Method
Let’s assume that we performed a cold
alignment measurement (Using the reverse
dial method) and found the readings to be
0.25 mm and 0.35 mm. You would plot the
movable shaft position as normal.

See Next

Dynamic and Thermal Movement

Manufacturer’s Offset Data – Offset and
Angularity Using Graphical Method

122
Shaft Alignment Training Course 11/27/2011

Dynamic and Thermal Movement

Manufacturer’s Offset Data – Offset and Angularity
Using Graphical Method

Now let’s assume that the thermal offset data

provided to us was a parallel offset (of the
movable machine to the stationary machine)
of (-0.125mm) and the angle of
(0.125/100mm). We would add this vector as
shown.

Dynamic and Thermal Movement

Manufacturer’s Offset Data – Offset and Angularity
Using Graphical Method

123
Shaft Alignment Training Course 11/27/2011

Dynamic and Thermal Movement

Manufacturer’s Offset Data – Offset and Angularity
Using Graphical Method

The required move to the front back foot is

now the delta between the cold alignment
readings and the specified values.

Dynamic and Thermal Movement

Manufacturer’s Offset Data – Offset and Angularity
Using Graphical Method

124
Shaft Alignment Training Course 11/27/2011

Laser Alignment

Laser Alignment Systems

Introduction
While dial indicators are still
widely used to measure the
positions of shaft rotational
centerlines, the popularity of
laser alignment systems has
grown considerably over
recent years. They are more
affordable and usable than
ever.

125
Shaft Alignment Training Course 11/27/2011

Laser Alignment Systems

Introduction
Laser alignment systems
work on a very similar
principle to dial indicator
systems.

Laser alignment systems are attached to the shafts

of the machine via brackets, and the shafts are
rotated
As the shafts rotate, the aim of the laser beams
change, which is detected and interpreted.

Laser Alignment Systems

The Basic Components of The Laser
Alignment System
All laser alignment systems comprise of two
“heads” that are attached to the shaft, either side of
the coupling.
One or two laser beams will pass between these
heads.
One or both heads are connected via a cable or
wireless communication such as infrared or
Bluetooth to an analyzer which will performs all
calculations.

126
Shaft Alignment Training Course 11/27/2011

Laser Alignment Systems

The Basic Components of The Laser
Alignment System
Most systems will also allow you to enter
tolerance information (or it will have tolerance
tables stored in memory), and allow you to enter
thermal/dynamic offset information.

Laser alignment systems will allow you also to

check and correct soft foot.

Laser Alignment Systems

Benefits of Laser Alignment Systems Over
Dial Indicators
There are number of opportunities to make
errors with dial indicators as bar sag and other
mechanical issues can cause reading to be
incorrect.

The resolution is limited to 1/00 mm, and

performing the calculations or using graphical
method can be error prone.

127
Shaft Alignment Training Course 11/27/2011

Laser Alignment Systems

How Do Laser Alignment Systems Work?

One or Two laser A laser beam that is

beams and a matching spread horizontally and
number of square aimed at a vertically
detectors. oriented detector.

Laser Alignment Systems

How Do Laser Alignment Systems Work?

The two basic components of the laser alignment

system are the “emitter” (sometimes called
“transmitter” and the “detector” (sometimes called
the “receiver”).

128
Shaft Alignment Training Course 11/27/2011

Laser Alignment Systems

How Do Laser Alignment Systems Work?
The emitter is basically a light emitting diode, or
LED. It emits the visible laser beam, which is
between 0.08-0.2 inches (2-5 mm) in diameter.

The lasers used in this

application will not
harm you – but do not
stare into the beam!

Laser Alignment Systems

How Do Laser Alignment Systems Work?
The beauty of laser beam is that it will continue in
a straight line for a very long distance. Thus laser
system can be used on large machines, and with
machines with long spacer couplings or jack shafts.
Laser beam do not sag!

129
Shaft Alignment Training Course 11/27/2011

Laser Alignment Systems

How Do Laser Alignment Systems Work?

Please note that laser beams

can reflect and refract off
steam, water vapor, heat
waves, and airborne dust
particles. So special
precautions may need to be
taken particularly harsh
environments.

Laser Alignment Systems

How Do Laser Alignment Systems Work?
Of greater concern is the need to
keep to laser optics clean. Smudges
and smears can reflect the beam.
You should clean the optics with
the cloth provided – do not use
rags or tissues, they can scratch
the lens.
Check with the manufacturer of your
system.

130
Shaft Alignment Training Course 11/27/2011

Laser Alignment Systems

How Do Laser Alignment Systems Work?

The detector is a “semiconductor photodiode”,

which is sensitive to light.

When the laser beam

strikes the detector, the
associated electronics is
able to determine the
exact position.

Laser Alignment Systems

How Do Laser Alignment Systems Work?

Even though the beam is

not a perfect point, the
electronics can look at
the circle of light striking
its surface and accurately
determines the position
of the center of the
beam.

131
Shaft Alignment Training Course 11/27/2011

Laser Alignment Systems

How Do Laser Alignment Systems Work?
Detectors range in size from
10 x 10 mm to 20 x 20 mm
(possibly larger sizes),
however not all of that surface
can be used because the beam
is up to 5 mm in diameter.
Once part of the beam leaves
the detector, it is not possible
to determine the position of
the center of the beam.

Demo session

132
Shaft Alignment Training Course 11/27/2011

Thank you

133