ROTATINGEQUIPMENTDEPARTMENT

EGYPTIANNITROGIENPRODUCTSCOMPANY

DOCUMENTNO. REV. Pages

AlignmentTrainingCourse

Prep.BY

ENG.HaithmMohamedSabry
Rotatingequipmentsengineer
ENPC

H.sabry H.mikky H.mikky

DATE

DESCRIPTION
PREP
,
D CHK
,
D APP
,
D
COMPANY
A
T
r
C
Alignment

Theprima
rotatingm
CONSEQU
a) Prem
b) Exce
c) The
coup
d) Loos
e) Loos
t: is to m
sameli

ryobjectiv
machinery.
ENCESOF
maturebe
essiveamo
shafts a
plinghubs
sefounda
seorbrok

make the
ne(comm

veofaccu

FDEFECTIV
earing,sea
ountoflu
re breaki
s.
tionbolts
kencoupli


centre lin
moncentre

uratealign
VEALIGN
al,shaft,o
bricantle
ng (or cr
s,typically
ngboltsm

ne for the
eline)atn

nmentisto
MENT
orcoupling
akageatt
racking) a
ycausedb
membrane



drive an
ormalope

oincrease
gfailures
thebearin
at or clos
byasoftf
e



d driven
erationco


etheoper
ngseals
e to the
footcond



couplin
machine
ondition.


ratinglife
inboard
dition



ng
rotor at t

spanof
bearings

1 -
2 -
3 -
the

or

W
If
t
T
M
M
WHATHA
fthealign
toeachot
Typesofm
Misalignm
a) Para
b) Ang
c) Com
Misalignm
a) Vert
b) Vert
c) Hor
d) Hor

PPENSTO
nmentisig
herevery
misalignm
ment(divis
alleloffset
ularmisal
mbinedmi
mentthrou
ticaloffset
ticalangu
izontaloff
izontalan
OROTATIN
gnoredthe
revolutio
ent
ionfromc
tmisalign
lignment
salignmen
ughonere
tmisalign
larmisalig
fsetmisali
gularmisa
NGMACH
ebothsha
n.
commonc
ment
nt
evolution
ment
gnment
ignment
alignment
INERYWH
aftsandco
centreline

isclassifi
t
HENITISM
ouplingha
e)canbef
edtofour
MISALIGN
alveswillf
fallofthe
rcompon
NED
flexorbe
threefor
ents
ndrelative
ms

Thefollowingtoolsmaybeusedinshaftalignment:
Dialindicator
Magneticbase
Feelergauges
Micrometer(inout)
Straightedge
Mirror
Spiritlevel
Torquewrench
Marker
Sandpaper
Plastichummer

To get accurate final coupling alignment we must know the parameters that must be
eliminated for every participate part component that may be affect the quality,
accuracyofthealignment.

1. Pumpmotorskiddistortionandwrapping
2. Themotor:
a) Softfeet
b) Holddownboltsandstuds
c) Basepadsandshims
d) Jackingbolts
e) Cablestrain
3. Thepump
a) Pipingstrain
b) Pumpsupportstrain
4. Shaftandcouplinghubs
a) Runout
b) Endplay(axialfloat)
5. Usedtools
a) Dialindicator
b) Alignmentfixturesag

6. Environmentssunlight

A
s
t
b

M
h
m
T

1. Pum
Afterposit
suction an
transverse
boltssoby

2. The
a) Soft

Meansthe
holding d
movingth
Thetypes
mpmoto
tionthep
nd discha
ely adjust
ythiselim

emotor
tfeet
emachin
down bolt
ebearing
ofsoftfoo
orskidba
umpskid
rge flang
the level
minateany

newillno
t tightene
housing,t
otarepar
asefram
onthefo
e and th
of the sk
wrapping

otsiton
d the feet
thebearin
rallel,angu
medistort
undation
e motor
kid by jac
ginthesk

itsfeetp
t will be c
ngandthe
ularorcom

tionand
byusings
sole plat
k screw a
idandhen
Jacksc
probably
clamped d
eshaftthu
mbination
wrappin
spiritleve
tes levelle
and shims
nceanyso
rew
yandwil
down dist
usaltering
n.
ng
l(0.02mm
ed longitu
around e
ourcefors
ancho
lwobble
torting the
gthealign
m/m)ont
udinally a
each anch
softfeet.
orbolt
ewhent
e frame a
nment.

the
nd
hor

he
nd
S
S
S
B
m
o

F
f
t

Softfeetc
Soft feet ca
Softfootc
By using f
mounted o
onlyparall
Feeler or t
formaking
thebase,p
a) Ensu
and
b) Insta
c) Tryt
d) Ang
one
conditions
an be foun
check:
feeler gau
on a mag
lelsoftfoo
taper gau
gcheckfo
primarych
urethatth
rust.
allthemo
topassfe
ularsoftm
eitherside
s.
d in three
uges or ta
gnetic base
ot.
uges are n
orinserts
heckforn
hebottom
otorinpla
elergauge
maybead
eonthem
basic cond
aper gaug
e or dial
not accura
hims und
ewmachi
mofthem
cewithou
esundere
djustedby
metalshim

ditions.

ges for bo
indicator
ate as usin
ertheun
ines
machinesfe
uttighten
eachfoot
usingste
msasshow
oth paral
mounted
ng dial ind
supported
eetandth
thefeet
tocheckp
ppedshim
wn.

lel and a
on the c
dicators h
d spacesb
hebasefre
parallelor
msorbyu
ngular, di
oupling a
however t
betweent
eefromd
rangulars
singelasto
ial indicat
nd shaft f
hey can u
the feeta
irtburrs
soft
omershim
tor
for
use
nd
ms

If
d
u
D

f the mac
diagonal f
undereach
Dialindica
a) First
b) Tigh
c) Set
d) Loos
e) Ifth
the
f) Rep
atth
Dialindica
a) First
b) Tigh
c) Rota
d) Loos
e) Reti
f) Sele
g) Che
chine wo
foot hold
hfoot.
atorandm
tcheckan
htingallho
upthedia
sethebol
hereading
foot.
eatthesa
heendof
atormoun
tcheckan
htenallho
atethesh
seeachfo
ghtenthe
ectthehei
ckagaint
bble on d
down ag
magneticb
ndcorrect
olddown
alindicato
tandobs
gisexceed
ameproce
work.
ntedinthe
ndcorrect
olddownb
aftsothe
ootandob
efootagai
ightreadin
hefeetac
diagonal f
gainst the
basetoch
forangul
boltstoco
orontopo
ervethed
ds0.05mm
edurefore
ecoupling
forangul
boltstoco
dialisloc
bservethe
inandrep
ngandpu
ccordingt
feet, mea
base and
heckevery
arsoftfoo
orrecttor
ofonefoo
dial.
mputshim
eachfoot
ghub
arsoftfoo
orrecttorq
catedatth
ereadingo
peatthesa
utabout80
heabove
sure the
d shims e
yfootisre
otusingfe
que.
ot.
mswithth
anddont
otusingfe
que.
hetopcen
onthehub
amesteps
0%ofdial
steps.
gap unde
equivalent
estingont
eelergaug
hesameam
tforgetto
eelergaug
ntre(12:00
b.
stoevery
readingv
er one fo
t to the h
thebase.
ge.
mountant
ocheckfin

ge.
0).
foot.
alue.

oot with t
half the g
tretighte
nalsoftfoo
the
gap
n
ot

S
m
g
h
T
m
a
T
f
e

b) Hold
Should be
movement
grinding b
holes.

c) Base
The base p
mounting
andshims
d) Jack
Thejackb
final align
expansion
ddownbo
e sufficien
tduringa
but be car
epadand
pad shoul
and the s
.
kingbolts
bolt must
ned the b
direction
oltsands
nt clearan
alignment
reful dont
dShims
d be free
slot shoul
sitsquare
bolts mus
duringno
tuds
nces in th
work,mo
t weak th

of burr, d
d be larg
elyand pu
st release
ormalope
he hole i
ountingbo
he bolt or

dirt and f
er enough
ushthefe
e to prot
erationso

n the ma
oltscanb
r by soft
lat contac
h to avoid
eetwithou
tect the
itcanaffe
achine fe
ereduced
grinding
c, shims sh
d contact
utlifting it
machine
ectinthev
eet to allo
dindiame
for the m
hould be
between

t;onceth
from un
verticalal

ow sidew
eterbylit
machine fe
slot for fr
bolt thre
hemachin
expectab
ignments
way
tle
eet

ree
ead
ed
ble
.
S
a
A
f
T
m
d
f
N
t
i
R
T
f

e) Cab
Somehigh
alignment
3. The
a) Pipi
Afterprob
forgroute
The objec
machinery
distortion
failureeve
Not that b
the piping
nsurethat
Recomme
Pipe
mm
The
the
Flan
Only

Thebasic
flangewhi
lestrain
hratedmo

epump
ngstrain
berlevellin
d.Aftergr
ctive of p
y are min
on shafts
enshaftal
beside mis
g during o
tthepips
ndationt
eflangebo
maximum
machine
pipeflang
ngefacese
yonegask
methodo
ilemeasur
otorhave
ngskidan
routfinish
piping alig
imized. Le
s, bearing
ignmenti
salignmen
peration
supportof
oavoidp
oltsholes
moffsetfr
andpipin
geouterd
eparation
ketperfla
ofverifying
ringthede
rigidand
ndcouplin
hedthem
gnment to
ess strain
housing.
sachieved
nt pipe, th
and the w
fthepipin
ipingstra
shallbelin
romthece
ngflanges
iameterfo
shallbew
angedcon
gpipstrai
eflectiono

bigcable
ng prealig
achinere
o verify t
n imposed
So if this
dwhilepi
hermal m
weight f t
ng.
inonthe
nedupwi
enterofth
facessha
orflanges
withinthe
nectionsh
nconsists
ofthema
itmustbe
gnmentro
leaseforp
that strain
d on the
false load
pstrainex
ovement
he fluid c
machine
thmachin
heboltho
llbepara
sabove10
gasketsp
hallbeuse
sofboltin
chineshaf
etakeinm
oughlyche
pipingact
ns impose
machine
ding can r
xists.
(expansio
causing pip
casing(AP
nerynozzl
ole.
lleltoless
0inchmax
pacingplus
ed.
gupthep
ftwithdia
mineditse
eckthesk
ivities.
ed by the
casing re
esult in ra
on and co
pe strain
PI686)
eboltsho
sthan0.0
ximumof
sorminus

pipingtot
alindicato
effecton
kidisrelea
e piping
sults in le
apid beari
ntraction
so we mu
oleswith1
01mm/cm
0.75mm.
s1.5mm
themachi
or.
ase
on
ess
ing
of
ust
1.5
of

ne

T
b
t
O
o

F
a
s

R
o
t
Three dial
basetoob
thebigger
Onemeth
onesideo
b) Pum
For centrif
and tight
shimsasth
4. Sha
a) Run
Runoutis
ofthefirst
twobasict
indicator
bservethe
flangedia
odcomm
rremove
mpsuppor
fugal pum
again whi
hesamev
aftandco
nout
alsorefer
tthingsto
typesofr
r should b
ehorizont
ameter.
onlyused
theweldi
rtstrain
mps with b
ile observ
valueand
ouplingh
rredtoas
ocheckon
unoutco
be mount
taloffsetd
tocorrec
ngcapan
bearing ho
ve the dia
checkaga

P
hubs
anoffce
nthemac
nditions,r
ted to rea
duringtig
ctthepipe
ndreweld
ousing su
l indicato
ain

umptypeO
enteror
chineryth
radialand
ad face an
htenthef
eflangem
again.
pport OH
or if the d

OH1
eccentric
hat isatte
facerun
nd rim an
flangesit
misaligned
1 loose t
ial read a
cconditio
mptedto
out.
nd dial wit
sprefert
byheatin
he suppo
above 0.0
onandsh
bealigne

th magne
ostartfro
ngpartfro
rt two bo
25 then p
ouldbeo
edTherea
etic
om
om
olts
put
one
are
W
s
o
If
b
o

If
m

W
b
m
o
F
i
g

When per
shafts rota
onlythem
f its diffi
betweent
outcheck
f any run
machined
b) End
Whenperf
beheldat
mount dia
observeth
Forrotorw
naccount
gotothem
forming r
ate are ro
misalignme
cult to ro
therunou
priortoth
Thr
out exist
ordiscard
play(axia
formingri
thesame
al on the s
hereading
withsleev
t.Forexam
magneticc
rim and fa
otate 360
entbetwe
otate the
utormisal
heactuala
reebasictyp
s more th
ded.
alfloat)
imandfa
eofitsax
shaft or co
gonthedi
vebearing
mpleelec
centerwh
ace alignm
by rotati
enthesha
shaft of s
lignments
alignment

pesofrunou
han 0.25m
cereading
ialtravelw
oupling fa
ial
gthenorm
tricmoto
henthefie

ment the d
ng the tw
afts.
stationary
sothefirs
t

utproblemsw
mm bent s
goradjus
whileface
ace and pu
malopera
rwitharm
eldisappli
dial indict
wo shafts t
y machine
ststepist

withshaftsa
shafts, co
sttheDBS
ereading
ush the ro
tingposit
maturesu
ied.
tors are s
the two d
e, the dial
tocheckth
andcoupling
upling sho
SEaxialsp
istakent
otor to ea
ionofthe
pportedo
et at 12,
dial will on
l cannot d
heshaft,c
hubs
ould be st
pacingthe
ocheckt
ach side se
erotormu
onsliding
3, 6, 9.bo
nly indicat
differentia
couplingr
traightene
eshaftmu
heendflo
everal tim
ustbetak
bearingw
oth
tes
ate
run

ed,
ust
oat
mes
ken
will

C
t
t
W
b
n
r
W
b
Compresso
their rotor
thiswesho
5. Use
a) Dial
When usin
beingchec
not set sq
runthroug

Whenthe
beat90t
orandtur
rs should
oulduset
edtools
indicator
ng a dial
cked,isim
uare to th
ghthecen

dialindic
totheface
rbinewill
be held a
twodialin
r
indicator,
mportant.
he directi
ntrelineof

atorispla
e
operatea
against the
ndicatorfo
, the posi
Theaccu
on of the
ftheshaft

acedonth
againstact
e active s
orfacerea
tion that
uracyofth
moveme
torcoupli

hefaceof
tivethrus
ide prior t
adingprim
the dial
hedialind
ent. The c
ng.
thecoup
tbearing
to setting
maryands
is set, in
dicatorisg
centreline
lingorhu

duringth
g the axial
secondary
relation t
greatlyaff
e of the p
b,theplu
ealignme
l spacing f
y
to the pie
fectedifit
lunger mu

ungershou
ent
for
ece
tis
ust
uld

W
m
T

H
b
(
r
r
b) Alig
Which is m
movement
Thereare
i. The
bar
ii. The
iii. The
iv. Clam
Holdthea
bar,andd
Particular
readings.U
readingsh
nmentfix
movemen
tthataffe
fourfacto
amount o
spanofth
stiffnesso
mpingforc
ssemblyi
ialindicat
rlyattheb
Usually,th
haveaneg
xturebrac
nt, or ben
ectstheac
oraffectt
of over hu
hebar
ofthebar
ceoftheb
nthehori
torassemb
bottom)a
hereading
gativevalu
cketsag
nding, in t
ccuracyof
heamoun
ung weigh
r
bracketto
izontalpo
blythroug
ndrecord
gsoneach
ue(typical
the rod d
fthereadi
ntofbrac
ht(weight
otheshaft
sitionand
gh90arcs
dwhatyou
hsideare
ly).

ue to gra
ings.
ketsag.
of the dia
t
drotateth
sandnote
usee.The
halfofthe
avity Dial
al indicato

heentirep
etheread
seareref
ebottom
bar sag i
or at the
pipe,brack
dingsatea
ferredtoa
readinga
s unwant
end of sp
ket,span
achpositio
asthesag
ndalloft
ted
pan
on
g
he
T
b
r
m

B
t
It

Tocompe
bottom re
reading. B
method.
6. Env
Be carefu
temperatu
tsprefer

nsatefor
eading an
But we w
vironmen
ul that t
ureinside
toworku
thesag,a
d the am
ill discuss
ntsunlig
hat when
pipingan
undercove
addtheam
mount of t
s simple m
ght
n perform
dthecasi
erorshelt

mountof
the sag o
method to
ming alig
ngaffecta
tertoavoi
thesago
bserved o
o compen
gnment u
andchang
idthis.
bserveda
on the ea
nsate the
under sun
gethealig

atthebott
ach side t
sag in ri
ns light
gnmentre
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o each si
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eadings
ach
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ace
ked

ROTATINGEQUIPMENTDEPARTMENT
EGYPTIANNITROGIENPRODUCTSCOMPANY

DOCUMENTNO. REV. Pages

FaceandRimmethod
Prep.BY

ENG.HaithmMohamedSabry
Rotatingequipmentsengineer
ENPC

Date Description PREP

,
D CHK
,
D APP
,
D

Prealignmentchecks.
As explained in the previous chapter several things cause misalignment, and should
alwaysbecheckedbeforebeginninganalignment.Theyareasfollows:
1. Pumpmotorskiddistortionandwrapping
2. Themotor:
a) Softfeet
b) Holddownboltsandstuds
c) Basepadsandshims
d) Jackingbolts
e) Cablestrain
3. Thepump
a) Pipingstrain
b) Pumpsupportstrain
4. Shaftandcouplinghubs
a) Runout
b) Endplay(axialfloat)
5. Usedtools
a) Dialindicator
b) Alignmentfixturesag
Thefourstepsofanyalignmentare:
1. Removeverticalangular(face)misalignment.
2. Removeverticalparallel(heightupanddown)misalignment.
3. Removehorizontalangular(face)misalignment.
4. Removehorizontalparallel(sidetoside)misalignment.
Aftersteps1and2,andshimming(theaddingorremovingofshims)iscompleted,steps
3and4aredoneatthesametimebymovingthejackbolts(sidewaysmovement).
Methodsofalignment.
1. Straightedgeandfeelergauge.
2. Rimandface(dialindicator).
3. Crossdialorreverseindicator(dialindicator).
4. Graphicalmethod.
5. Laseralignment.

Inourcoursewewillconcernontherimandfacebyusingstraightedge,dialindicator
methodstheyalwaysusedmorefrequentlyinourwork.

1. Straightedgeandfeelergaugesmethod
Alignment with a straight edge and feeler gauges is not very accurate this method
should only be used on low RPM machines where alignment is not so important.
Micrometermustalwaysbeused,tomeasurethefeelergaugethicknesswhenchecking
agap,toensureitsaccuracy.
Tocarryoutanalignmentusingastraightedgefollowthefollowingsteps:
ShimmingtheM.T.B.S.sothatpointsAandBarethesame.IfpointAisthelargestthen
thebacklegsneedtobeshimmed.IfpointBisthelargestthenthefrontlegsneedto
beshimmedwiththestraightedgeonthehighercouplinghalf.
Usethefeelergaugestodeterminetheverticalparallelmisalignment.

Stepsthreeandfourremoveangular(faceoraxial)misalignmentandhorizontalparallel
(sidetoside)misalignment
Thesestepsareusuallydone together, usingthejackingboltsonthe M.T.B.S.machine
tobeshimmed(locatedonthesidesofthebase)
Forfinalhorizontalaxialoffset,movetherearsidejackingboltsonly.Forthehorizontal
radial offset, move either either leftside, or both rightside, jacking bolts the same
distance

T
o
T
b
T
b
d
R
2. Dial
Theriman
orfaceof
Thisisago
berotated
Thefaced
bothvertic
directlyre
Remembe
indicator
ndfaceme
acoupling
oodtechn
doritwou
dialreads
calandho
latedtoth
rthemat
rmethod
ethoduse
ghub.The
niquetou
uldbediff
theamou
orizontalp
hediamet
hematical
estwodia
eotherdia
useinsitu
iculttoro
untofang
planes.Be
terthefac
lformula.

lindicato
alreadsof
ationswh
otateoneo
ular(axial
ecauseoft
cereading
rs.Oneis
fftherim
hereoneo
ofthemac
l)misalign
theangle,
gsaretake
smounted
ofthecou
ofthema
chinerysh
nmentat9
,theaccu
en.

dtoreado
upling.

chinerysh
hafts.
90tothe
racyofth
offthefro
haftscann
shaftaxis
ismethod
ont
not
sin
dis

The rim dial reads the amount of parallel offset misalignment from the shaft axis in
boththeverticalandhorizontalplanes.
It is important that the dials are read in the same position every time. That is, four
positions at 90 to each other. These positions should be read in the same way as a
clock face; 12 oclock, 3 oclock, 6 oclock, and then 9 oclock. They are viewed from
behindtheM.T.B.S(movablemachine)machinetobeshimmed.
Procedure:
1. Attach the alignment bracket firmly to one shaft normally the movable machine
and position the indicators on the face and rim surface of the other shaft (or
couplinghub).
2. Zerotheindicatorsatthetwelveo'clockposition.
3. Slowly rotate the shaft and bracket arrangement through 90 Intervals stopping
at the three, six, and nine o'clock positions. Record each reading (plus or minus)
remembertosetthesmallclockin5toeasyfollowthemainindicator
4. Returntothetwelveo'clockpositionto12toseetheindicatorrezeroreading.
5. Repeatsteps2through4toverifythefirstsetofreadings.

Theruleisthetotalreadingoftopandbottomequalrightandleft.
Thesumofthetwomeasurementsonbothsidesofzeroshouldequalthemeasurement
thatisoppositeofthezero.

Whyrimreadingstwicetheactualoffsetexplain?
Whentakethereadingfromonesidetotheotheronashaft,thetotalamountthatthe
indicator(oranymeasurementsensor)observesistwicetheamountthatthe
centrelinesofrotationareactuallyout

Rimandfaceformula.
Tousetherimandfaceformula,itisimportanttoknowwhichmeasurementsaretaken
andwhere.

D=diameterofthepaththefacedialwilltravel.
S1=shimpackingforthefrontlegs(+/)signindicatesaddorremoveshims.
S2=shimpackingforthebacklegs.
TIR=totalindicatorreading.
L1=length(paralleltothecentrelineoftheshaft)fromwherethedialsareread,tothe
firstholdingdownbolt.
L2=lengthtotherearholdingdownbolt.

Formulaforcorrectionofaxialandradialmisalignment...
S1
L1
D
TIR(f ace)
TIR(rim)
2

S2
L2
D
TIR (f ace)
TIR (rim)
2

Note:TIR(rim)/2arethetotalindicatorrimreadingdividedbytwo.
This determines the actual amount of radial offset misalignment.

ProcedureSummary
1. Perform pre-alignment checks.
2. Align approximately using rule and straight edge. If the space enough.
3. Attach dial indicators to flange of motor and position one dial at 12 oclock on the
pump rim and one at the top of the pump face.
4. Measure the following dimensions carefully.
D Diameter of Pump Flange.
L
1
Distance from Pump Flange to Front Foot of Motor.
L
2
Distance from Pump Flange to Back Foot of Motor.
5. Push flanges to back positions to eliminate end float and set the two dials to zero.
6. Rotate both flanges at 90
0
intervals making sure the flanges are pushed back each
time and record the dial readings.
7. Rough horizontal face and radial offset. This will reduce inaccurate vertical
readings. It will also reduce the number of times that the shims have to be inserted
8. Using the formula find the amount of shims to remove or add to eliminate vertical
misalignment.
9. Reset the dials to zero at the 3 oclock position and repeat step 6 (horizontal
reading).
10. Using the formula find the amount of movement required to eliminate horizontal
misalignment.
11. Place the magnetic base and dial indicators of the sides of the front and back legs.
Set to zero and move the motor to the required amount using the jack screws.

1. PreciseHorizontalalignment

2. PreciseHorizontalalignment

Planviewofthemachineinsteadofanelevation.Jackingboltsareshowntofacilitythe
horizontalmovementofthemachine.

H1=L1/D*TIR(face)TIR(rim)/2
H2=L2/D*TIR(face)TIR(rim)/2
Datumsideis3clocksorzerostartpointandtakea180bythedialsoTIR(face)isthe
resultantreadintheindicatoron9clocks.