Shaft Alignment

Contents
Introduction

to alignment
Types of misalignment
Alignment Methods
Causes/Effects of misalignment
Couplings
Types of coupling

Shaft Alignment

Alignment

is a technique to bring rotational axis

of coupled machines co-linear.

 Every

shaft, bent or straight, rotates about an

axis that forms a straight line.

Co-linearity
Shafts in this same straight line are
considered co-linear, or in the same
straight line.

Types of Misalignment

Offset, or Parallel the

shafts are parallel to each
other, but are not coplanar, or in the same
plane. This can be both
vertical and horizontal.

Angular the shafts are not in

the same plane, which causes a
difference in measurement
between measurements made
180 degrees opposite on the
coupling faces.

Its almost always a combination of both!

Parallel Offset
Parallel

offset between motor and pump

Angular Misalignment
Angular misalignment between motor and
pump

Shaft Alignment Methods

Straight Edge and Feeler gauge

Reverse Indicator Method

Face and Rim

Laser Alignment

Causes of Misalignment
Bearing

wearness
Failure of seals or mechanical seal
Extreme temperatures
Piping stresses
Distortion of base plate
Not aligned right from the begining

After effects of misalignment

Excessive

Vibration
Coupling Failure
Bearing Failure
Mechanical Seal / Packing Failure
Shaft Failure (Bent / Broken)
High Energy Consumption
Low Efficiency

Pre-alignment Assumptions
Can

shafts be rotated freely

Soft Footing

Soft foot can be offset, angular,

or both
Thermal

Growth

Misalignment affecting bearing life

Bearing life and misalignment

Misalignment affecting energy

consumption
Energy consumption and misalignment

Misalignment causing high

temperature
.

Misalignment a source of Vibration

Misalignment causing vibration

Misalignment is single greatest source of machine

vibration shown on the pie chart. Its
impact is dramatically shown in the two
thermographic images of the temperature of an
electric motor housing before and after shaft
alignment. The 30C degree temperature drop
represents several years of additional trouble-free
operating life for the motor.

Validity and Repeatability of data

Obtain two consecutive sets of data and
check data for repeatability.
For each set of data, ensure the data is
mathematically valid. If a set of data
obtained on the face or the rim is valid, the
sum of the top (12:00) and bottom
(6:00) readings will equal the sum of the side
(9:00) and side (3:00) readings

Straight Edge
Straight edge method

Better than doing nothing

Quick and easy
Accuracy varies greatly between users
Gives no real guidance on how to align

Face and Rim Method

Face and Rim

When using the rim-face method, one common source of error

specifically related to the validity and repeatability of the face
readings is error due to shaft end-play (axial movement.) Axial
movement of either shaft will adversely impact the accuracy of
the face readings.
Assuming that the source of end-play cannot be eliminated and
that the rim-face methodis to be used, the only accurate way to
determine the amount of error and correct for it isto set up two
face dials 180 degrees apart and obtain two sets of face data
permeasurement. Any difference in the numerical values, other
than the mathematicalsigns, which will obviously be reversed,
is due to axial movement. The error can be determined and
mathematically subtracted from measurements

Face and Rim Method

Now

suppose readings are

0

+.005

Rim

+0.010

+.005

-.007

Face

-.005

+.002

Face and Rim

Now measure following distances.

D=dia of hub where readings are being taken.
L1=distance from face of motor hub to center of front motor foot
L2=distance from face of motor hub to center of rear motor foot
TIRF= total indicator reading on face
R=rim reading which if+ will be added and subtracted if negative
y1=L1/D*TIRF+R/2
y2=L2/D*TIRF+R/2
s1=L1/D*TIRF+R/2
s2=L1/D*TIRF+R/2
if rim reading is + it must be added and if - it must be subtracted

Face and Rim

y1

= 12/6 X (-.005) + .010/2 = - 0.005 Take

out .005 shims from front foot.
y2 = 24/6 X (-.005) + .010/2 = - .015 Take
out .015 shims from rear foot.
Similarly 3 and 9 O clock readings will be
used to calculate s1 and s2

Reverse Indicator Method

Reverse Indicator Method

The reverse indicator method is an acceptable method, but it

does take a great deal of time.
Very accurate especially for small diameter flanges
Not affected by axial float.
Can be used with a flexible coupling in place.
You have to rotate both shafts

Reverse Indicator Method

Essentially, the fundamental principle of the reverse rim dial method and
laser systems is to determine shaft position based on two different offset
measurements (rim readings) taken at two different points along the length
of the shafts. Since no face readings are obtained with this method,
measurement inaccuracies due to shaft endplay are essentially eliminated.

Reverse Indicator Method

Pump in this example will be fixed and electric motor will be moved into
alignment with pump. The alignment can be done either with coupling
installed or coupling totally removed. Attach the dial indicator bracket
to the movable unit (motor) coupling hub or shaft whichever is more
convenient and rigid. Obtain the readings on the fixed unit (pump)
coupling hub or shaft.
Also attach the dial indicator bracket to the fixed unit (pump) coupling
hub or shaft and obtain the readings on the movable unit coupling hub
or shaft. All readings must be taken on the periphery of coupling hub
shaft. All indicator readings must be recorded as viewed from fixed unit
or stationary unit. Readings are taken by rotating shaft and noting dial
indicator at increments of 90 (i.e. starting at 12 o clock position and
taking readings at 3,6,9 o clock positions and ending at 12 o clock
where it was zeroed.

Reverse Indicator Method

Dial on pump

Dial on motor

0
-.015

-.005
-.02

+.004

-.006
+.01

Reverse Indicator
Total indicator readings are divided by two to get actual differences pump line is
our reference, reading on dial on pump will be plotted such that + reading will
be plotted above the graph and -ve below the graph centerline. Readings on
dial on motor will follow opposite convention i.e -ve above centerline and +ve
below. In this case -.020"/2 =-0.010 will be plotted below as it is negative and
+0.010"/2=+0.005" though positive will be plotted negative as this is reading
taken when dial is on motor.

motor
pump
c1

f1

f2

Reverse Indicator

Now measure following distances.

c
distance from first indicator riding on pump hub
to where the second
indicator is riding on motor
hub
f1 distance from first indicator on pump hub to
center of front feet of motor (movable unit)
f1 distance from first indicator on pump hub to
center of rear feet of motor(movable unit)
Suppose readings are

Reverse Indicator

Reverse Indicator

Laser Alignment

CSI 2130

The CSI 2130 can be

equipped with up to 7 different
applications:
Route-based vibration collection
Advanced vibration analysis
Dynamic balancing
Basic/advanced laser alignment
Transient analysis
ODS/Modal analysis
Cross-channel analysis

CSI2130

The CSI 8225 Laser Alignment system is designed to

get the job done quickly and accurately.provides a
confidence check for every alignment correction
before the machine is moved. Review alternate
solutions for a bolt bound machine with the touch of a
button. Adjust the laser heads to a convenient angle
to watch the real-time display of changes to
alignment. Instant feedback on tolerance is provided
in the formof an intuitive bulls-eye graphic.
When the job is complete, load the data to AMS
Suite: Machinery Health Manager for beforeandafter documentation and reporting.

 CS

2130 Laser Heads

Laser Alignment
CS2130 LASER HEADS
NEW colour coded laser heads which match equipment
shown on the screen in the alignment program
Each laser head has its own inclinometer for
double the accuracy
Laser head takes a data point every 2 deg of rotation,
so 360 total data points for a full rotation
NEW NiMH batteries for increased power, battery
life and enhanced RF signal strength
Resetting the laser heads is simply done using the On/Off key
NEW Dual Live Mode allows
live simultaneous vertical and
horizontal alignment
NEW Auto Data Checker
validates alignment data as it is
dumped

The radial vibration caused by coupling misalignment is typically highly directional on

both the driver and driven units. Misalignment occurs in a certain direction and, as a result,
the radial forces are not uniformly applied in all radial directions like that from unbalance.
2. The vibration frequencies due to misalignment are usually 1 x, 2x and 3x RPM, and
may appear in any combination depending on the type and extent of misalignment.
Angular misalignment normally causes vibration at 1 x RPM, whereas offset or parallel
misalignment causes vibration predominantly at 2 x RPM. In fact, offset misalignment is
60

probably the most likely cause of a predominate 2 x RPM vibration. Combinations of

angular and offset misalignment may show combinations of 1x and 2 x RPM and in some
cases even 1x, 2x and 3 x RPM.