MACHINERY ALIGNMENT

Prepared By WA

Misalignment
Deviation of relative shaft from collinear
axis of rotation when equipment is running
at normal operating conditions

Types of Misalignment
Parallel Displacement or OD Displacement

Face Displacement or Angular Displacement

Combination

Symptoms of Misalignment

Premature bearing, seal, shaft and coupling failure

Excess radial and axial vibration
High Casing / Bearings / Oil Temperatures
Excessive oil leakage from bearing seals
Coupling is hot
Foundation bolts get loosen
Coupling bolts broken or loosen
Shafts are breaking (or cracking) at or close to the
inboard bearings or coupling hubs
Similar machine has less vibration

Effect of Misalignment

Machinery alignment
Making the shaft centerline of one
machine element coincides, or nearly
coincides, with the shaft centerline of
second machine element
Before undertaken an alignment job, it is
prudent to check for other deficiencies like

Pre-requisites of Machinery
alignment
Foundation :
Adequate size and good condition ?
Rule of thumb : 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

Pre-requisites of Machinery
alignment
Base Plate :
Designed for adequate rigidity ?
Machine mounting pads level, flat, parallel,
coplanar, clean ?

Piping :
Is connecting piping well fitted, supported
and sufficiently flexible ?
Not more than 0.003 vertical & horizontal
movement occurs at flexible coupling when
the last pipe flange is tightened

Pre-requisites of Machinery
alignment
Dutchman :
If pipe flange angular misalignment exists, a
Dutchman or tapered filler piece may be necessary
Thickness = 1/8 + (Max.gap Min.gap) Gasket OD/Flange OD

Coupling :
Driver half couplings should not be installed loose
Coupling cleanliness and lubrication
Coupling selection

Pre-requisites of Machinery
alignment
Soft Foot :
This condition occurs most frequently on
machines with four or more feet, where one
leg is short and requires something to fill the
gap to keep it from rocking

Shims :
No dirty shims
No very thin shims

Tools reqd for Machinery

alignment
Dial Set (two dials)
Two brackets (for reverse indicator
method)
Steel Ruler
Meter tape
Vernier Caliper
Mic 0-1mm
Graph Paper

Bracket Sag
Downward inclination of alignment bracket due
to gravity is called Sag
To measure Sag we install a setup similar to that
which is to be used in field & rotate it from top to
bottom through 180 & note the sag.
Generally sag should be checked when using
clamp-on jigs with reverse indicator for spans
greater than 6
For rim measurement when using Face & Rim
method for spans more than 6
Face measurements are generally not affected
greatly by Sag

Alignment Methods
There are four alignment methods

Rim and Face

Face and Face
Reverse Indicator
Laser alignment

Alignment Methods
Reverse Indicator :
Advantages :
Accuracy is not affected by axial movement of
shafts in sleeve bearing
Both shafts turn together, so coupling eccentricity
& surface irregularities dont reduce accuracy
Geometric accuracy is usually better with this
method
With suitable clamp-on jigs, this method can be
used without disconnecting the coupling or
removing its spacers

Alignment Methods
Reverse Indicator :
Limitations :
Both Shafts must be rotated, preferably by hand
Less geometric accuracy for large diameter
coupling with short span

Alignment Methods
Face and Rim :
Advantages :
It can be used on large, heavy machines whose
shafts can not be turned
Better Geometric accuracy for large diameter
coupling with short span

Limitations
Run-out errors due to shaft or coupling eccentricity
Low Geometric accuracy
If used on a sleeve bearing machine, axial float
error may occur

Alignment Methods
Face and Face :
Advantages :
It is suitable for long spans such as cooling towers
drives

Limitations
No advantage over other methods except long
spans

Face and Rim Method

Procedure
Lock out
Use proper tools &
Fixtures
Clean feet & pads
Determine Indicator
Sag & Record
Rough alignment
Eliminate Soft foot
Complete Record
sheet

Take readings
Correct for Sag
Calculate Reading
Confirm Shim change

Face and Rim (Calculation)

Alignment reading includes both misalignment
and Bracket Sag
Sag must be removed from reading
Calculation of shims
C shims reqd = Angular displacement x C/A
B shims reqd = Angular displacement x B/A

Calculation for shims for parallel alignment using

formula
Shims reqd = Parallel displacement / 2

Reverse Indicator Method

Procedure
Lock out
Use proper tools &
fixtures
Clean feet & pads
Determine indicator Sag
& Record
Provide Coupling Gap
Rough Align

Eliminate Soft foot

Complete Record Sheet
Take driver to driven
readings
Correct for Sag
Plot displacement
Confirm Shim change

Reverse Indicator Method

Distances to be taken
Dial to dial or D to C
Dial to first foot or C to A
First foot to rear foot or A to B

HOT ALIGNMENT
Calculation for Thermal Growth
Rise in inches = Temp. diff x Centerline in
inches x 6 x 10-6 / 2