Know About Alignment

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Alignment

Importance & Methods of Doing It


Bently Nevada
Click on the text to view the details…….

• Misalignment : Introduction…
• Types of misalignment…
• Methods of doing alignment…
• How to record & read alignment readings…
• Concerns for good alignment…
• Scientific diagnosis of misalignment…

End of presentation
What Is Misalignment?

• Deviation of the relative shaft position from collinear axis of


rotation when the equipment is running at normal operating
conditions.

Axis of
rotation

Coupling Hub Shaft


Effects of Misalignment
• @ 50 % of machinery malfunctions caused by it.

• Bearing loading differs then design.


– Higher loading causes fatigue as a result of high stresses
applied just below the load carrying surfaces and can be
observed as spalling of surface metal.
– Lighter loading may create instabilities inside bearing.

• Causes vibration and wear & tear of critical parts.

• Damage to outer race of the antifriction bearing.


Effects of Misalignment
• Breaks the lubricant film inside the bearing &
increases the friction between moving parts. This
results in increased power consumption.

• Increases the operating temperature of the machine.

• Generates Heat in the coupling.


Causes of Misalignment
• Poor workmanship during alignment.
• Improper grouting or shrinkage after grouting.
• Improper foundation or larger holes for holding down bolts.
• Thermal expansion due to a process heating.
• Vibration due to unbalance, resonance and bearing
problems etc.
• Forces transmitted to the machine by piping and support
members.
• Soft foot.
• Improper alignment of directly coupled machines.
How to Recognize Misalignment….Few Symptoms
• Excessive Radial & Axial vibrations.
• Premature bearing, seal, shaft and coupling failures.
• High casing temperature at or near the bearing or high
discharge oil temperature.
• Repetitive failure of coupling elements & seals.
• Hot coupling while running & soon after shut down.
• Loose coupling elements, foundation bolts.
• Excessive amount of grease inside the coupling guards.
• Shafts are braking at or close to the inboard bearings or
coupling hubs.
Return to main menu
Types of Misalignment

• Parallel or Off-set

• Angular

• Skew
Parallel or Off-set Misalignment

• Occurs when the shaft centerlines are parallel but displaced


from one another.
• It consumes more power than the angular misalignment.
Angular Misalignment

• Occurs when the shaft are joined at a coupling in such a way


as to induce a bending force on the shaft.
• It affects pin bush coupling more than tyre coupling.
Skew Misalignment

• Combination of offset & angular misalignment.


• Most common type of misalignment.

Return to main menu


Alignment Methods
• Approximate or Rough Alignment method
– Use of Straight edge, Taper gauge & Filler gauges
– Twin wire method

• Precision Alignment
– Face & Rim Dial Indicator method
– Reverse Indicator Method

• Laser Alignment method


Straight Edge, Taper Gauge & Filler Gauges
Straight Edge

• Top & bottom coupling gap can be measured & adjusted


accordingly.
• This tool can be used to rough align the machinery before
precision measuring instruments are used.
Straight Edge, Taper Gauge & Filler Gauges
• When these instruments are used for alignment face
& rim readings are affected considerably by…
– Smoothness of coupling surfaces.
– Trueness of coupling bore (concentricity and angularity).
– Differences in outside diameters (OD) of the coupling
halves.
• If coupling OD are different but shaft diameters are
equal then straight edge can be used directly on the
shafts before the hubs are installed on the shaft
ends.
Twin Wire Method

• This tool can be used to rough align the machinery before


precision measuring instruments are used.
• Two wires are fixed on two shafts and after rotating 180 degree,
the offset & angular misalignment can be measured.
Face & Rim Dial Indicator Method

Steady Movable

Alternate Arrangement

• Dial gauge fixed on the face will indicate angularity and dial gauge fixed on
rim will indicate offset.
• Take the largest possible diameter on the face of coupling hub to take face
readings. Record this for further moves.
• Sometimes two dial gauges are used for face readings to compensate for
axial float.
Face & Rim Dial Indicator Method
Steady Movable

A
D

A
Face & Rim Dial Indicator Method
Actual Position of Movable Machine
Center line of Stationary machine
f2
- f1 A
x

b c
+
Front Feet Rear Feet

Position of rim dial gauge


Face & Rim Dial Indicator Method
• Reduce problem to only parallel misalignment.
– Remove f1 amount of shim from front leg & f2 amount of
shim from rear leg.
– f1 = (y * b) / D
– f2 = (y * (b + c)) / D
• Correct parallel misalignment by removing equal
amount of shim (x/2) from both front & rear leg.
– Remember that total relative up/ down position shown by
dial gauge is in actual double the parallel misalignment
present. Hence correct half amount with shims.
Face & Rim Dial Indicator Method
• Stand left side of the movable machine facing to
wards stationary machine.
• Fix the fixtures of the dial gauge on the stationary
machine and put the dial pointers on the movable
machine.
• Use clock method and take four readings at 12
o’clock, 3 o’clock, 6 o’clock & 9 o’clock.
• Do rough horizontal adjustments.
• Take the readings for vertical adjustment for 12 & 6
o’clock position. Rotate both the shafts with one
reference. Make dial gauge zero at 12 o’clock.
Face & Rim Dial Indicator Method
• First plot the rim readings as per sign convention
shown in figure with some suitable scale.
• Consider the face readings and calculate the angle
A, from relation tan A = y / D.
• Plot the line at an angle as shown in figure and as
per the sign convention. This is the original
centerline of the movable machine.
• Do the shim adjustment as necessary.
• Similarly do the horizontal adjustments.
Face & Rim Dial Indicator Method
• Advantages.
– Good for large diameter coupling hubs where shafts are close
together so y & D will be larger.
– Easier to visualize the actual shaft positions of the movable
machine.
– Can be used where one of the shafts cannot be rotated during
alignment.
• Disadvantages.
– Did not take care of axial float in motor bearings.
– Requires removal of coupling spacer.
– Not suitable for long distanced shaft.
– Face & rim readings are effected by smoothness of the coupling
halves & trueness of coupling bore if both shafts are not rotated.
Reverse Indicator Method

Steady Movable

• Dial gauge is fixed on stationary as well as movable machine.


Reverse Indicator Method
Actual Position of Movable Machine
Center line of Stationary machine
f2
+ - f1 A
x1 x2

+ a b c
-
Front Feet Rear Feet
Position of rim of movable dial gauge
Position of rim of fixed dial gauge
Reverse Indicator Method
• Stand left side of the movable machine facing to wards
stationary machine.
• Fix the fixtures of the dial gauge on the stationary
machine and put the dial pointers on the movable
machine.
• Use clock method and take four readings at 12 o’clock,
3 o’clock, 6 o’clock & 9 o’clock.
• Do rough horizontal adjustments.
• Take distances a, b, c and plot it on a graph paper as
per scale on a straight line which indicates the
centerline of the stationary machine.
Reverse Indicator Method
• Take the readings for vertical adjustment first by one by
one dial gauge readings. Make the dial gauges zero at
12 o’clock position and rotate both shafts to 6 o’clock
position. Use the sign conventions as shown in figure.
• First plot the reading of movable dial gauge (x2) & fixed
dial gauge (x1) with suitable scale.
• Plot the line at an angle as per the sign convention
shown in the figure extending up to rear feet. This will
show the original centerline of movable machine.
• From the figure calculate the distance f1 & f2 and do
shim corrections accordingly.
• Similarly do the horizontal adjustments.
Reverse Indicator Method
• Advantages
– Geometrically more accurate than face and rim methods as
readings are obtained on larger measurement triangles.
– Negligible effect of axial float of motor on the rim readings.
– Possible to keep the coupling spacer in place when taking the
readings.
• Disadvantages
– Both shafts have to be rotated.
– Should not be used on closed – coupled shafts where the distance
between the shafts is less than the coupling diameter on which the
dial gauge is taking reading.
– Difficult to obtain readings on extremely long shaft. For example
cooling tower drive system.
Laser Alignment Method
• Principle of operation
– Consists of two transmitter & detector(TD) units and one display
unit connected with TD.
– Operating principle is similar to conventional reverse indicator
method.
– After mounting on two shafts, the transmitter prism can be adjusted
both laterally and vertically to center the laser beam on the position
sensitive detector (PSD).
– Readings are obtained by generating a coherent beam from an
infrared emitting semiconductor laser and reflected back in to the
detector via a prism.
– When two shafts are rotated 180 degrees the laser beams &
detectors will describe two half circles. Center of these half circles
represents rotational center of the shafts.
Laser Alignment Method
• Principle of operation
– The detectors measure the relative position of the two
half circles. Display units calculates the irregularity from
the distance between the two TD units and the difference
between the measured value.
– Measured values are represented as offset and angular
error on the display.
– Display unit also shows the position of the movable
machine feet.
– Values can be displayed on real time scale.
– Shaft rotation as small as 60 degree can also give
accurate readings.
Laser Alignment Method
Laser Emitter Laser Receiver

Above figure shows input dimensions required for display units.


Laser Alignment Method
• Advantages
– Easy to use & interpret the results.
– Easy to fix and remove the entire system by quick connection
fixture.
– No requirement of complex calculations, all done by machine.
– No indicator sag as linkages are replaced by optics.
– No need to remove the coupling spacer and DBSE of the range is
10 to 20 m can be possible.
– Readings not affected by float.
– Feature of detecting & correcting soft foot.
– Can be used for horizontal & vertical machines.
– Feature of using thermal alignment corrections for hot alignment.
– Feature of extra polating readings for doing corrections for
stationary machine if not possible for movable machine.
Return to main menu
Understand Dial Indicator First…
• Dial indicator have one graduated
LC Scale
dial with two different scales. One
for main scale and another
graduated to least count (LC) of
the dial indicator.
• Pointer up & down movement is
read by adding LC to main scale.
• If pointer is pressed meaning
moving up, scale pointer turns
Main Scale
+ clockwise and it reads + ve.
• Always give pretension to pointer
- and record initial reading.
Pointer
How to record & read alignment readings ?
Direction Of Rotation

@ Record the dial gauge readings at 1 to 4 positions.


1 @ 1 & 3 shows relative top & bottom misalignment.
@ 2 & 4 shows relative side vise misalignment.
@ We consider 1 as reference or 0 dial reading.
4 2 @ Thumb rule : ( 2 + 4 ) = ( 1 + 3 ).
@ We align the m/c to bring 1 to 4 in tolerance range.
@ View from moving to stationary machine.
3 @ Rim readings show radial misalignment.
@ Face readings show axial misalignment.

- Understand the type of misalignment based on face & rim dial Reading.
- It is a good practice to correct axial misalignment first & radial then after.
Face & Rim Dial Indicator Method
Direction
Of
+ 0.00 + 0.00
Rotation

+ 0.08 + 0.02 - 0.01 - 0.07

+ 0.10 - 0.08

Rim Readings Face Readings

What does this mean?


Face & Rim Dial Indicator Method
Rim Readings Face Readings
Top-bottom misalign = 0.10; Top-bottom misalign = 0.08;
Moving m/c is up. Moving m/c is away at bottom.
M S M S

Side view
Side vise misalign = 0.10; Side vise misalign = 0.08;
Moving m/c is little right side. Moving m/c is little away at right.

S M M S

End view Top view


Axial misalignment need to be corrected first and then the parallel.
Face & Rim Double Dial Indicator Method
Steady Movable

It is a common practice to use two dials for face readings to get rid
of the axial float in the rotor. Subsequently, two readings are taken
as half after subtracting corresponding position dial readings.
Face & Rim Double Dial Indicator Method
Direction of Rotation

0.00 0.00 +0.07

+0.08 +0.02 -0.08 -0.04 +0.11


-0.01

+0.10 -0.09 0.00

Rim Readings 0.00

Position 1 to 4 are in the direction of rotation staring from 0 - 0.06 - 0.02


dial reference. For two axial dials, 0 dial references are 180
degree opposite as shown.
- 0.08
Final axial readings will be half value of the difference
between readings of same position. E.g. for position 3 final
reading is, ( (– 0.09) - (+ 0.07) ) / 2 = ( - 0.08) Face Readings
Face & Rim Double Dial Indicator Method
Rim Readings Face Readings
Top-bottom misalign = 0.10; Top-bottom misalign = 0.08;
Moving m/c is up. Moving m/c is away at bottom.
M S M S

Side view
Side vise misalign = 0.10; Side vise misalign = 0.08;
Moving m/c is little right side. Moving m/c is little away at right.

S M M S

End view Top view


Axial misalignment need to be corrected first and then the parallel.
Laser Alignment Method……
Static machine vertical position Movable machine vertical alignment
viewed from side and resting on feet viewed from side and resting on feet

Vertical alignment as viewed from Side


V -0.11 -0.09 0.21 0.23
MM MM
H -0.09 -0.04 0.20 0.22
Horizontal alignment as viewed from Top

Static machine Horizontal position Movable machine horizontal alignment


viewed from top with four machine feet viewed from top with four machine feet
Laser Alignment Method……
Vertical offset = 0.09 mm. Rear feet vertical
Vertical gap = 0.11 mm Movable machine low position = 0.23 mm high
Front feet vertical
at bottom
position = 0.21 mm high

V -0.11 -0.09 0.21 0.23


MM MM
H -0.09 -0.04 0.20 0.22
Front foot horizontal
Horizontal gap = 0.09 mm
position = 0.20 mm Rear foot horizontal
nearest viewer Horizontal offset = 0.04 mm
away from viewer Position = 0.22 mm
toward viewer
away from viewer
•Positive values are upwards or away from viewer
•Negative values are downwards or toward viewer
Return to main menu
Alignment Tolerances
• The tolerances are the maximum allowable deviation from desired values,
whether zero or targeted offset for thermal growth.
• Best practice is to use the alignment tolerances as specified by equipment
manufactures.
• The table below can be helpful if no limits are specified.
Offset Angular
RPM mm mm/100 mm
0000-1000 0.13 0.10
1000-2000 0.10 0.08
2000-3000 0.07 0.07
3000-4000 0.05 0.06
4000-5000 0.03 0.05
Axial Float of Shaft
• Almost all machines with journal or sleeve bearings
have some float, but it may be manageable, by
applying sufficient pressure at the end of the shaft
during its rotation to keep it firmly seated against the
thrust bearing or plate.
• In case of large machinery or machinery which needs
to be energized to obtain the desired rotation,
application of sufficient pressure on the shaft is often
difficult and dangerous.
• However, axial float doesn’t affect the rim readings
much as compared to face readings.
Axial Float of Shaft

• If axial float is manageable, a choice of methods for


both of the two dial indicator method can be used.
However, if the distance between the points of
contact of the two dial indicators set to take rim
readings for the reverse indicator method is larger
than the diameter of travel of the dial indicator set
up to take face readings for the face & rim method,
then reverse indicator method should be used.
Different Types of Couplings
• Flexible : Tyre, Pin bush, Lovejoy, ESBI Valkan
• Semi Flexible : Fluid
• Rigid : Geared, Resilient, Hydraulic, magnetic

Flexible coupling can handle some misalignment but


will generate heat and it will increase forces on the
shaft.
This will create vibrations and coupling elements,
seals, bearings will fail prematurely.
Shaft Alignment Vs. Coupling Alignment
• If all couplings are bored straight and true through their exact
center with perfectly machined rim and face, it may be possible
to align the two coupling halves and obtain correct machinery
alignment.
• But irregularities in the machining process and even the forces
imposed on the coupling halves during installation have large
margin of error. Coupling alignment should be avoided
because of this.
• This is not to say that dial indicators should not be placed on
the coupling halves to obtain measurements; But two shafts
should be rotated simultaneously to obtain the desired
readings. In this manner, the couplings actually become an
extension of the shaft centerlines and irregularities do not affect
the readings.
Alignment With Shaft-mounted Brackets
• Any object that is securely attached to the shaft and
rotated with the shaft, in theory, becomes a part of the
shaft. So specially designed brackets can be used for
alignment.
– They are adjustable, and can be easily mounted on shafts of
varying size. Also dial indicators can be mounted on them.
– The use of brackets permits easy and accurate “indicator Sag”
checks.
– Because brackets with attached dial indicators can be quickly
installed and flexible couplings do not have to be
disassembled to obtain readings, more accurate “Hot
alignment” checks can be made.
– They can be mounted either on shaft or coupling hubs,
provided they are not loose.
Indicator Sag

• Indicator sag is the term used to describe the bending of the dial indicator mounting
hardware as the dial indicator is rotated from the top position to the bottom position.
• This bending always takes place during the rotation of the dial indicator. The degree to
which the mounting hardware bends depends on the length and strength of the hardware.
• As the bending occurs, significant errors can occur in vertical rim readings of misalignment.
• It is always best to determine the amount of indicator sag present in your equipment before
starting the alignment process.
Soft Foot
• It is the term applied to that
conditions that exists when
all four or six feet of the
machine are not supporting
Short Foot the weight of the machine.
• If this is not corrected prior
to alignment, will lead to
frustration, loss of time and
running in this way may
yield cracks at the soft foot
Angled Foot due to fatigue resulting
from loose nut/ bolts.
Soft Foot
• Determining & correcting Soft-Foot
– Remove all dirt, rust and burrs from the bottom of the machine’s
feet, the shims to be used.
– Set the m/c in place, but do not tighten the hold-down nuts.
Attempt to pass a thin feeler gauge underneath each of the four
feet. Determine exact amount of gap beneath the foot feeler
gauges and place the amount of shims. This will be considered as
being the initial soft-foot correction.
• Final Soft-Foot correction
– Tight all hold down nuts in sequence with a torque wrench.
– Measure the movement of each foot with dial indicator after
loosening it one by one. Add the additional shims as per the
movement noticed.
– Retighten the hold down nut and repeat the entire process once
more, to be sure no movement is present as soft-foot.
Tightening of Holding Down Nuts
• Correct tightening sequence will
help to insure that any unequal
stresses that may cause a shifting
of the movable machine during the
tightening procedure.
• Tighten all nut-bolts with same
amount of force.
• Loosen them in opposite
sequence.
• Always tighten the nuts before you
take readings, though final
adjustments are not done.
Hot Alignment
• When machine is subjected to high temperature it
will grow upwards resulting in level differences
between the cold & hot state and can create
misalignment in hot condition.

• One way of achieving the correct alignment in hot


condition is to pre misalign the machine in cold state
based on the calculation of thermal growth of
stationary & movable machine.
Thermal Growth
• Thumb rule for calculating thermal expansion
– 1.0 mm for every meter length for 100 degree C rise.
• Axial Expansion provision in Bearing
– Increase in temperature will result in thermal expansion of
the rotor.
– Adequate provisions are given by OEMs to respond it in hot
condition.
• Duct Loading due to thermal Expansions
– Thermal expansion of Pipelines & Ducting may impose
forces on the casing.
– Expansion joints, spring supports etc. are the used
practices to counter them.
General Rules for Good Alignment
• Be sure that machine base and bottom are clean and free of any
rust or burrs. Wire brush/ files may be used for this.
• Use only clean shims without any burrs.
• Minimize the number of shims by using appropriate thickness.
• Check & correct soft-foot prior to alignment.
• Always use correct tightening procedure for holding down nuts.
• Determine the amount of indicator sag before starting the
alignment.
• Always try to put dial pointer at 90 degree angle to the surface.
• Use jack bolts for lifting & shifting the machine for up-down, side
wise or angular movement.
• Maintain Distance between shaft end (DBSE) while alignment, =
Coupling spool length + ( (Total Axial float of connecting m/cs)/ 2)
Return to main menu
Scientific Diagnosis of Misalignment
• Changed preload condition as viewed from Orbit
Scientific Diagnosis of Misalignment
• Changed shaft centerline position across the
coupling as viewed from the average shaft center
line plots

Return to main menu


Scientific Diagnosis of Misalignment
• By vibration spectrum analysis (Look for Changes…)
Applicable for Casing Vibrations Mainly where we don’t
have Shaft C/L across the coupling and orbits:
– There is high energy, low frequency radial & axial vibration
amplitudes.
– Misalignment can causes axial / radial vibration at the running
speed frequency (1X) mainly.
– Pure parallel misalignment can produces radial vibration at twice
or three times the running speed frequency (2X, 3X)
– Relative phase for 1x, X-Y casing probes might be much higher
than 90 degree…approaching to 180 deg based on severity of
the preload
Scientific Diagnosis of Misalignment
• Wear Particle Analysis (Oil Analysis..a supporting
tool)
– Curly cutting wear particle of aspect ratio – 5:1 to 50:1
might be seen in the Ferro gram.
Thank you !!!
Bently Nevada

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