Kingdom of Saudi Arabia

Saline Water Conversion Corporation

General Directorate Of Training Programs
Training Center – JUBAIL

S.MARIMUTHU. GEN.MECHANICAL TECHNICIAN. SWCC. YANBU PLANT

ID.402667

MAINTENANCE DEPARTMENT
MECHANICAL ADVANCED COURSE

MACHINEALIGHNMENT

"

Course Code:23209
Version 1.0
Prepared by: Fawaz Alghamdi
Date:J A N 2 0 0 5
 SWCC TRAINING CENTER
AL-JUBAIL

MECHANICAL MAINTENANCE COURSE

MACHINERY ALIGNMENT

LESSON No. 1.
SUBJECT/TOPIC : MISALIGNMENTAND ALIGNMENT

TIME : hours

OBJECTIVE : At the end of this lesson the trainee will be able to

demonstrate and understanding of Misalignment
and Alignment.

LOCATION : Al-Jubail Training Center

TRAINING AIDS : Overhead projector,

transparencies, white board.

REF.MANUALS : NUS Training Manual

HAND-OUTS : Trainees Manual

LESSON OUTLINE :

1. Introduction.
2. Identifying Misalignment.
3. Shaft Alignment using a Straight Edge.
4. Wedge Gauge.
 SWCC TRAINING CENTER
AL-JUBAIL

MECHANICAL MAINTENANCE COURSE

MACHINERY ALIGNMENT

LESSON No. 2.

SUBJECT/TOPIC : HEAT AND ITS EFFECT ON

ALIGNMENT

TIME : hours

OBJECTIVE : At the end of this lesson the trainee will be able

to describe the effect of Heat on Alignment
without error.

LOCATION : Al-Jubail Training Center

TRAINING AIDS : Overhead projector, transparencies,

chalkboard, chalk.

REF.MANUALS : NUS Training Manual

HAND-OUTS : Trainees Manual

LESSON OUTLINE :
1. Introduction. 6. Dowel Pins.
2. Preparations. 7. Aligning Belt Driven Machinery.
3. Run-Out. 8. Tension Setting.
4. Correcting vertical Misalignment. 9. End Float.
5. Correcting Horizontal Misalignment.
 SWCC TRAINING CENTER
AL-JUBAIL

MECHANICAL MAINTENANCE COURSE

MACHINERY ALIGNMENT

LESSON No.3.

SUBJECT/TOPIC : ALIGNMENT BY RIM AND FACE

METHOD

TIME : hours

OBJECTIVE : At the end of this lesson the trainee will be able

to provdes information in simple way to
accomplish the alignment .

LOCATION : Al-Jubail Training Center

TRAINING AIDS : Overhead projector, transparencies,

White board, Marker.

REF.MANUALS : NUS Training Manual

HAND-OUTS : Trainees Manual

LESSON OUTLINE : Detailed procedure by

calculation and graph
 SWCC TRAINING CENTER
AL-JUBAIL

MECHANICAL MAINTENANCE COURSE

MACHINERY ALIGNMENT

LESSON No.4

SUBJECT/TOPIC : REVERSE INDICATOR METHOD.

TIME : hours

OBJECTIVE : At the end of this lesson the trainee will be able

to provides information in simple way to
accomplish the alignment by reverse indicator
method both by forula and graph.

LOCATION : Al-Jubail Training Center

TRAINING AIDS : Overhead projector, transparencies,

White board, Marker.

REF.MANUALS : NUS Training Manual

HAND-OUTS : Trainees Manual

LESSON OUTLINE : 1- Introduction .

2- Procedure applied
3- Formula and graph detailed
procedure
 SWCC TRAINING CENTER
AL-JUBAIL

MECHANICAL MAINTENANCE COURSE

MACHINERY ALIGNMENT

LESSON No. 5
SUBJECT/TOPIC : REVERSE MISALIGNMENT
METHOD WITH THERMAL GROWTH ALLOWANCES AND
TEMPERATURE GROWTH FACTORS.

TIME : hours

OBJECTIVE : At the end of this lesson the trainee will be able to

Perform Alignment by reverse indicator method
taking into account different thermal position or
growth factor calculation .

LOCATION : Al-Jubail Training Center

TRAINING AIDS : Overhead projector,

transparencies, White board

REF.MANUALS : NUS Training Manual

HAND-OUTS : Trainees Manual

LESSON OUTLINE :

1. Reverse Alignment method.

2. Calculating the adjustments.
3. Aligment language and symbols.
4. Alignment movements.
 SWCC TRAINING CENTER
AL-JUBAIL

MECHANICAL MAINTENANCE COURSE

MACHINERY ALIGNMENT

LESSON No. 6.
SUBJECT/TOPIC : VERTICAL PUMPALIGNMENT

TIME : hours

OBJECTIVE : At the end of this lesson the trainee will be able to

understand the basic concept and procedure of
vertical pump alignment.

LOCATION : Al-Jubail Training Center

TRAINING AIDS : Overhead projector,

transparencies, Whiteboard,.

REF.MANUALS : NUS Training Manual

HAND-OUTS : Trainees Manual

LESSON OUTLINE :

1. Important fundament points for vertical

alignment.
 SWCC TRAINING CENTER
AL-JUBAIL

MACHINE ALIGNMENT MODULE HOURS

LES SUBJECT/TOPIC THEORY PRACT TOTAL

No HOURS HOURS HOURS
ALIGNMENT BASICS PART 1
a. Introduction
1. b. Identifying misalignment 5 5 10
c. Shaft alignment using straight edge
d. Wedge gauge
ALIGNMENT BASICS
PART2
a. Misalignment.
b. Factor affecting
2. c. Alignment Tolerance 5 5 10
d. Misalignment Detection
e. Types of Alignment
f. Alignment Record.

3. ALIGNMENT BY RIM AND FACE METHOD 5 5 10

REVERSE INDICATOR METHOD
4. 2 3 5

REVERSE ALIGNMENT METHOD WITH THERMAL

5. GROWTH ALLOWANCES AND TEMPERATURE 2 3 5
GROWTH FACTORS
VERTICAL PUMP ALIGNMENT
5. 5 5 10

TOTAL HOURS FOR HEAT EXCHANGERS

24 26 50
MACHINE ALIGHMENT ALIGNMENT BASICS PART 1

LESSON
1 ALIGNMENT BASICS PART 1
LECTURE

Objectives
To understand the basic of alignment particularly the importance of
alignment and understanding of different factors which woodheap to
make alignment a best possible way.

1.0 ALIGNMENT THEORY

Misalignment is one of the most common faults found in rotating

equipment. Understanding how to properly diagnosis and correct for
misalignment in plant equipment and how to deal with common pitfalls
while out in the field is essential in doing the job right the first time.

The alignment of shaft centerlines on coupled machines is one of the

most important aspects of machine installation. Contrary to popular
opinion, flexible couplings will not always compensate for even
moderate amounts of shaft misalignment. Misalignment is any
condition in which the shaft centerlines are not in a straight line during
operation.

Misalignment generates unnecessary forces. Precision alignment

removes these forces resulting and cyclic forces resulting in reduced
vibration and noise levels, minimized shaft bending and cyclic fatigue
reduced energy costs, and increased bearing, seal, and coupling life.

Shaft centerline misalignment can be classified as either angular or

offset (also called parallel). Angular misalignment occurs when the
shaft centerlines meet at an angle. Offset misalignment occurs when
the shafts are parallel, but offset from each other. The misalignment
may be vertical, horizontal, or a combination of the two. Most shaft
misalignment is a combination of both angular and offset misalignment.
graphically illustrates the alignment types.

Another type of misalignment not associated with couplings is bearing

misalignment. the centerlines of two coupled shafts can be properly
aligned, but the bearings on one side of the coupling may be
misaligned. Bearings can be misaligned if they are not mounted in the
same plane; if they are cocked relative to the shaft; or because of
machine distortion due to soft foot, an uneven base, or thermal growth.

Lesson 1 Page 1
MACHINE ALIGHMENT ALIGNMENT BASICS PART 1

2.0 ECONOMICS OF MISALIGNMENT

There are a number of cost benefits of precision alignment. It can help

reduce plant operating costs by reducing energy costs. Precision
alignment also results in increased maintenance savings through
reduced parts consumption and reduced overtime. Finally, it can help
decrease equipment downtime and increase product quality.

A recent study performed at the University of Tennessee found that

even small amounts of misalignment could significantly reduce bearing
life. The study found that if, on average, a motor was offset misaligned
by 10% of the coupling manufacturer’s allowable offset, there was a
corresponding 10% reduction in inboard bearing life. Furthermore, if a
motor was offset misaligned by 70% of the coupling manufacturer’s
allowable offset, there was a corresponding 50% reduction in inboard
bearing life (Hines et al). the results of the table at the top of this page.

3.0 ALIGNMENT TOLERANCES

Alignment tolerances have often been treated with a halfhearted

“just get it close” attitude. But, alignment tolerances are actually
the measurement of a job well done and they provide the
definition of what close actually is.

There are two reasons to use tolerances. The key reason is to

establish goals. If you know when the job is finished. If there is
not a goal, there cannot be a quality alignment.

Lesson 1 Page 2
MACHINE ALIGHMENT ALIGNMENT BASICS PART 1

The second purpose of alignment tolerances is to establish

accountability. Accountability is the evaluation of alignment
quality. If there is no tolerance to compare an alignment to, how
can the quality to the alignment be judged? Accountability can
create competition, driving a mechanic to get the job done
better.

Misalignment is one of the most common faults found in rotating

equipment. Because of the frequency of occurrence, machines
are often aligned with out taking the time to properly diagnose
the machine fault. Diagnosing misalignment in a machine can
be difficult because the vibration, phase, and temperature
characteristics are dependent. On the type of coupling used.
Misalignment leads to reduced bearing, seal and coupling life.
Precision alignment reduces plant operating costs through
reduced maintenance and energy costs as well as reduced
equipment downtime.

Asset optimization is possible with a balance of Technology,

Expertise, and Work Processes.

In theory, machine alignment is a very straightforward process.

With some type of measuring device extended across the
coupling, the shafts are rotated to several positions (at least
three) to determine the relative position between them. Since
alignment is a iterative process (meaning that the misalignment
should continuously decrease with each machine move), it is
theoretically only a matter of sufficiently repeating alignment
corrections until an acceptable solution is achieved. In fact,
quality alignment is not dependent on the type of measurement
system used. Any good dial indicator set or laser system should
be sufficient to perform quality alignments.

Therefore, in heavy industrial applications, where the cost of

downtown can be in excess of $ 10,000 per hour, the
fundamental question for an alignment program is not simply
“Can I successfully align the machine?” but rather fastest
alignment solution so that I can start production again?”

Furthermore, since misalignment is often compounded by

structural faults such as ‘soft fool’, piping strain, induced frame
distortion, excessive bearing clearance, shaft rub, etc., it may
not be possible to align the machine without first addressing
these additional problems. These pitfalls can turn an otherwise
simple alignment job into an all day affair – frequently with
unsatisfactory result despite conscientious effort and a
considerable investment in manpower and downtime.

Lesson 1 Page 3
MACHINE ALIGHMENT ALIGNMENT BASICS PART 1

For this reason, it is crucial for the personnel performing

alignments to be aware of the kinds of structural faults that can
complicate the alignment process and that they learn to
recognize the tell – tale signs of bad measurements before they
invest valuable downtime in an unproductive exercise.

4.0 COLLECTING VALID DATA

Some fairly simple yet powerful techniques can be applied to

determine the validity of alignment readings before investing
time executing a machine move that may be wrong. If using a
dial indicator set, it is useful to apply the data validity rule to
each set of readings. The data validity rule compares the
readings taken at the four cardinal positions: Top + Bottom =
Left + Right. It provides a quick way to determine the validity of
an alignment solution before moving the machine. This simple
check is able to catch many set – up errors and mechanical
faults such as:

 Loose brackets.
 Sticking indicators.
 Indicators set too high or too low.
 Improperly recorded data values and / or
signs.
 Sleeve bearing float.
 Surface irregularities or eccentricities.
 Excessive bearing clearance.

Small deviations from the validity rule are to be expected. If the

difference is more than 10%, it is possible that the coupling may
be loose enough to provide excess torsional play (“backlash”).
To reduce the coupling engaged while rotating the shafts from
the driven machine in the normal direction of rotation.

If the error is greater that 20% the cause should be determined.

This could be a problem with the alignment fixture(s) or a
concern with the machine being aligned. Alignment problems
occur from loose fixtures or improper use of fixtures. Possible
machine concerns include locked couplings, spalled bearings,
machine binds, etc. If the data validity rule is not checked when
such a problem exists, these potential machine faults will remain
undetected and substantially complicate the alignment process.
Even worse, the objective of increasing machine reliability
through quality alignment will not be accomplished.

When using a laser alignment system, the potential for user

error is greatly reduced de to the automatic measurement and
recording of readings. However, the data validity rule can still
be very useful to indentify structural faults such as excessive

Lesson 1 Page 4
MACHINE ALIGHMENT ALIGNMENT BASICS PART 1

bearing clearance and other forms of structural looseness. To

apply the validity rule with a laser system, it is necessary to
record all four cardinal readings (top, bottom, left, right) and plug
them into the formula. If, however, the alignment solution is
based on only three of the four cardinal readings, the user will
not have the ability to check the validity of the solution.

In one such example involving a feed water pump in a power

plant, an alignment was attempted using only three of the four
cardinal measurement (top, left, and right – the bottom reading
was omitted). The machine was moved as indicated by the
laser system but on improvement in the alignment condition was
achieved. Numerous readings and machine moves were
implemented but failed to result in any improvement in the
alignment condition.

When the reading for the fourth position (on the bottom) was
manually collected and the values were plugged into the
equation, it was clear that the validity rule was being violated.
Visual inspection of the machine train indicated that one of the
feet on the gearbox had been bolted down with the wrong size
bolt head – thereby substantially reducing the hold – down force
at this foot. This allowed the foot to lift slightly during shaft
rotation creating substantial error in the readings. After
replacing it with the proper size bolt, the operator was able to
align the machine in just a few moves. (Note: more advanced
system are currently available that will automatically apply the
validity rule to the obtained readings and indicate whether
acceptable levels for deviation have been exceeded.)

It is important to realize that otherwise straight – forward

alignment jobs can become highly complex and yield
unacceptable results if the technician does not address the
quality of the alignment measurement and potential frame stress
conditions (frame distortion, soft foot, and piping strain) during
the pre – alignment check. These steps should all be conducted
before the technician ever begings to move the machine.

5.0 MOVING THE MACHINE

Every machine is considered moveable, even those with rigid

piping attached. Some machines are more easily moved than
others. The aligner has the option to move one or the other, or
both machines.

Machines shall be adjusted with small, precise movements.

Excessive force, that could cause internal or external damage, is
to be avoided. Steel-hammer blows on bare steel or iron

Lesson 1 Page 5
MACHINE ALIGHMENT ALIGNMENT BASICS PART 1

machine housings are unacceptable. Hammering on wooden

blocks is OK. Jackscrews are the preferred movement method.

Horizontal movements shall be monitored with dial indicators, or

other measuring instruments, to know when to stop.

"Bolt bound" conditions can be handled in various ways,

depending on the situation at the job site. The following methods
are allowable:

1. Moving both machines

2. Undercutting the bolt diameter to remove threads
3. Reducing bolt size one nominal fractional size (i.e., 3/4
bolts to 5/8 bolts is OK)
4. Enlarging the hole is OK if structural integrity is not
compromised
5. Tilting the machine with differential shimming

After all movement is done, the machines will be secured by

tightening the holddown bolts to the recommended torque in
accordance with the manufacturer’s instructions. If no
instructions are available, the torque values in Appendix D shall
be used.

After torquing the holddown bolts, a final set of shaft-to-shaft

readings will be taken and reported as the final orientation.

Doweling of machines in place will not be done unless the

installation instructions specifically require it.

6.0 UNDERSTANDING DIAL INDICATOR

A positive reading indicates that the plunger is pushed inward

and the dial rotates in a clockwise manner, thus indicating a
positive reading.

A negative reading indicates that the plunger is extended

outwardly and the dial rotates in a counter clockwise manner
indicating a negative reading.

Dial indicators have many different face designs and maximum

indicator travel. It is important to become familiar with the dial
indicators and other measuring devices that you are going to
use.

For the case where a dial indicator is mounted on the driven

equipment and the plunger touches a surface on the driving

Lesson 1 Page 6
MACHINE ALIGHMENT ALIGNMENT BASICS PART 1

equipment. A positive value of the difference between the top

and bottom readings would indicate that the plunger is
depressed greater at the top, thus the axis of the driving
equipment (indicator plunger contacts this equipment) is higher
than the driven equipment.

6.1 OTHER HELPFUL HINTS WHEN USING A DIAL INDICATOR

Adjust indicator face to zero. Rotate shaft one complete

revolution and note the maximum positive or negative value.
Return the shaft to location of maximum value and readjust face
to zero.

Rough align equipment to ensure that equipment to ensure that

equipment alignment is within the indicator total travel.

Make sure that supporting hardware is reliable and rigid. Areas

of attachment should be large enough for indicator supports and
clean for mounting

7.0 SHIMS MATERIAL

The best choice for shim material is stainless steel. This

material is very stable and is easy to maintain. Carbon steels
should be avoided because it will rust and eventually
compromise the machinery alignment. Synthetic or plastic shim
material should be avoided for industrial applications because it
is easily damaged and under heavy load will deform which
compromises the alignment condition.

The shims used for industrial applications should be large

enough to adequately support each foot. Commercial shims are
available in various dimensions. These shims are precut and
dimensioned to standard thicknesses which are labeled on a
small tab. These shims are easy to install and are difficult to mix
up. If shims are manufactured in the field they should be large
enough to support the machine foot and all edges should be
smoothed to eliminate burrs. Kinked or otherwise damaged
shims should be discarded and new ones obtained. The shims,
the base plate surface, and bottoms of the machine feet should
be clean and free of defects prior to installing any shims.

8.0 WHICH MACHINE MOVES?

Generally, the stationary machine has certain constraints which

make it impractical to move it. Pumps have rigid piping attached,
generators have complex cooling systems, and gear boxes are

Lesson 1 Page 7
MACHINE ALIGHMENT ALIGNMENT BASICS PART 1

relatively sensitive to any orientation other that flat and level.

When these machine types are moved the attached systems
must be relocated to eliminate sources of strain.
Multiple case machine trains, such as dual compressors driven
by one turbine, pose another problem. All three machine shafts
must operate co-linearly to function efficiently. By studying the
graphical plot of the current alignment and the desired alignment
it may prove most effective to move the center machine case,
instead of moving two or three machines.

Energy is continuously added to increase the fluid velocities within the

machine to values in excess of the occurring at the discharge such that
subsequent velocity reduction within or beyond the pump produces a
pressure increase. The categories of that pump are include all kinds of
centrifugal pumps and air lift pump and in lesson two they define in
detail.

Lesson 1 Page 8
MACHINE ALIGNMENT ALIGNMENT BASICS PART 2

LESSON
ALIGNMENT BASICS
2 PART2
LECTURE

Objectives
This lesson further explains the importance of alignment by
mentioning different damages which misalignment caures and
important preliminary to accomplish the

1.0 MISALIGNMENT EFFECTS

1.1 EFFECT ON COUPLING

The most affected part of a unit that suffers from misalignment is the
coupling. Regardless of the type employed on a unit, either rigid or
flexible, the coupling does not compensate for gross permanent
misalignment. Some people are of the opinion that since the coupling
is termed “flexible” it requires less accurate alignment. This is not so.
This type of coupling provides allowances only for unintentional,
unexpected, but ever present short periods of misalignment created by
the inherent characteristics of the unit’s operation. It is because these
flexible couplings are designed to accommodate these forces that they
do not fail as readily as bearings or seals, which are not designed for
any great amount of misalignment.

1.2 EFFECT ON BEARING, SEALS AND SHAFTS

Stresses that accompany misalignment also have a severe effect upon

bearings, both antifriction and plain, thereby reducing their life. Proper
alignment cannot extend the natural life of an antifriction bearing.
Misalignment can certainly reduce their natural life. When the life of a
bearing is determined, it is done without misalignment forces being
present.

1.3 SHAFT AND OTHER PARTS

Most mechanical seals are designed to function properly only when

minimum shaft deflection is encountered, thus, mechanical seals fail
due to shaft deflection created by misalignment.

Unlike other mechanical problems which begin as a minor deficiency

and grow into something quite noticeable and major, misalignment is

Lesson 2 Page 1
MACHINE ALIGNMENT ALIGNMENT BASICS PART 2

as severe the first revolution as it is when the machine finally fails.

This is the case when a machine does not shift due to misalignment
forces. It is through this minor deficiency that the major failure can
stem. It is true that stresses from misalignment are in direct proportion
to the speed of the unit, with the amount of initial misalignment
remaining constant. Speed of unit should generally dictate the
tolerances allowed for alignment. Operating characteristics will also
govern initial and operating alignment tolerances. The following
discussion of shaft alignment is dependent on keeping these thoughts
of mind.

2.0 FACTOR AFFECTING ON ALIGNMENT

Prior to discussing the particular procedure to be employed on a given

unit, there are several factors that may mechanics either don’t
understand or fail to consider..

2.1 PIPING STRAIN

Practically all manufactures assembled units, both driver and driven on

a common base are factory alignment. This factory alignment only
serves the factory purpose to determine if and how the unit can be
alignment within its mechanical limits.

Factory alignment was supposedly obtained with the base in an

absolutely level, unstressed position, but when the unit grant and
piping installed on it many undue stresses are involved to disturbed the
alignment.

For achieving the maximum possible factory aligned mechanical limit

the unit must be grout in a level foundation after that stage take a
preliminary alignment reading and record it.

Install all piping on the pump and electrical connection, checked and
measure the alignment distortion.

This will allow noting any movement of the shafts caused by stresses
imposed by the piping .

Stress relieving or some other means of eliminating these stresses

may have to be performed. Additional pipe supports may be required.
If blinds have been placed in the lines during shut down, final
alignment not be performed until these have been removed.

Note: On a installed unit, when pump casing or piping removed for

maintenance purpose and at the time of reinstallation the piping strain
can again activate.

Lesson 2 Page 2
MACHINE ALIGNMENT ALIGNMENT BASICS PART 2

2.2 DOWEL PINS AND PUMP CASING JOINTS

On some unit dowel pins are provided for exact pump casing joint,
because it is very critical to the proper operation of the pump.

Manufacturers of these pumps require that this joint be evenly loaded

to insure proper operation of that unit. Most pump designs allow a
space at this joint. During the assembly of the pump, the mechanic
equalizes this space using feeler gages. From this point on in the
installation and alignment of the pump, this space should not be
disturbed. However, some mechanics unwisely use this adjustable
joint to achieve proper alignment. By doing this, there is danger of
reducing axial impeller clearance at the tips of the impeller vanes.

2.3 PUMP BEARING’S SUPPORT FIG. 1-1

If this type pump has an adjustable support leg under the inboard
bearing, it should not be secured until the case joint clearance has
been equalized. Then, with a dial indicator monitor, pull this leg down
1 to 3 mils (.001 - .003”). This will insure proper support of that bearing
without placing an undue strain on the casing.

Fig. 1-1. Pump Bearing Support.

Lesson 2 Page 3
MACHINE ALIGNMENT ALIGNMENT BASICS PART 2

2.4 SOFT FOOTING

All driver support feet must be on the same plane. This condition is
extremely important and should be one of the first problem areas to be
checked. Drivers with four or more feet are the only ones to possible
create this problem. The trade name of that problem is known as
“Soft Footing” . Fig. 1-2 The soft footing created when one foot is
slightly higher, or lower in elevation. The soft footing created two
major problems.

Fig. 1-2. Soft Footing.

First exact alignment is very difficult to achieve, because this foot is

tightened down with the hold down bolt or nut it must do one of two
things it must spring the frame work and come down or it must break
the foot. The spring action create different alignment reading and
condition of this sort is a big handicap to the person doing the
alignment.

Secondly, this condition of having a soft foot will introduce undue

stress within the unit itself. Bearings, mechanical seals, seals, and
wear rings suffer without need. Vibration, parts breakage, and ultimate
failure is possible when this condition is not resolved. The shaft no
longer runs within a line bored bearing housing, one is displaced in
reference to the other.

2.4.1 METHOD FOR ELIMINATE SOFT FOOTING

First point for eliminate the soft footing, better used minimum number
shims rather than a bulk of small measurement shim because that can
create a spongy foot and that will behave as a soft foot.

Secondly if that is a permanent problem it must be eliminate by

shimming before the alignment. To eliminate the possibility of a soft
foot, attach a dial indicator to the support pedestal and set the indicator
button on top of one of the support feet. Zero the indicator. Now
loosen the support nut and read the indicator. If the indicator is
deflected more than 3 mils move to the adjacent foot and take a

Lesson 2 Page 4
MACHINE ALIGNMENT ALIGNMENT BASICS PART 2

reading in the same manner. If the reading on the second foot

exceeds the first reading, the second foot should be shimmed. Repeat
this procedure until you obtain an indicator reading of less than 3
(0.003”) mils when one foot is loosened and the others are tight.

2.5 MAGNETIC CENTER

An electric motor is said to run in its magnetic center. This means that
the rotor is pulled into operating position by the magnetic force
whenever the motor is running. For this reason the coupling length
can not be determined when the machine is at rest unless a mark has
been made, showing the running position. If there is no mark the
motor must be started to see just where the shaft moves to, while it is
running. Then the coupling spool is made up to suit the distance
between couplings for operating conditions. Also lock the axial
movement of the shaft while aligning, because that axial movement
differ the each face reading.

2.6 SHAFT DEFLECTION, COUPLIGN WEAR AND UNEVEN BEARING

WEAR

 The shaft deflection affects the concentricity of

the center line and causes of misalignment.

 The coupling wear in case of that when rotating

only one coupling for alignment can affects the
parallelism of the two mating halves of coupling
and causes misalignment.

 Uneven bearing wear again affects the

concentricity of the shaft center line, the same as
in the case of shaft deflection.

The above mention factors must be checked before a alignment job

started by runout reading.

For taking run-out reading the dial magnetic base fixed on the base

plate and dial on the coupling OD and set it zero. The shaft is

rotated and the indicator observed to see if the permitted amount of

deflection is not exceeded.

2.7 HEAT GROWTH (PURPOSE OF HOT CHECK)

Lesson 2 Page 5
MACHINE ALIGNMENT ALIGNMENT BASICS PART 2

Since there is a temperature change in a unit from the shut down

temperature to the running temperature, we can also expect to have a
dimensional change caused by this change in temperature. Depending
upon the design and service of the unit, this change in dimension will
vary in amount and direction. This is why a “hot check” is vital to
proper alignment. As a rule, hot alignment is performed when there is
a temperature difference between driver and driven of 150 degrees or
more. Here again this is a general rule. Each particular unit will
determine how it is to be aligned.

Basically there are two concepts about a hot check. One concept is to
achieve perfect alignment, unit aligned in cold and then put the unit on
stream. Once the operating temperature are reached, the unit is shut
down and alignment is again checked. Additional moves are made
once the unit is cold again to compensate for hot movement. There are
several disadvantages to this method.

 First is the fact that an additional shim change time

will be required.

 Time consumed for dimensional changes and shut

down

The second concept of hot alignment is that of knowing where the unit
will go. If the facts are not known as to the unit’s movement, it is easy
to second guess the units movement, if the facts, or calculations, are
correct as to where the unit will move, the unit will align itself. If it does
not, at least it will move in the desired direction. One apparent
advantage of this concept is that it is possible not be forced into an
additional shim changed based upon hot readings. There is one
limitation. If cold alignment is drastically off, as in the case with a
steam turbine driving a cold service pump, putting the unit on stream
should be done slowly and cautiously to allow warm up and positioning
of the shafts.

Nearly all units are aligned cold with allowances made for expected
thermal growth. Regardless of whether these allowances have been
made or not, a hot check should be performed. This check will confirm
the hot position of the shaft

3.0 ALIGNMENT TOLERANCES

Perfect alignment is the desired objection but in the practical field and
in many cases the achievement of (0.00) alignment reading is quite
difficult and time consuming job. So the alignments for a unit can
accept with some tolerances. Remember a stock set of alignment
tolerances which are suitable for all of industry just simply does not
exist. As key a good alignment tolerances for a given unit is one which
permit the unit to run without creating forces great enough to causes

Lesson 2 Page 6
MACHINE ALIGNMENT ALIGNMENT BASICS PART 2

the components to fail prematurely. According to that view forces

generated by misalignment are directly related to the speed of the
shafts, it is logical to use speed as the governing agent to establish
alignment tolerances. Economics is the other factor for establishing the
acceptable tolerances. For example, a pump which requires a new
seal every six weeks would hardly warrant the time required to
establish perfect alignment. This is especially true when the shafts can
be placed within tolerance within a an hour or so. On the other end of
the spectrum is a unit which is not planned to come down in two years.
The extra time required to achieve perfect alignment is justified.

Some people in industry use the vibration caused by misalignment as

the criteria for alignment tolerances, but a practical expenses, that a
very low tolerances can be double without an appreciable change in
the amplitude of vibration.

Listed below are some tolerances that are based upon speed and
generally accepted in production industries.

The slow speed range will encompass the majority of electric and
steam driven units.

SLOW SPEED 3550 RPM & Below

5 Mils on OD
3 Mils on Face

HIGH SPEED 3600 RPM & Above

2 Mils (TIR) on OD

1 Mil (TIR) on Face

Flexible coupling manufacturers describe the capabilities of their

couplings on the basis of maximum angular misalignment, among other
things. This is the amount at which their coupling will still function.

Lesson 2 Page 7
MACHINE ALIGNMENT ALIGNMENT BASICS PART 2

This can hardly be used as the criteria for establishing alignment

tolerances.

4.0 MISALIGNMENT DETECTION

It should be noted that misalignment can be detected while the

machine is in operation. Forces caused by misalignment will create
vibration as mentioned before. The characteristics of this vibration is
what can be used to determine a condition of misalignment. It specially
is the direction of this force that is the key, a high axial force. A high
axial force is generated when the misalignment is primarily angular.
This is influenced to a large extent by the type of coupling transmitting
the forces. When the type of mis-alignment is primarily OD, or parallel,
the axial forces subside and a larger radial force is evident as shown in
Fig. 1-3. To determine where the forces are and in what direction they
are in is a simple task provided an adequate instrument is available.

Fig. 1-3. “A” is measuring Axially and “B” is measuring radially

vibration for detecting misalignment.

The most effective manner to confirm misalignment is with dial

indicators. As was mentioned earlier, the alignment of two shafts can

Lesson 2 Page 8
MACHINE ALIGNMENT ALIGNMENT BASICS PART 2

be well outside the tolerances normally established and still not

produce an alarming vibration level. This is due primarily to the type
coupling employed and the type of misalignment in the unit. Each type
of misalignment has its own characteristics of vibration and dial
indicator readings.

5.0 TYPES OF MISALIGNMENT

Basically, there are three conditions that may exist for misalignment.

As shown in Fig. 1-4, the shaft are parallel to each other but offset
somewhat. This condition is known by several terms.

5.1 PARALLEL MISALIGNMENT

But more commonly by parallel or, better yet OD. Shaft center lines do
not intersect to correct for this condition movement is made for one half
the TIR of OD indicator.

Fig. 1-4. OD Displacement.

5.2 ANGULAR OR FACE MISALIGNMENT

This type of misalignment is represent by Fig. 1-5 should be noted that

the shaft center lines intersect at only one point, as opposed to being
concentric. Any adjustments to this condition should be made against
TIR of face Indicator.

Fig. 1-5. Angular or Face Displacement.

Lesson 2 Page 9
MACHINE ALIGNMENT ALIGNMENT BASICS PART 2

5.3 MISALIGNMENT BY COMBINATION OF ANGULAR &

PARALLEL

That condition involves a combination of these two condition as shown

in Fig. 1-6.

Fig. 1-6. Angular Parallel Displacement.

In order to make the task of shaft alignment more interesting, we must

cope with these conditions in both the horizontal plane, looking at the
side of the unit, and in the vertical plane, looking down on the unit.
Again, the utopia is to get these shafts on a concentric center line
throughout their entire length, or TIR OD of “O” and TIR FACE of “O” in
both planes during the hot check. Depending upon speed and unit,
deviation from the exact alignment can be tolerated.

The specific procedure that should be, or better yet “can be”, used to
align the shafts will be governed primarily by the unit. Since there is an
unlimited number of different sizes and types of units requiring
alignment, let’s narrow this down to three categories. Each category is
a separate procedure; two indicator, Reverse Indicator, and Dynamic to
Static Methods.

6.0 ALIGNMENT RECORDS

Regardless of the procedure employed for shaft alignment, a sound set

of records should be maintained for each particular unit being aligned.
These records not only aid the mechanic during the aligning process,
but also serve as permanent record for future alignment.

The record shown in Fig. 1-7 was designed for one particular
procedure of alignment, the Indicator Reverse Method. With very
minor alternations, this same form can be used for each particular
procedure discussed in this study. The majority of the form is self-
explanatory. However, on each procedure the reference of direction is

Lesson 2 Page 10
MACHINE ALIGNMENT ALIGNMENT BASICS PART 2

essential. This form provides for the location of North. Any direction is
suitable but North is generally used. Direction will prove to be of great
value when determining lateral shifts. Inside the circles are located a
portion of an arrow. It should be completed to show the direction of
rotation of the unit, which is also the direction the shafts were turned to
obtain Indicator readings.

Fig. 1-7. Alignment Record Sheet.

Lesson 2 Page 11
MACHINE ALIGNMENT ALIGNMENT BY RIM & FACE METHOD

LESSON ALIGNMENT BY RIM AND FACE

METHOD
3 DETAILED PROCEDURE BY
LECTURE CALCULATION AND GRAPH

Objectives
This lesson provides information in simple way to accomplish the
alignment by rim and face method by formula and graph.

You can use the Rim & Face Method to perform a calculated precision
alignment process. You may use a variety of shaft alignment fixtures.
We recommend that you use a commercial package designed to
accommodate a variety of shaft diameters. The fixtures should include
an assortment of rods to span various coupling lengths. These
packages expedite the precision alignment process. Also, sag values
can be pre-determined for the standard rod assortment.

To perform the Rim & Face Method, you must:

Mount the dial indicators fixtures.

Measure the A, B, & C dimensions.
Obtain as-found readings.
Determine the vertical foot positions.
Make vertical corrections.
Make horizontal corrections.
Re-measure and record final alignment values.

1.0 UNTING THE DIAL INDICATOR FIXTURES

1. To mount the fixtures follow these steps:

2. With the coupling broken, mount the fixture to the stationary

shaft or coupling hub.

3. Span the coupling with a rod.

4. Rotate the fixture to 12:00.

5. Attach the face dial indicator. The dial indicator plunger must be
centered for equal positive and negative travel.

6. Attach the rim dial indicator. The dial indicator plunger must be
centered for equal positive and negative travel.

2.0 FIXTURE MOUNTING PRECAUTIONS

Lesson 3 Page 1
MACHINE ALIGNMENT ALIGNMENT BY RIM & FACE METHOD

Regardless of the specific hardware being used, the following precautions should
be observed.

 Never attach the fixture to the flexible portion of the

coupling.

 Maximize the sweep distance of the face dial indicator

for the geometry of the machine being aligned. If the
face dial contacts the coupling facedirectly, ensure the
plunger of indicator contacts the coupling near its outer
edge.

 Ensure fixtures are mounted at a position where rotation

is possible. It is desirable to have 360 degrees of
rotation.

Before obtaining alignment measurements, determine dial

indicator bar sag of the rim dial indicator and ensure dial
indicator readings are valid and repeatable.

Fig1

1 The “A” Dimension is the diameter of face indicator

travel. The A Dimension should be slightly less than the
coupling diameter.

This is the most critical dimension.

Measure A very carefully.

Lesson 3 Page 2
MACHINE ALIGNMENT ALIGNMENT BY RIM & FACE METHOD

2. The “B” Dimension is the distance from the rim

indicator to the front foot bolt center. This dimension is
measured parallel to the shaft.

3. The “C” Dimension is the distance between front and

rear foot bolt centers. This dimension is measured
parallel to the shaft.

3.0 OBTAINING AS-FOUND READINGS

To obtain a complete set of as-found readings, perform the steps

below:

1. Rotate the dial indicators to 12:00.

2. Set the rim dial indicator to the positive sag value.
3. Set the face dial indicator to zero.
4. Record the setting of both dials at 12:00.
5. Rotate the dial indicators to 3:00.
6. Determine and record the reading on both dials.
7. Rotate the dial indicators to 6:00.
8. Determine and record the reading on both dials.
9. Rotate the dial indicators to 9:00.
10. Determine and record the reading on both dials.
11. Rotate the dials to 12:00 and ensure both dials return
to their original setting.

Document as-found results using a format similar to that shown below.

Fig 2

4.0 MEASURING & INTERPRETING VERTICAL MISALIGNMENT

To measure vertical misalignment, perform the following steps:

Lesson 3 Page 3
MACHINE ALIGNMENT ALIGNMENT BY RIM & FACE METHOD

1. Rotate the dial indicators to 6:00.

Fig 3

2. Set the face dial indicator to read zero.

3. Set the rim dial indicator to the sag value.
4. Rotate both shafts (if possible) to 12:00.

Fig 4

5. Record the DIR and DIF dial indicator TIR values.

To determine offset and angularity from the 12:00 TIR’s, use the
following rules:

Coupling Offset = Rim Dial (DIR) TIR

2

Shaft Angularity = Face Dial (DIF) TIR

A dimension

Lesson 3 Page 4
MACHINE ALIGNMENT ALIGNMENT BY RIM & FACE METHOD

5.0 MEASURING & INTERPRETING HORIZONTAL MISALIGNMENT

To measure horizontal misalignment, perform the following steps:

1. Rotate the dial indicators to 9:00.

Fig 5

2. Set both dial indicators to zero.

3. Rotate both shafts to 3:00.

Fig. 6
4. Record the DIF and DIR dial indicator TIR values.

To determine offset and angularity from the 3:00 TIR’s, use the
following rules:

Coupling Offset = Rim Dial (DIR) TIR

2

Shaft Angularity = Face Dial (DIF) TIR

A dimension

Lesson 3 Page 5
MACHINE ALIGNMENT ALIGNMENT BY RIM & FACE METHOD

6.0 CALCULATING THE FRONT AND REAR FEET POSITIONS

 Front foot position calculation:

= ( Face TIR x B) + 1/2 Rim TIR

A

 Rear Foot position calculation:

= ( Face TIR x (B+C)) + 1/2 Rim TIR

A

 Positive values mean the foot is high, shims must

be removed.
 Negative values mean the foot is low, shims must
be added.

7.0 RIM-FACE CALCULATION PRECAUTIONS

1. Ensure the rim and face dial indicator TIR’s are

properly determined from the dials prior to
performing calculations.

2. Be careful NOT to make mathematical errors

when subtracting signed numbers.

3. Observe parentheses in the equations. Perform

operations inside parenthesis first.

4. Do NOT make human errors substituting real

values into the equations.

Lesson 3 Page 6
MACHINE ALIGNMENT ALIGNMENT BY RIM & FACE METHOD

5. Ensure the A, B, and C dimensions are accurate

and are properly entered into the equations.

4
8.0 CONSTRUCTING A RIM-FACE GRAPH

To construct a scaled Rim-Face graph, perform the following steps:

1. Obtain graph paper with 10 divisions between bold

lines.

2. Turn the graph paper so that the long side is

horizontal.

3. Draw a horizontal line at the center of the page.

 This line represents the stationary shaft center

and is drawn across the page midway down the
graph dividing the page. It is helpful if this line is
on top of one of the bold lines.

4. Determine the horizontal plotting scale.

 Always use the largest scale possible. Measure

the distance from the stationary indicator plunger
to the center-line of the rear feet of the movable
machine. Standard graph paper is about 10
inches across. The largest horizontal scale will be
the machine distance divided by the page width.
Note your horizontal scale.

5. Make a vertical line on the extreme left of the

horizontal line.

This mark represents the point where the rim dial indicator contacts the
shaft or coupling hub and is labeled: DIR.

6. Make a second vertical line representing the point along the

shaft length of the front feet of the movable machine (RF).

7. Make the third vertical line representing the point along the shaft
length of the rear feet of the movable machine(RF)

Lesson 3 Page 7
MACHINE ALIGNMENT ALIGNMENT BY RIM & FACE METHOD

Fig.7

9.0 PLOTTING OFFSETS

After setting up the graph, the next step is to plot two offset points. One
is the offset measured in the plane of the rim dial indicator (DIR). The
other offset point is derived from the face dial indicator (DIF) reading
and the “A” dimension. To plot the offsets, perform the following steps:

1. Determine the vertical scale.

 The vertical scale is typically 1 mil (0.001”) per

division. In cases of gross misalignment where the
offsets will not fit on the page, a larger scale, such
as 2-3 mils per division, is sometimes required.

2. Plot the offset from the rim dial indicator on line DIR.

 Use the horizontal line representing the stationary

shaft centerline as the reference. All points above
this horizontal line are positive (+) and all points
below the line are negative (-). Ensure you divide
the Rim Dial TIR by 2 to obtain an offset value.

3. Plot the second offset point using the shaft slope

(Face TIR / A dimension).

Lesson 3 Page 8
MACHINE ALIGNMENT ALIGNMENT BY RIM & FACE METHOD

 Plot this point counting from the DIR offset point!

In the rim-face graph example below, the DIR offset is - 10 mils

and the shaft slope is + 4 mils over an A dimension of 5”.

Fig.8

10.0 DETERMINING MOVABLE SHAFT POSITION

After plotting the two points, to determine the movable shaft position
perform the following steps:

1. Using a ruler or straightedge, draw a line through the two offset

points that extends to the rear feet of the movable machine.

2. Count the number of squares in the plane of the front and rear
feet to determine the position and corrections needed.

In the example below, the feet of the machine are 2 mils low; shims
need to be added. The rear feet are positioned 6 mils too high; shims
need to be removed from both rear feet.

Lesson 3 Page 9
MACHINE ALIGNMENT ALIGNMENT BY RIM & FACE METHOD

Fig.9

11.0 RIM-FACE GRAPHING PRECAUTIONS

1. Ensure proper horizontal and vertical scaling

techniques are consistently used.

2. Always double check the position of vertical lines

drawn to represent the DIR, FF, and RF.

3. Ensure the two plot points are properly determined

from TIR’s.

4. Ensure positive offsets are plotted above the

horizontal reference line and negative offsets are
plotted below the line.

5. When interpreting the graph to determine the

movable shaft’s front and rear feet positions in the
vertical plane, observe the following rules:

 If the movable shaft is above the horizontal

stationary shaft reference line the shaft is too
high.

Lesson 3 Page 10
MACHINE ALIGNMENT ALIGNMENT BY RIM & FACE METHOD

 If the movable shaft is below the horizontal

stationary shaft reference line, the shaft is too
low.

6. When interpreting the graph to determine the

movable shaft’s front and rear feet positions in the
horizontal plane, view the graph the way you view the
machine, that is, standing behind the movable
machine facing the stationary machine. Also observe
the following rules:

 If the movable shaft is above the horizontal

stationary shaft reference line the shaft is
positioned to the right.

 If the movable shaft is below the horizontal

stationary shaft reference line, the shaft is
positioned to the left.

12.0 MAKING VERTICAL CORRECTIONS

To correct vertical misalignment, follow the steps below:

1. Determine the vertical position of the movable

machine using calculation and/or graphing
techniques.

 Positive values at the feet mean that the

movable machine is high, therefore you will
remove shims.

 Negative values mean that the movable

machine is low, so you will add shims.

2. Make shim changes to both front feet and both rear

feet as needed.

3. Always check shim thickness with an outside

micrometer. Precut shims aren't always what they're
marked; many shim manufacturers designate shims
with the “nominal” thickness.

4. Use consistent and correct torquing procedures.

5. As shim changes are made, check for and take

precautions to avoid creating soft foot conditions.

Lesson 3 Page 11
MACHINE ALIGNMENT ALIGNMENT BY RIM & FACE METHOD

13.0 MAKING HORIZONTAL CORRECTIONS

To correct horizontal misalignment, follow the steps below:

1. Rotate the dial indicators to 9:00 and zero them.

2. Rotate both shafts (if possible) to 3:00.

3. Adjust the dial indicators to one-half values.

4. Move the front feet of the movable machine as you

watch the rim indicator move to zero.

5. Move the rear feet of the movable machine as you

watch the face indicator move to zero.

6. Repeat steps 4 & 5 until both dial indicators read

zero.

Fig.10

Lesson 3 Page 12
MACHINE ALIGNMENT REVERSE INDICATOR METHOD

LESSON
REVERSE INDICATOR METHOD
4 BY FORMULA AND GRAPHDETAILED
PROCEDURE
LECTURE

Objectives
This lesson provides information in simple way to accomplish the
alignment by reverse indicator method both by formula and graph.

1.0 INTRODUCTION

The dial indicator reverse method of shaft alignment is the most

accurate procedure. By using conventional tools and instrument,
achieve a great amount of accuracy in minimum time. In this method
two dial indicator are fixed on the both coupling’s rims, just exactly
reverse to each other, and all reading taken on the two coupling rims.
As mention in Fig. 4-1.

Since the face reading does not involve in this procedure, the thrust
and axial float does not affect the reading obtained and that is the
major advantage of this procedure.

2.0 WHERE THIS PROCEDURE APPLIED

Since this procedure of alignment have many advantages and use of

this procedure a is limited only by the characteristics of the unit itself.
Here are some advantages and use limits. Considered these as a
general.

Fig. 4-1. Reverse Indicator Method.

Lesson 4 Page 1
MACHINE ALIGNMENT REVERSE INDICATOR METHOD

1. This method is preferred when the distance between the

adjacent shaft ends greater than one half the coupling diameter.
2. It is preferred especially for large equipment operating at high
speed.
3. This method is also preferred when coupling run-out cannot be
eliminate.
4. When one or both shafts have end float or have axial movement
of the shaft.
5. also preferred, when gear type couplings are used.
6. More over this procedure can be used for all kind of equipment
due to its accuracy in a very short time.

3.0 DETAILED STEPS OF PROCEDURE

Any procedure that is effective has a definite outline. It was proven in

the Two Indicator Method and will be proven in this procedure. Since
both are procedures to achieve alignment of two rotating shafts, each
has steps that are common to each other. The discussion of the steps
in the previous procedure are applicable to this procedure.

3.1 LOCK OUT

3.2 CLEAN FEET & PADS

3.3 DETERMINE INDICATOR SAG & RECORD

If using two brackets, check the sag for both brackets list the sag for
the driver to driver bracket.

3.4 PROVIDE FOR COUPLING GAP

3.5 ROUGH ALIGN

3.6 ELIMINATE SOFT FOOT

3.7 COMPLETE RECORD SHEET WITH INFORMATION & DIMENSION

a) Measured the distance from the bracket to the post and

record as mention in Fig. 4 - 2.
b) Measure the distance from the center of the bracket to
center of the in board feet and record it.
c) Measure the distance from the center of the bracket to
center of the out board feet and record it

Lesson 4 Page 2
MACHINE ALIGNMENT REVERSE INDICATOR METHOD

3.8 TAKE A ROUGH ALIGNMENT BY STRAIGHT EDGE AND MINIMIZE

THE SIDE TO SIDE DIFFERENCE UP TO THE POSSIBLE LIMITS

3.9 TAKE READINGS

a. First of all dial indicators are attached to each half coupling

hub using brackets - see Figure 4 -2. The indicator on the
stationary machine hub (usually the driven machine) is set to
zero at point 1. The indicator on the moveable machine hub
(usually the driver) is set to zero at point 2. Points 1 and 2
must be 180° apart.

b. Both shafts are turned together clockwise 90° and indicator

readings are recorded. This process is repeated until four
sets of readings on each hub are recorded. The readings
are checked for consistency, and another entire set of
readings is taken. If readings are not repeatable, the
problem must be found and eliminated in the machinery, the
tools, or the method.

Equipment I.D. : __________________

Date______________________

Type of Unit : __________________ Date of Last Alignment______

Running Sped : ___________________

KW:______________________

Coupling : Manufacturer ___________ Type:

_____________________

Coupling Manufacturer’s tolerances : Angular ________Parallel

_________

Notes:___________________________________________________
____

________________________________________________________
____

Coupling Bracket I.D.: ______________ Bracket Deflection:

__________

Movable Machine: _________________ Stationary Machine:

_________

Lesson 4 Page 3
MACHINE ALIGNMENT REVERSE INDICATOR METHOD

Fig. 4-2. Alignment Record Sheet.

Lesson 4 Page 4
MACHINE ALIGNMENT REVERSE INDICATOR METHOD

Fig. 4 -2. Position of Brackets Viewer.

3.10 CORRECT FOR SAG

From previous discussions we know that indicator bracket sag only

directly affects the bottom OD reading. We also know that it is a
negative value. To correct for sag we simply subtract it, algebraically,
from the bottom OD reading. Each bracket has a different value for
sag and each must be handled independently.

Lesson 4 Page 5
MACHINE ALIGNMENT REVERSE INDICATOR METHOD

4.0 USING ANALYTICAL METHOD FOR CALCULATING SHIMS

(FOLLOW THE FIG. 4 -4)

Fig. 4 -4. Sample diagram of reading and shaft positions.

Lesson 4 Page 6
MACHINE ALIGNMENT REVERSE INDICATOR METHOD

4.1 VERTICAL MOVEMENT

 BA is the bottom reading at coupling “A”

 BB is the bottom reading at coupling “B”
 D1 is the distance between couplings
 D2 is the distance between coupling “A” and front support feet of
movable machine..
 D3 is the distance between coupling “A” and back support feet of
moveable machine

Now:-

i. The shim correction required at front support feet.

BA + BB D BA
{ }x 2 -
2 D1 2
ii. The shim correction require at back support feet.

BA + BB D BA
{ }x 3 -
2 D1 2

4.2 HORIZONTAL MOVEMENT

Normally for the horizontal alignment, no need of calculation but if

machine is large and have jack bolts then this calculation is helpful for
accurate horizontal movement. For horizontal movement dial set
“ZERO” at left side and take the reading on the right side of the
coupling.

* RA is the right side reading on coupling “A”

* RB is the right side reading on coupling “B”

iii. Movement required at front support feet.

RA + R B D RA
{ }x 2 -
2 D1 2

iv. Movement required at back support feet

RA + R B D RA
{ }x 3 -
2 D1 2

Lesson 4 Page 7
MACHINE ALIGNMENT REVERSE INDICATOR METHOD

Example: Fig. 4 -5.

Fig. 4 -5.

VERTICAL MOVEMENT

Shim correction required at front support feet.

BA + BB D2 BA
{ }x -
2 D1 2

BA = -10 BB = + 20 D1 = 8” D2 = 12)
D3 = 24”

 10 + 20 12 (-10)
{ }x -
2 8 2
10 12
x + 5 = 12.5
2 8

Add 12.5 Thou shims at front support feet.

Shim correction required at back support feet.

BA + BB D3 BA
{ }x -
2 D1 2

Lesson 4 Page 8
MACHINE ALIGNMENT REVERSE INDICATOR METHOD

 10 + 20 24 (-10)
{ }x -
2 8 2

10 24
x + 5 = 20
2 8

Add 20 thou. Shims at back support feet.

Movement required at front support feet =

RA = R - L = -15 - (+5) = - 20
RB = R - L = 6 - 14 = -8

RA + R B D RA
{ }x 2 -
2 D1 2

(20) + (-8) 12 (-20)

{ }x -
2 8 2
 28 12
x + 10
2 8

= -21 + 10 = -11

Move 11 thou. Towards right.

Movement required at back support feet =

RA + R B D RA
{ }x 3 -
2 D1 2

(20) + (-8) 24 (-20)

{ }x -
2 8 2

 28 24
x + 10
2 8

= -32

Move 32 thou. Towards right.

Lesson 4 Page 9
 MACHINE ALIGNMENT REVERSE INDICATOR METHOD

5.0 ALIGNMENT PROCEDURE

Outline of Alignment Procedure

Step 1: Familiarize with terms, techniques and procedure.

*follow all safety rules and procedures*

Step 2: Learn about the machine you are aligning.

a. Visually check coupling, pipehangers, base bolts, coupling

spacing etc.
b. Check for coupling & shaft run out.

Step 3: Know the characteristics of your tool. Perform a Sag Check

Step 4: Prepare the machine.

a. Remove all existing shims from under the feet-if old shims
are to be used, clean them thoroughly. -always use minimum amount of
shims.

b. Clean the base thoroughly. -scrape and file away all rust,
nicks, and burrs

c. Examine the base bolts and holes.-retap if necessary -

replace bolts if necessary

Step 5: Installation of alignment brackets

a. Clean mounting surface, file off nicks and burrs.

b. Check indicators for sticking and loose needle.
c. Aim indicator stem directly toward center line of shaft.

Step 6: Measurement

- measure distance between the two indicators

- measure distance between indicator and front feet.
- measure distance between front and back feet.

Step 7: Layout graph paper

- mark indicator position

- mark feet position.
- remember to mark + and - signs

(this eliminates confusion)

example: graph layout

Lesson 4 Page 10
MACHINE ALIGNMENT REVERSE INDICATOR METHOD

Step 8: Preliminary Horizontal Move

Step 9: Check for Soft Foot

Step 10: Perform Vertical Move

Step 11: Tighten all bolts and recheck indicator readings.

Step 12: Remove alignment brackets.

6.0 LEARNING HOW TO GRAPH PLOT

Graphical alignment is a technique that shows the relative position of

the two shaft centerlines on a piece of square grid graph paper.

First we must view the equipment to be aligned in the same manner

that appears on the graph plot. In this example we view the equipment
with the "FIXED" on the left and the "MOVEABLE" on the right. This will
remain the same view both vertically and horizontally.

Lesson 4 Page 11
MACHINE ALIGNMENT REVERSE INDICATOR METHOD

Scale: Each Square = 1.0"

Scale: Each Square × = .001"

Measure:
A. Distance between indicators = 10"
B. Distance between indicator and front foot = 5"
C. Distance between feet =11"

To eliminate confusion the plus and minus signs

should be marked on the graph.

Graph paper layout

7.0 VERTICAL MOVE

Lesson 4 Page 12
MACHINE ALIGNMENT REVERSE INDICATOR METHOD

The vertical move is the part of the alignment process that aligns the
two shaft's centerlines nto their proper up and down position. Usually
you will have to add or remove shims in this step. The indicators are
zeroed on the top and read at the bottom. (start with a plus + reading if
you need to compensate for sag)
Example:
the indicator on the motor pump -12

the indicator on the motor reads +8

This means that the shafts are one half the total indicator reading from
being collinear at these points.

Using a square grid graph paper to illustrate the position. Under the
indicator position mark the point that is half the indicator reading. ( -6
for pump side indicator and +4 for the motor side indicator) Connect
these two points with a line and then continue the line past the lines
representing the feet on the motor. The graph now shows that the front
foot needs to have a .003" shim added and the back foot needs to have
a .001" shim added.

Now
with your shims in place. Tighten all bolts and take and check your
readings. If the readings are within tolerance than your equipment
should be aligned.

Lesson 4 Page 13
MACHINE ALIGNMENT REVERSE INDICATOR METHOD

8.0 HORIZONTAL MOVE

The horizontal move is the part of the alignment process that aligns the
shaft's centerlines from side to side. View the machine from the pump
end, zero the indicators on the left, and then rotate and read on the
right. Make sure that you always view the pump from the same
direction in order for you to keep the left and right directions correct.
There is no sag compensation on the horizontal move.

For example:
the indicator on the pump reads –8
the indicator on the motor reads +10

The shafts are collinear at 1/2 the Total Indicator Reading.

Using graph paper to illustrate the position. Under the indicator

position mark the point that is 1/2 the indicator reading. (-4 for the
pump and +5 for the motor) Connect these points and extend the line
past the motors feet. This will show you how much you need to move
the motor for horizontal alignment.

These indicator readings mean that you need to move the motor:

front foot .006" left

back foot .007" left

Lesson 4 Page 14
MACHINE ALIGNMENT REVERSE INDICATOR METHOD

You can avoid graphing the horizontal move by zeroing the indicators
on the left and rotate them to right. Now turn the indicator needles half
way to zero and begin to walk the motor into place by moving the
fartherest foot toward zero and then the nearest foot. Slowly walk the
motor into place by alternating the moves until you obtain two zero
indicator readings.

Now begin the procedure for the vertical move. Be sure to check your
equipment for sag and soft foot.

Lesson 4 Page 15
Machine alignment Reverse Alignment Method With Thermal Growth

LESSON REVERSE ALIGNMENT METHOD WITH

5 THERMAL GROWTH ALLOWANCES AND
TEMPERATURE GROWTH FACTORS
LECTURE

Objectives
To perform alignment by reverse indicator method taking into
account different thermal position or growth factor calculation.

1.0 REVERSE ALIGNMENT METHOD

Before the machines can be successfully aligned, the desired Ambient

Condition positions must be determined. Once both the present and
Desired readings are ascertained, the necessary vertical and horizontal
moves can be computed. Although the corrective adjustment may be
plotted on suitable graph paper, mathematical computations offer
greater accuracy. However, for demonstration purposes, both methods
will be used in the following example.

2.0 CALCULATING THE ADJUSTMENTS

2.1 DESIRED STATE OFFSET INDICATOR READINGS AT

AMBIENT CONDITIONS

Readings recommended by the manufacturer necessary to

compensate for thermal movement, in hopes of achieving collinear
alignment at normal service condition.

Fig. 1-1

2.2 PRESENT STATE INDICATOR READINGS OBTAINED

AT AMBIENT CONDITIONS

Lesson 5 Page 1
Machine alignment Reverse Alignment Method With Thermal Growth

Fig.1-2

2.3 ALIGNMENT LANGUAGE

1. Ambient Condition: A machine is considered to be at

AMBIENT CONDITION when it is shutdown, blocked in, and
hascooled until its temperature has equalized to atmospheric
conditions with lube oil on.

2. Service Conditions: A machine is considered to be at

SERVICE CONDITION when it is stabilized at its normal
operating condition.

3. Collinear Alignment: A machine is con. sidered to be

COLLINEAR ALIGNED when the shafts are in the same straight
line (no misalignment).

4. Offset: Offset is the measured distance from the shaft center of

one machine, to the projected center line of the second
machine. Vertical offset is measured from top to bottom.
Horizontal offset is measured from left to right.

5. Total Indicator Reading (TIR): The differential between two

indicator readings obtained 1800 apart. When zeroed at the top
and rotated 1800 to the bottom, the reading obtained is the
vertical total indicator reading. If the indicator was zeroed at the
left side and rotated 1800 to the right side, the reading obtained
would be horizontal total indicator reading. The total indicator
reading is always twice the offset.

6. Offset (TIR): Same as 4 above but expressed in total indicator

readings.

7. Sweep Readings: The Sweep Readings are the readings

obtained by sweeping the coupling 3600 with the dial indicator
and noting readings at 900 intervals. The readings are taken at
Top (T), Right (R), Bottom (B), and Left (L) of coupling being
indicated.

Lesson 5 Page 2
Machine alignment Reverse Alignment Method With Thermal Growth

8. Present State: A machine's present state is the bench mark of

an alignment problem. This is the original misalignment at
ambientcondition prior to making any corrections.

9. Desired State: A machine's desired state is the alignment

target. This is the desired ambient condition alignment offset
needed to compensate for the thermally - induced movement to
be incurred between ambient and service conditions.

10. Final Readings: Readings obtained after the final adjustment

has been made.

11. Indicator bracket sag is the amount of deflection by the

indicator bracket attachment induced by gravity force. A
correction for this deflection should be applied to the indicator
readings

SYMBOLS:
T = Top of Coupling
R = Right side of Coupling
B = Bottom of Coupling
L = Left side of Coupling
TIR =Total Indicator Reading
Vo = Vertical Offset
Ho = Horizontal Offset
V1 = Distance from the present to desired state of Mach B's
projected CL at Coupling "A"
V2 = Distance from Coupling "B's" present to desired state
less V1

Note: V1 and V2 are only intermediate steps needed to form

a working Triangle for calculations.

= Near Foot of Machine B or the Nf

Measured Point Nearest to the
Coupling

Ff = Far Foot of Machine B or the Measured point farthest

from the Coupling

Lesson 5 Page 3
Machine alignment Reverse Alignment Method With Thermal Growth

D1 = Distance between the Indicator Planes, Plunger-to-

Plunger.

= The distance from the Indicator D2

Plane of Machine "A" to the Near
Measured Point of Machine "B"
(Nf)

CL = Center Line

CZ = Center Zone, Center of the Linear Zone of Proximeter

Graph Curve.

2.4 MEASURED DISTANCES

In order to graph or mathematically compute the correct adjustment

needed to achieve the desired alignment, it will be necessary to
establish three (3) measurements. These measurements are critical to
the success of one – move alignment and must be accurate to within
1/16 inch.

1. We must know the distance between the planes in which the

dial indicator readings were taken (Plunger to Plunger). This
distance is referred to as D1.

2. It is also necessary to know the distance from the indicator

plane of machine “A” to the near adjustment plane of
machine “B” . This is the distance between the indicator
plane of Machine “A” to the near foot (Nf) of Machine “B”
referred to as D2.

3. The distance between the indicator plane of “A” to the far

adjustment plane is needed. This distance is referred to as
D3 and is the distance between the indicator plane of
Machine “A” to the far foot (Ff) of Machine “B”.

Lesson 5 Page 4
Machine alignment Reverse Alignment Method With Thermal Growth

Fig.1-3

2.5 ALIGNMENT MOVEMENTS

The vertical and horizontal adjustment necessary to move Machine “B”

from PRESENT to DESIRED relative position can be computed. The
shim adjustment at the near foot (Nf) and far foot (Ff) can be
determined in the vertical movement formula.

The side to side movement at near foot (Nf) and far foot (Ff) can be
determined in the horizontal movement formula.

1. Vertical Movement.

B3  B1 (10)  (36)
V1  or  23
2 2

B4  B2 (20)  (48)
V2   V1or  (23)  11
2 2

V2  D2  1112
Nf  V1or  (23)  40
D1 8
At near Foot of "B", Add 0.040 Inch Shims

V2  D3
Ff   V1or  11 24  (23)  56
D1 8

At Far Foot of "B", Add 0.0.056 Inch Shims

Lesson 5 Page 5
Machine alignment Reverse Alignment Method With Thermal Growth

2. Horizontal Movement.

(R 3  L3 )  (R1  L1 ) (15)  (5)  (24)  (12)

V1  or  16
2 2

(R4  L4 )  (R2  L2 ) [(6)  (14)] [(22)  (26)]

V2   V1or  (16)  22
2 2

V2  D2  22 12
Nf  V1or  (16)  17
D1 8

At near Foot of "B", Move Right 0.017 0.040 Inch

V2  D3
Ff   V1or  22  24  (16)  50
D1 8

At near Foot of "B", Move Right 0.017 0.050 Inch

Note: Observe all algebraic signs. If answer is plus, move machine “B”
up or left. If answer is minus move machine “B” down or right.

Fig.1- 4

Lesson 5 Page 6
Machine alignment Reverse Alignment Method With Thermal Growth

Fig.1- 5

Instructions for using the alignment specifications and worksheet. Each

note in the discussion is indicated on the attached example by a circled

number.

3.0 DETERMINING AMOUNT OF INDICATOR BAR SAG

indicator bar sag can be determined by firmly affixing it to a sag – free

shaft mandrel, usually 4 – inch diameter or larger, dependent on
length. The mandrel may be supported between lathe centers,
mounted on knife edges, or held and rotated by hand. With the
indicator bar positioned on top of the mandrel, the sag of bar will be
down toward the mandrel. Set indicator face to read zero at this
position. By zeroing the indicator, you have errored the indicator by the
amount of the sag. Rotate the mandrel 180º (indicator at bottom
position). The indicator bar will sag away from the mandrel; hence the
indicator reading will be twice the actual bar sag.

 TIR 
  Sag
 2 

Lesson 5 Page 7
Machine alignment Reverse Alignment Method With Thermal Growth

Once the indicator bar sag is determined, it should be permanently

stamped on the bar. This true sag must be accounted for when
determining sweep readings.

4.0 CORRECTING BY THERMAL GROWTH FACTOR

When machinery is operating the moving parts cause friction that in turn
creates heat buildup causing the machinery to expand. This expansion in
the machinery is called Thermal Growth. The amount of movement can be
predicted when you know the machinery's material, temperature change,
and the distance between shims and shaft centerline.

4.1 CALCULATING THERMAL MOVEMENT

Fig.1-6

Growth = T x L x C Growth in mils

T = Change in F L = Inches, shim to shaft center line

C = Growth factor

Example:

T = 40 L = 14” C = 0.0063

T x L x C = Growth

40 x 13 x 0.0063 = 3.27” = 0.003”

Lesson 5 Page 8
Machine alignment Reverse Alignment Method With Thermal Growth

Growth Factors:
0.0126 = Aluminum
0.0100 = Bronze
0.0059 = Cast Iron
0.0074 = Stainless
0.0063 = Mld Steel

4.2 GRAPHING THERMAL MOVEMENT

Most machinery must be misaligned cold so that the shafts will be

collinear during normal operating conditions. Graphing the move
above shows us that the pump does not move (no change in
temperature) and the motor rises an estimated .003" (3 mils).

Fig.1-7 Pump stays the same

Motor rises .004" at both feet

Lesson 5 Page 9
Machine Alignment Vertical Pump Alignment

LESSON VERTICAL PUMP ALIGNMENT

6 DETAILED PROCEDURE BY
LECTURE CALCULATION

Objectives
The objective of this module is to make students understand the
basic concept and procedure of vertical pump alignment.

1.0 IMPORTANT FUNDAMENT POINTS FOR VERTICAL ALIGNMENT

Please note down following points to understand and perform vertical

pump alignment.

a. In vertical pumps we will only add the shim to correct angular

misalignment and we will make correction of angular misalignment
in two planes.

b. The angular correction is done with the help of simple

relation between distance from centre of bolt hole to
centre of opposite bolt hole of flange, coupling diameter,
correction shim required and angular reading (difference
of gap between coupling hubs top and bottom).

c. You should go through the derivation of angular

correction formula.

d. It should be noted that when we make angular correction

it will change the radial position.

e. The change of radial alignment or position can be

calculated easily by another relation which is between
correction shim thickness, flange diameter where shims
are added, angular reading and distance between
shimming point to coupling hub face. Check the figure
and derivation. There is also example of solved problem.

Remember we select two planes for angular correction.

1.1 VERTICAL PUMP ALIGNMENT AND EFFECT OF VERTICAL

ANGULAR CORRECTION ON RADIAL POSITION.

See fig 1
Y is the distance between flange opposite bolts centers.
X is the shim required for angular correction .

Lesson 6 Page 1
Machine Alignment Vertical Pump Alignment

C is coupling diameter change due to shim x added.

b is distance from shimming point to coupling hub face.
R is the shift in radial position(radial alignment)
By geometry of triangles we can get the simple relation as given below.

See fig 1

A/C=X/Y X(angular correction shim required)=A/C * Y

R/b=X/Y R(radial position shift)=X/Y * b

For angular alignment Shim required = Angular reading x Distance

between opposite bolts of flange .

Coupling Diameter Radial alignment position change due to angular

correction .

= Shim Added x distance between shimming point and coupling

hub face.

Distance Between opposite bolts holes centers of flange

b
C
A

Fig. 1-6

Lesson 6 Page 2
Machine Alignment Vertical Pump Alignment

1.2 EFFECT OF ADDING SHIMS (FOR FACE CORRECTION) ON

RADIAL READINGS IN VERTICAL PUMPS

See figure 2.

Flange DD’ position shifts to position DD” and Shaft YA shifts to new
position YA’ .

B = G .
W DD”

B = G*W
DD”

W = Distance from shimming point to coupling hub

G = correction shim thickness.
DD’ = Distance between opposite bolts holes centres of flange
B = Change in radial position. Point(A) shifts to Point (A’)

D Shimming Distance D”

DD” Shifts Y
To DD”
G

D’
YA Shifts
To YA’

A
B

A’

Fig 2-6

Lesson 6 Page 3
Machine Alignment Vertical Pump Alignment

SOLVED EXAMPLE

. 0

+2 A +6 D DD’ = 22” D’

+8

ANGULAR READING

E’

FLANGE

IS.D = 0.001”
Coup Dia = 6”

Distance Between Flange and Coupling Hub = 20”

DD’
22”
C

6” 20”

20”
A’

Fig3-6

Lesson 6 Page 4
Machine Alignment Vertical Pump Alignment

VERTICAL PUMP ALIGNMENT CALCULATION.

Shim reqd at D’ = 4 x 22 = 14.65 thous or mils.

6

Shim reqd at E’ = 8 x 22 = 29.28 mils.

6

When we put shim of 14.65 mils at D’ we will also need to put shim of
14.65/2 at E and E’ (which is 7.3 mils) so that there is no soft footness
or gap.

When we put shim of 29 mils at E’ we will also need to put shim of 29/2
mils shim at points D and D’ (which is 14.5 mils)

So net result is:

AT D’ = 14.65 + 29/2

= 14.65 + 14.5 = 29 mils

AT D = 29/2 = 14.5 mils

AT E’ = 295 + 14.5/2 = 36.3 mils

AT E = 14.5/2 = 7.25 = 7 mils

But if we remove shim of same size from all four positions which are D,
D’, E, E’ there will be no effect or change in alignment.

So net shims reqd to be added at points D, D’, E, E’ are:

AT D’ = 29 – 7 = 22 mils

AT D = 14.5 – 7.2 = 7.3 = 7 mils

AT E’ = 36.3 – 7.2 = 29 mils

AT E = 7.25 – 7.2 = 0 mils

Lesson 6 Page 5
Machine Alignment Vertical Pump Alignment

DD’
24”
C

6” 20”

A’

Fig 4-6

Lesson 6 Page 6