Professional Documents
Culture Documents
TAUFEEQ
Contents
Introduction/Definition
Types of Alignment
Alignment States
Pre Alignment Checks
Alignment Methods
Thermal Growth
Centering
Reciprocating Machines Alignment
Alignment of V Belts, Pulleys, Sprocket & Gears.
Effects of Misalignment.
Case Histories
Introduction
To bring the rotating members of driver and driven machines
in the desired line.
Example
In case of shafts, bringing the two shafts in a straight line / desired
line.
In case of pulleys, bringing the neutral axis or the faces of two
pulleys in a straight line.
In case of gears, achieving the rolling contact between the gears.
In case of sprockets, bringing the faces in a straight line.
Types of Alignment
Axial Alignment
Axial alignment means to check the relative position
between the axis perpendicular to the axis of rotation of
the two members to be coupled. In other words, it must
be checked that the said axis are parallel or have the
required divergence.
Axial alignment can also be classified as
Axial Vertical alignment
Axial Horizontal alignment
Alignment States
Cold Alignment
Alignment which is carried out when the machine is at cold
state.
Hot Alignment
Alignment which is carried out when the machine is at hot
state.
In Situ Alignment
Alignment which is carried out when the machine is in
operation.
Pre Alignment Checks
Before undertaking an alignment job, it is
prudent to check for other deficiencies which
would largely nullify the benefits or prevent the
attainment and retention of good alignment.
Below is the List of factors to be considered
before checking the alignment:
Pre Alignment Checks (Contd.)
Foundation
Adequate size and good condition. A rule of thumb
calls for concrete weight equal to three times
machine weight for rotating machines and five
times for reciprocating machines.
Grout
Suitable material, good condition, with no voids
remaining beneath base plate. Tapping with a
small hammer can detect hollow spots, which can
then be filled by epoxy injection or other means.
Pre Alignment Checks (Contd.)
Baseplate
Designed for adequate rigidity. Machine mounting pads
should be flat, parallel and clean. Shims should be made
from corrosion and crush-resistant material. If commercial
pre-cut shims are used, check for actual versus marked
thickness to avoid a soft foot condition. Machine hold-down
bolts should be of adequate size, with clearance to permit
alignment corrective movement. Pad height should have at
least 2 in. jacking clearance beneath center at each end of
machine element to be adjusted for alignment. If
jackscrews are required, they are to be mounted with legs
sufficiently rigid to avoid deflection. Water or oil cooled or
heated pedestals are usually unnecessary, but can in some
cases be used for onstream alignment thermal
compensation.
Pre Alignment Checks (Contd.)
Piping
Check the associated piping is well fitted and supported,
and sufficiently flexible, so that no more than 0.003 in.
vertical and horizontal (measured separately not total)
movement occurs at the flexible coupling when the last
pipe flanges are tightened.
Coupling Installation
Some authorities recommend installation on typical pumps
and drivers with an interference fit, up to .0005 in. per in. of
shaft diameter. This can give problems in subsequent
removal or axial adjustment. If an interference fit is to be
used, we prefer a light one-say 0.0003 in. to 0.0005 in.
overall, regardless of diameter. Coupling cleanliness, and
for some types, lubrication, are important and should be
considered.
Line Diagram
Turbine HP LP
Casing Casing
Alignment Methods (Shafts)
There are three methods of aligning the centerline of two
shafts:
Desired Line
B A
Note :
Motor and pump lines to be drawn as per suitable scale
Alignment Methods (Cont.)
Value measured
y Desired Line
x
D C B A
Actions required :
Remove shims of thickness x from motor rear feet
Remove Shims of thickness y from motor front feet
Alignment Methods (Cont.)
x
y
Value measured
Desired Line
D C B A
Actions required :
Move motor rear side towards Elect. Shop by x
Move motor front side towards Elect. Shop by y
Reverse Method
Following are the advantages of this method:
Accuracy is not affected by axial movement of shafts
in sleeve bearings.
Both shafts turn together, either coupled or with
match marks, so coupling eccentricity and surface
irregularities do not reduce accuracy of alignment
readings.
Face alignment, if desired, can be derived quite
easily without direct measurement.
Reverse Method (Contd.)
Note :
For having accurate readings, ensure dial indicator rod
remains perpendicular to the face while taking readings.
Alignment Methods (Cont.)
Dial Indicator
Dial Indicator works with the index of mm scale.
Before rotating the shaft and collecting the
misalignment data, ensure that all the three dial
indicators are set to zero. Also make sure that
traveling margin is available in these indicators.
When recording the data, the plus sign shall be given
when the rod of the dial indicator goes back into its
seat or move inward. Minus sign shall be given when
the rod comes out.
When the dial indicator main pointer rotates by 3600,
the dial indicator small pointer will show 1mm
displacement of the rod
Alignment Methods (Cont.)
Radial Alignment
Place the dial indicator on the rim of the
coupling hub and secure it with the help of
suitable outfit.
Measure the data during a rotation of 360 0. The
algebraic sum of the values read on the
horizontal plane (900 & 2700) will be equal to
the values read on the vertical plane (0 0 and
1800).
When noting down the alignment values,
always specify the hub (Driver or Driven) on
which the dial indicator moves.
Alignment Methods (Cont.)
Action required :
Place shims of thickness x/2 mm under all the feet of machine B
Alignment Methods (Cont.)
-y -y
+x
(-y -y = +x)
x Side View
Radial Vertical Misalignment =
2
Action required :
Remove shims of thickness x/2 mm from all the feet of machine B
Alignment Methods (Cont.)
Radial Alignment (Horizontal Plane)
Dial Indicator readings:
0 B
A
B
+x -x
A
0
(x -x = 0)
x Plan View
Radial Horizontal Misalignment =
2
Action required :
Move the motor (A) upward by distance x/2. During movement,
ensure that axial alignment may not get disturbed.
Alignment Methods (Cont.)
Axial Alignment
Place the two dial indicators at 180 0 by the
vertical axis.
The necessity to use two dial indicators is due
to the fact that axial displacement of the two
shafts to be coupled may occur during the
rotation of the two flanges.
By the use of two dial indicators the possible
displacements along the axis are annulled,
where the face displacements of the two hubs
to be coupled remain unattended.
Alignment Methods (Cont.)
A1 a=0 A2 e
b f h
d
c g=0
b d f h
-c g=0 A2
c-e
Axial vertical misalignment = A1= -c
2 A2 = 0
Side view
Whenever misalignment result has minus
sign, the flanges are open downwards.
Alignment Methods (Cont.)
b d f h
c=0 g=0 A2
c-e
Axial vertical misalignment = A1= 0
2 A2 = 0
Side View
Whenever misalignment result is 0, there
is no axial misalignment in vertical plane.
Alignment Methods (Cont.)
b d f h
A2
+c g=0
c-e
Axial vertical misalignment = A1= +c
2 A2 = 0
A1 a=0 A2 e
b d f h
c g=0
The value of axial misalignment on the horizontal plan will be the algebraic half
difference of the reading (considered with their signs) made on the dial indicators
(b d) (h - f)
A1 and A2 after a rotation of 900 and 2700 c.e.
c g=0
A2
(b - d) - (h - f) A1 = - b
Axial horizontal misalignment =
2 A2 = - f
Left
Plan view
Whenever misalignment result has minus
sign, the flanges are open to the left.
Alignment Methods (Cont.)
+b -d +f -h
c g=0
A2
(b d) (h - f)
Axial horizontal misalignment =
2 A1= +b
A2 = + f Left
c g=0
A2
(b d) (h - f)
Axial horizontal misalignment = =0
2
A1 = b
A2 = f
Left
Misalignment result is o, the flanges are
axially aligned in horizontal plane. Plan view
Alignment Methods (Cont.)
a=0 e
b A1 d f A2 h
c g=0
Alignment Methods (Cont.)
C-E
Where X= (Consider the sign)
2
L = Distance b/w the feet.
External Centering
External Centering refers to the checking of machine
rotor center when the machine is in assembled form.
Reciprocating M/cs Alignment
Perform the following operations in order to
align and to couple the machine which then
form the unit.
Install the flywheel in the compressor shaft
end.
Record the shaft deflections as follows.
Put on inside micrometer in the crank nearest the
driver as shown in figure.
Slowly rotate the shaft and read the shaft deflection
in a complete turn.
Reciprocating M/cs Alignment
Detect the mean oscillation of the flywheel during a
complete revolution of the compressor shaft and stop
the shaft at this point.