Introduction to Alignment
Fault Analysis
Unbalance
Misalignment
Pulleys faults
Bent shaft
Shaft crack
Mechanical looseness
Journal bearing faults
Rolling element bearing faults
Rotor rub
Electrical motor problems
Pumps Problems
Gear faults
File: ONLINE.PPT / MD Page 1
Misalignment
Misalignment is a major cause of
machinery vibration.
Some machines have been incorporated
with self-aligning bearings and flexible
couplings that can accommodate quite a
bit of misalignment.
However, despite these, it is not
uncommon to come across high
vibrations due to misalignment.
Parallel Misalignment
The shaft centerline of the two machines
is parallel to each other and have an offset.
mm/s
10
3.1
0.31
mm/s 1X 2X 3X 4X
Please Note:
Misalignment may be appears on 1X
Radial Vibration approx. 180 ° phase shifted component only
2X often highest peak
File: ONLINE.PPT / MD Page 2
Angular Misalignment
The shaft centerline of the two shafts
meets at angle with each other.
10
3.1
0.31
1X 2X 3X
Please Note:
Axial Vibration approx.. 180 ° phase shifted Misalignment may be appears on 1X
And in phase in radial direction. component only
1X , 2X or 3 X highest
Angular Misalignment
File: ONLINE.PPT / MD Page 3
Combination Misalignment
Misalignment Results (1)
– Vibration.
– Bearing failure.
– Seal Leakage
Seal Manufacturer verifies:
50 times longer machine operation through proper shaft alignment
File: ONLINE.PPT / MD Page 4
Misalignment Results (2)
– Coupling Failure, even in flexible types!
– Internal heating.
Misalignment Results (3)
- High energy consumption.
Kw = (Volts * Amps * PF * 1,732 )
1000
File: ONLINE.PPT / MD Page 5
Alignment Methods
Misalignment is corrected at the feet.
Mechanical Alignment Techniques
Rough Alignment Dial Indicator Alignment
File: ONLINE.PPT / MD Page 6
Rough Alignment
Straight edge/feeler gauge
method
Determine the direction and
amount of offset using a straight
edge and feeler gauges.
Measure the gap at two points
180° apart to determine the
direction and amount of angular
misalignment.
Face & Rim Method
The rim dial measures offset
The face dial measures
angularity
File: ONLINE.PPT / MD Page 7
Reversed Indicator Method
Widely acknowledged as
the “preferred method” of
shaft alignment.
Both dials measure offset
on the Rim. The Angular
error is the slope between
the two offset values.
Easy to plot or calculate
the feet correction values.
Laser Alignment Technique
Single laser systems with a singleTwin laser systems using the •
or double detectors. Reversed-Rim method.
File: ONLINE.PPT / MD Page 8
Determining Thermal Growth Values
Manufacturer’s Specs
Thermography
Optical Measurements
Proximity Probes
Pipe Strain
Due todilatation and contraction, both hot
and cold machinery tend to produce pipe
strains. The generated strains are well
capable to cause position change in the
coupling.
The use of spring cans can effectively
relieve piping strains.
Detaching largebore piping prior to
alignment can also reduce these strains.
File: ONLINE.PPT / MD Page 9
Foundation
If the foundation does not act as a rigid support for both
static and dynamic loads, unacceptable moves may occur;
therefore foundation should be checked prior to alignment
job.
Soft Foot
File: ONLINE.PPT / MD Page 10
Soft Foot Check
Checked by Dial indicator
or laser alignment instrument
Machinery Movement
File: ONLINE.PPT / MD Page 11
PULLEYS
ALIGNMENT
Belt Drive Problem Cont.
Sheave Misalignment
Sheave misalignment will generate strong axial 1X components and
axial harmonics of the fundamental belt frequency.
Parallel Angular Both
File: ONLINE.PPT / MD Page 12
Measuring Pulleys Misalignment
Laser Pulleys Alignment
File: ONLINE.PPT / MD Page 13
Laser Alignment Technique
Benefits of Shaft Alignment:
Laser beams are not affected by gravity or
bracket sag.
Laser tools are rotated to various positions
around the rotational centers of shafts. This
process allows the laser to measure just the
rotational centers, and is not affected by shaft or
coupling eccentricity, or runout.
Most laser shaft alignment systems have on
board software to calculate extremely accurate
values for shimming and horizontal corrections.
Example of power Saving
Machine information:
Motor rated power = 132 KW
Voltage = 380 V
Power factor = 0.86
Ampere Before Alignment = 210 amps.
Ampere After Alignment = 203 amps.
Accurate laser Alignment was performed on the
raw water pump and results according to
acceptable tolerances
File: ONLINE.PPT / MD Page 14
Power Saved due to accurate laser Alignment
kW = (Volts x Amps x Pf x 1,732 )
1000
kW = (380 x 7 x 0.86 x 1,732 ) = 3.96 kw
1000
Energy Saved = 3.96 kw x 24 hrs / day x 250 days / Year
= 23,772.7 kw h / year
Cost Saved = 23,772.7 kwh / year x 0.1 $/Kwh
= 2,377.27 $ / year
File: ONLINE.PPT / MD Page 15
