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Featured Lesson
Shaft Aligment
3
Detecting
Misalignment
Featured Article
7
Self-Inflicted
Reliability
Problems
Video
13
Spotlight Video:
Shaft Alignment
Fundamentals
5 Step Alignment
Proceedure
ALL
NEW!
S E E B A C K C O V E R F O R D E TA I L S
Series 4 | Issue 7 | October 2018
About Mobius Institute
Mobius Institute is a worldwide provider of reliability improvement, condition monitoring
and precision maintenance education to industrial plant managers, reliability engineers
and condition monitoring specialists, allowing plants to be successful in implementing
reliability improvement and condition monitoring programs. Mobius delivers training via
IN THIS ISSUE public, in-plant and online education programs.
3 FEATURED LESSON Mobius Institute Board of Certification is an ISO/IEC 17024 and ISO 18436-1 accredited
certification body providing globally recognized certification to reliability professionals,
Shaft Alignment -
vibration analysts, ultrasound analysts and thermal imaging specialists.
Detecting Misalignment
Mobius further contributes to the condition monitoring industry by hosting the CBM
Conference and the www.CBMconnect.com media site worldwide.
6
SCHOLARSHIP NEWS
7
FEATURED ARTICLE
Self-Inflicted Reliability
Certification Manager - Roberta Clark - roberta.clark@mobiusinstitute.com
Problems
13 VIDEO SPOTLIGHT
Shaft Alignment
Jason Tranter, BE (Hons), CMRP, VA-IV
14 UPCOMING COURSES
18
SALES & SUPPORT (+1) 615-216-4811
TRAINING PARTNERS
Highlighting Mobius
Mobius Quick
(+61) (0)3-5983-2970
Authorized Training Contact CERTIFICATION
As a condition monitoring
Shaft Alignment professional, you need to
CONTINUED ON PAGE 4
Energy consumption A definition of misalignment: If the pump was uncoupled and you turned
its shaft, it would rotate around a straight
Misaligned machines can also consume
“Shafts are misaligned when their line. This is the pump’s rotational centerline.
more energy. Although studies have
rotational centerlines are not collinear When it is uncoupled, it is easy to turn
produced varying results, it is generally
when the machines are operating under the shaft (well, as easy as it will ever be).
considered that a misaligned machine will
normal conditions.” The same is true for the motor - its shaft
consume up to 15% more energy. Large
also has a rotational centerline. Ideally,
studies have documented savings of
the motor and pump will be mounted
between 3% and 8%. When two machine components, for so that the two rotational centerlines are
example a motor and a pump, are aligned perfectly - there will be no offset,
Consider the following equations. If we can assembled and coupled together, there is and no angle between the shafts in either
reduce the consumption of a 30 HP (22 kW) likely to be some misalignment - in fact, it the vertical or horizontal direction. The
460 Volt motor from 36 amps to 32 amps, is guaranteed. The pump will have been coupling will bolt together easily, and there
and we are paying 0.06 per kW Hour then attached to its piping, and the motor will be minimal stress on the bearings, seals
the savings are approximately $1,500. connected to its conduit, and both will have or any other components when the shaft is
been bolted to their baseplate. turned. In this case the shafts are said to
kW = (Volts x Amps x pf x 1.732)/1000 be “collinear”.
You will see an offset and angle introduced Later we will discuss the alignment Due to the nature of misalignment, there
in the vertical direction, and then you will procedures, and we will discuss tolerances are at least two physical signs that shafts
see a different offset and angle introduced (which tell us how good the alignment must are not aligned: the machine will vibrate
in the horizontal direction. The result is two be to achieve maximum life), but for now it in characteristic ways, and the coupling
shafts that are misaligned. In actual fact, is safe to say that if you are not correctly may get hot which can be detected with
when the components are coupled together, using dial indicators or a laser alignment non-contact temperature guns or thermal
the coupling will be forced to “give” in order system, the machine will not be within imaging cameras.
to accommodate the misalignment, and the tolerance.
two shafts may be forced to bend slightly.
Bend in shafts due to misalignment (exaggerated) We have just described all of the reasons
why you should perform shaft alignment: Detecting, correcting and maintaining
Think about what is happening inside this damaged bearings, shafts, seals, and proper shaft alignment will keep your
machine - what is happening to the shaft, couplings. If you have experienced any of machinery properly maintained and ill
and the bearings, and the seals, and the these problems then it is probably due to prevent costly, unplanned downtime.
coupling? With every rotation the shaft misalignment.
has to flex - it is forced to stay within the
bearings. That puts strong radial and axial t
Other physical signs include loose or
forces on the coupling, bearings, seals and broken hold-down bolts, loose shim packs
shaft. or dowel pins, excessive oil leaks at bearing IN OUR NEXT ISSUE:
seals, and loose or broken coupling bolts.
Have you ever looked at route based
Detecting Misalignment vibration spectra and waveform data in
There are two ways to determine if a machine alarm, and couldn’t figure out the source
is misaligned: you can look at the mainte- causing the high vibration?
nance records and alignment records to
see if the machine was misaligned, and you In our next issue we will be featuring an
can monitor various physical parameters introduction to Modal Analysis. Modal
such as vibration and temperature. Analysis s a powerful diagnostic tool that
allow the vibration analyst to visualize,
First, if a machine has not been “precision” analyze and identify corrective actions to
aligned, that is, it was aligned “by eye” or solve vibration issues on rotating machines
only using a straightedge, then it is very Misalignment can be detected via physical signs and structures.
likely that it will be misaligned.
You should always perform “root cause
analysis” when a machine fails. Root cause
analysis is used to determine why a machine
failed. It is not good enough to simply
repair it and put it back in service - what
is to stop the same fault from developing
again? Issues like lubrication, imbalance,
resonance and misalignment should be
considered when a machine fails. And thus
when a machine is put back into service,
it should be precision balanced and precision
aligned, and the lubrication program should
Machines will likely be misaligned if precision
alignment was not performed be maintained.
Vibration analysis is an important skill, but being a vibration analyst, with people counting on you to make timely, accurate diagnoses, is
a demanding role. Education and accredited certification are key to success, and the CBM Conference enable analysts to further their
knowledge and meet people who face the same challenges. Unfortunately, not everyone in the world has access to that training or the
conference. While we try to minimize costs, for a whole variety of reasons those costs are too high for some people who desire to join our
profession.
Mobius Institute, in association with the CBM Conference, will help twelve people each year to achieve Category II certification through
its scholorship program. Our top recipient, selected by a panel will be awarded travel and admission to one of the worldwide CBM Con-
ferences each year.
To learn more about the benefits of the Mobius Scholarship program visit our website.
Self-Inflicted
Reliability
Problems
This article was first featured in the April 2017 issue
of Maintenance Technology, now Efficient Plant
Balancing And you may think that if you can’t see the water in oil
When you balance to ISO 1940 grade G 1.0 the cyclical forces on the bearings, then the oil must be fine. Sadly, that is not correct. By
shaft, and structure are minimized and thus you gain greater reliability. If you the time you can see the water the life of the bearing
do not have a balancing standard, then unbalance will be a root cause of is halved.
failure. And if you wait until the unbalance generates “high” vibration, then you
will have reduced the life of the equipment and supporting structure.
CONTINUED ON PAGE 9
CONTINUED ON PAGE 10
Conclusion
The condition monitoring group has an important role to play. Providing an
early warning minimizes the impact of premature failure, and detecting and
eliminating the root causes ensures that we achieve the greatest life and value
from our precious assets.
We see this as a very common problem. Laser alignment systems can achieve terrific results. And a precision aligned machine
is far more reliable than a machine that has been “roughly” aligned with an alignment system, and far superior to a machine
aligned with a straight edge. But if your maintenance technicians do not appreciate why that last shim should be installed, and
why the motor must be moved such a small amount to the left or right, then those corrections will not be made - and yes, it
does matter.
Research by Tedric A. Harris, in the book “Rolling Element Bearing Analysis” (John Wiley & Sons) showed that just 5 minutes
(5/60 of a degree) of angular misalignment can reduce the life of a bearing by half. Yes, precision matters
ASSET
RELIABILITY
PRACTITIONER [ARP]
TRAINING & CERTIFICATION ASSE
RELIAB
CATEGORY - I CATEGORY - III
I ADVOCATE III PROGRAM LEADER
CATEGORY - II
II RELIABILITY ENGINEER X
PRACTITION
A HOT DEAL FOR CBM CONFERENCE ORLANDO ATTENDEES
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You will not find a better conference offer, so register today for CBM Conference USA in Orlando and
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USA 2018
ISO 17024 AND ISO 18436-1 ACCREDITED November 12 - 15, 2018
For questions about CBM Conference USA or to reserve your seat for the accredited ARP Category I training
and exam, contact Becky Partipilo at (615) 216-4811 x 3 or by email at becky.partipilo@mobiusinstitute.com.
www.thecbmconference.com
FEATURED VIDEO
ET
Shaft Alignment Fundamentals
5 Step Alignment Procedure
BILITY
Shaft alignment is often overlooked in the maintenance process. It is something that is done in a
hurry, just before you have to start up the equipment again with the production manager breathing
down your neck. Yet poor alignment is responsible for over 50% of all failures in rotating machinery.
Even though shaft alignment is so important to the whole maintenance process there are seldom
written down guidelines and procedures for alignment.
In this presentation we will present the shaft alignment fundamentals and teach the 5-step alignment
procedure. If correctly followed you will increase your success rate in alignment and improve on
your equipment’s up time.
NER [ARP]
Related Video
9 Minutes of Knowledge
Diagnosing Misalignment
This presentation provides a quick introduction on diagnosing misalignment.
Often depicted as an easy condition to diagnose. Unfortunate this is not nec-
essarily true. It is essential to use every tool possible to detect and diagnose
the condition, and precision align the machine. We look at the different types
of misalignment and how to properly detect it.
ISO 18436 CAT-II VIBRATION ANALYST Course [+] ISO 18436 CAT-III VIBRATION ANALYST Course [+]
AMT 01 ALIGNEMENT laser METIER au CETIAT Lyon [+] ISO 18436 CAT-II VIBRATION ANALYST Course [+]
www.thecbmconference.com
VIBRATION HALL OF FAME
Kaine Rathbone
CAT IV
Certificate: M-8297-01
Exp: 10 December 2019
Location: Warabrook, NSW, AU
Rao Vamsidhar
CAT IV
Certificate: M-123038-01
Exp: 23 November 2020
Location: Visakhapatnam, Andhra Pradesh, IN