Alignment

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ALIGNMENT

There are two types of alignment methods: Face and perif Reverse alignment Reverse alignment is the most accurate method, but should be used in conjunction with Face and Perif method Face and Perif method: vertical Alignment (Angular)

Fixed machine

D1 F1 D2

Machine to be moved F2 Fig. 1

D3 F1=First hold down bolt F2=Second hold down bolt D1=Diameter of the circle made by dial indicator tip when coupling of the fixed machine is rotated 360 deg. (mm) D2=Distance from Pointer of dial indicator to first holding down bolt F1.(mm) D3=Distance from pointer of dial indicator to second holding down bolt F2. (mm) Always align angular misalignment first in both vertical and horizontal alignment. For vertical alignment, zero dial indicator at T.D.C .Rotate through 180 and note total indicator reading (T.I.R) and sign. To calculate the amount of shims required under F1 and F2, following method can be used Ratio between D1 & D2,D1 & D3 are required. Example Say: D1 = 50mm D2 = 100mm D3 = 200mm

R1=100 /50=2

and R2=200/50=4

If dial indicator reading = +0.2mm Then distance between coupling faces are greater at the top than bottom Add 0.2 X 2= 0.4mm at F1 0.2X 4 =0.8mm at F2 When T.I.R = o.1 or less check for height alignment, as per the fig 2

Fixed machine

Machine to be moved Fig. 2 F1 F2

Once angular alignment has been achieved, equal amounts of shims can be removed or added as calculated below. zero dial indicator at T.D.C .Rotate through 180 and note total indicator reading (T.I.R) and sign. For a minus dial indicator reading ,add shims under m/c to be moved equal to that of the indicator reading. For a plus indicator reading remove shims under machine to be moved equal to that of the indicator reading.

HORIZANTAL ALIGNMENT(ANGULAR) Three dial indicators are required. Positions are shown in fig 3

F1 Fixed machine D1

F2

Machine to be moved F1 F2 Fig. 3

D2 D3 Method Zero dial indicators (D.I) and rotate through 180.Note the reading and sign minus or plus. Using fig. 1 find ratio R1 and R2,calculate distances to move m/c at D2 and D3 . Zero dial indicators positioned at feet of m/c to be moved and move machine until indicators read calculated dimensions when T.I.R = 0.1mm or less, horizontal alignment can be checked. Positions D.I as shown in Fig 3 .Zero DI and rotate through 180.Note indicat or eading and sign. Zero D.I position at feet of m/c to be moved and mov machine until both D.I indicate error previously recorded. (2) REVERSE ALIGNMENT A D1

Fixed machine F1

Machine to be moved F2 Fig. 4

http://www.saasblg.com/index_files/Alignment.htm

15/02/2013

Alignment

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F1 B D2 D3 P

F2

A=clock dial indicator on coupling hub (fixed m/c) B=clock dial indicator on Coupling hub (machine to be removed) F1=First holding down bolt F2=Second holding down bolt D1=Distance between dial indicators D2=Distance from p to first holding down bolt D3=Distance from P to second holding down bolt Before starting the alignment, an alignment Graph must be made-see attached graph 1 Install clock dial indicators as in Fig 4 2 With Marker pen mark of the positions of dial indicators on the coupling hubs. METHODS FOR VERTICAL ALIGNMET Always stand with the fixed m/c on your left hand side, and m/c to be moved on your right hand side. (1) (2) (3)

Position the dial indicators as shown in the fig 4. with the A dial on the top of the Fixed m/c coupling hub, and the B Dial indicator at the bottom of the m/c to be moved. Set the indicator to zero and turn both coupling hubs through 180.Note the T.I.R of the A dial indicator and if the reading was plus or minus. Set the B dial indicator to the top and turn both coupling hubs through 180.The B dial will now be back at the bottom of the hub. Note the T.I.R of the B dial indicator and if the reading was plus or minus

PLOTTING READINGS ONTO GRAPH A 0.2 0.14 0.05 0,0 0.15 D1

F1

F2

A= + 0.4 /2 =0.2 B= 0.28/2 =0.14 Reverse sign

Subtract shim =0.05 mm Add shim = 0.15 D2 D3

Example: A dial reading of +0.4 mm T.I.R B dial reading of -0.28mm T.I.R On the A line of the graph, plot half the T.I.R of the A dial indicator to pre-determined scale. As the reading was plus, the mark has to go above the pump center line.

On the B line of the graph, plot half the T.I.R of the B dial indicator to the same scale ,but in this case you must reverse the sign. In the Example from minus to plus This is very Important. Plot point on graph above center line.

Note:If the reading B dial was plus, reverse sign to minus. Plot point below center line of graph. Place a straight edge through the two points and draw a straight line passing through points F1 and F2.Te distance from the center line to the plotted line will be the amount of shims to be added or subtracted from F1 and F2 respectively. If the plotted line is above the center line, subtract shimsand below add shims. HORIZONTAL READINGS

A F1 Fixed machine F2 Machine to be moved F1 B F2 Fig. 5

Horizontal readings are taken the same way as for vertical readings. Only the dial indicators are set in plan view.

In the horizontal position the m/c to be moved is physically moved on the base frame, as shown in Fig 5.Placing dial indicators at the feet of the m/c to be moved, move m/c in accordance with plotted graph. Ensure that you are moving m/c in the correct direction. Make a note on the graph which way a minus or plus has to be moved in the horizontal position i.e Away or Towards you. Please note the following rules: (1) Always check that you have the correct distance between coupling ends. (2) When aligning Multistage Centrifugal pumps, fill pump casing with water push pump shaft into pump body to separate wear plate faces. This is very important as the wear plate faces can pick up if this is not done. (3) Always rotate both couplings together to eliminate coupling run out. MORE

http://www.saasblg.com/index_files/Alignment.htm

15/02/2013