ADHOC Team Training

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‫شـركـة مصــر‬
‫للصيانـة‬
Egyptian Maintenance Company
AD-HOC Team Specialized
Training Courses
Professional Alignment
Course
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MISALIGNMENT
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• 40% of machine failure is due to

misalignment.
• Misalignment generate additional dynamic
forces on the structure.
• Increase power consumption by 8%.
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• It is the process to bring the
shafts center line of Movable
machine to be in-line with
Stationary machine.
• Adjustment of the relative
position of two coupled
machines, so that the center
line of the axis will be
concentric when the machines
are running during normal
operation.
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• Side Effect of
Misalignment
– Bearing failure.
– Vibration.
– Coupling Failure,
• Even in flexible types!
– Internal heating.
– Shaft Fatigue.
– Seal Leakage.
– High energy consumption.
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Misalignment is the main cause of
Machine Potential Failure
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Preloaded
Bearing bearing
failure.
3

Life =
16700

RPM [ Capacity * Load

Force ]
Bearing life proportional to
Cubed the inverse of force
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Seal Leakage
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High Vibration
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Coupling Failure, even in flexible
types
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Shaft Fatigue
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Internal heating.
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High energy consumption.
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1-What is center of mass ?

Introduction
2-What is center of rotation ?
3-What Co-linearity ?
4-What is Misalignment ?
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1- Center of mass
The center line of the mass around
which the body is balanced.
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2- Center of rotation.
The axis at which the body rotates
around.
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3- Co-linearity
When the center of rotation of two
shafts form one single line.
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4-
4- Misalignment
Misalignment
When
Whenthethe
center of rotation
center of twoof
of rotation shafts
two are
shafts
not while
are not
co-linear the machines
co-linear are
while the machines
operating
are operating.
.
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Types of misalignment.
1-Offset Misalignment
(Parallel
Misalignment)
2-Angular
Misalignment
3-Offset & Angular
Misalignment (Combined
Misalignment)
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Planes of Alignment.
1-Horizontal alignment

2- Vertical alignment
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Alignment procedures
1- Pre-alignment checks.
2- Alignment check.
3- Alignment correction.
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1- Pre-alignment checks.
1.1- Identify from the manufacture recommendation the
1.1.1 Cold alignment values.
1.1.2 Tolerance.
1.1.3 Thermal compensation values if found.
1.1.4 Distance Between Shaft Ends (DBSE).
1.2- Visual check.
1.2.1 Bent or broken bolts.
1.2.2 Cracked or chipped concrete or grout.
1.2.3 Machine condition (leakage,……..etc.)

1.3- Deciding the method of alignment

1.3.1 Straight edge and filler method.
1.3.2 Rim-Face method.
1.3.3 Reverse Rim method.
1.3.4 Laser method.
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1- Pre-alignment checks.
1.4 Equipment lock-out and Tag-out procedures
1.5 Check shaft and coupling run out.
1.6 Check for correction of soft foot.
1.7 Check for correction of pipe strain.
1.8 Check the DBSE.
1.9 Prepare shims with deferent sizes with the same shape as
original, stainless steel.
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1.5-How to check coupling Run-out
Fix the magnetic base on the machine Coupling Run-out
skid and mount the indicator on the rim or
on the face, depress the indicator and
then zero. Rotate the shaft and record
the reading at the 3,6,9, and 12 clock.

Rim Run-out Check

Face Run-out Check

 ADHOC Team Training
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1.6-How
1-Move indicators to 12 o'clock position, depress
indicators and then zero. Loosen one base bolt. If
indicator moves away form zero, place the amount of
shims that will slide under that foot. Retighten bolt and
make sure the dial indicator needle does not move.
Repeat this procedure for the remaining feet.
2-Fix the magnetic base on the machine skid, place
the indicator on the bolt head, depress indicators and
then zero. Loosen one base bolt. If indicator moves
away form zero, place the amount of shims that will
slide under that foot. Retighten bolt and make sure the
dial indicator needle does not move. Repeat this
procedure for the remaining feet.
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Bent Bent
Up Down

Parallel Baseplate
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 ADHOC Team Training
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Checking
Pipe strain occurs when the pipe and pump, due to
misalignment, are forced together. This will
introduce a lot of strain on the machine attached to
the pipe. The problem seen in the alignment
process is that the “stationary” machine will move
if we loosen the bolts.
The effect of pipe strain can be checked by using a
dial indicator while the flange is loosened.
1.Mount the dial indicator with the magnetic base
on the frame or base plate or as described in the
“run-out procedure.
2.Zero the indicator.
3.Loosen the bolts on the flange and read the value
on the indicator.

The pipe strain check can obviously also be done

with a laser based shaft alignment system in the
same procedure.
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2- Alignment
check.
Alignment methods
2.1 Straight edge and filler method.
2.2 Dial indicator method.
2.3 Laser method.
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2.1 Straight edge and filler method.

Use Straight
Edge and
Feeler
Gauges
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2.2 Dial indicator method.
Some concepts
The dial indicator is device that
measures relative distance with
accuracy up to 1/100 of a
millimeter.

Note: In positive (+ve)

Out negative (-ve)
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Bar Sag
0
Dial Indicator Bar

Mandrel
Dial and Indicator must be mounted on
Mandrel to simulate exact mounting
distances on equipment being aligned

Rotate Mandrel 180* to identify Sag

-10
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2.2 Dial indicator

method.

2.2.1 Rim-Face 2.2.2 Reversed-Rim

Alignment Method Alignment Method
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Rim-Face Alignment Method
-Take the initial set of readings.
a. Zero the dial indicators at the 0o position.
b. Rotate the shafts simultaneously taking readings every
90o, (0o, 90o, 180o, 270o). Record readings on the reverse
dial indicator worksheet.
-Determine d' the initial readings are good.
a. Add top Cr) and bottom (B) together for both planes and
the two side readings (S) together for both planes.
b. Take the difference of the two readings. If the difference
exceeds 0.002", there is something wrong with the
readings. Inspect the set up and make any necessary
adjustments.
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Dials reading example:

0 0

-3 10
R A
43 -5

30 5

Remember, when the dial indicator reads positive, the probe is being
pushed in. When it reads negative, the probe is extended.
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Dials reading example:

Add sag reading 10

0 0

-3 10
43
R A
-5

40 5

Remember, when the dial indicator reads positive, the probe is being
pushed in. When it reads negative, the probe is extended.
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How can we analyze

this reading

Graphical Mathematical
method method
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Graphical method
Example vertical direction
A Motor
First divide the radial reading by 2
A = 100mm
A = hub diameter
B = distance between B = 300mm B C
hub and front feet C = 500mm
C = distance between front
feet and rear feet
100
5
TIRface The face dial reading TIRRim
TIRRim The Rim dial reading 2 S1
TIRface = 5
TIRRim = 40 S2
A S1 from graph is - 5 (remove 5)
Tir
face S2 from graph is +20 (add 20)
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Tir face
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Mathematical method
D = hub diameter
D Motor
L1 = distance between
hub and front feet D = 100mm
L2 = distance between hub L1 = 300mm L1
and rear feet L2 = 800mm L2

L1
S1= D ×TIRface - ( TIRRIM
2 ) =
300
× 5- ( )
40
= -5
100 2

- ( ) × 5- ( )
L2 TIRRIM
S2= D ×TIRface 2
=
800 40
= 20
100 2
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2.2.2 Reversed-Rim Alignment Method
-Take the initial set of readings.
a. Zero the dial indicators at the 0o position.
b. Rotate the shafts simultaneously taking readings every
90o, (0o, 90o, 180o, 270o). Record readings on the reverse
dial indicator worksheet.
-Determine d' the initial readings are good.
a. Add top Cr) and bottom (B) together for both planes and
the two side readings (S) together for both planes.
b. Take the difference of the two readings. If the difference
exceeds 0.002", there is something wrong with the
readings. Inspect the set up and make any necessary
adjustments.
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Dials reading example:

0 30

7 7
R1 R2
23 13

20 0

Remember, when the dial indicator reads positive, the probe is being
pushed in. When it reads negative, the probe is extended.
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Dials reading example:

Add sag reading 10

0 20

7 7
Ra Rb
23 13

30 0

Remember, when the dial indicator reads positive, the probe is being
pushed in. When it reads negative, the probe is extended.
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How can we analyze

this reading

Graphical Mathematical
method method
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Graphical method a
Example vertical direction Motor
First divide the radial reading by 2 b
A = 200mm
A = distance between
B = 200mm
A B C
the 2 dials
C = 500mm
B = distance between
hub and front feet
C = distance between front
feet and rear feet 15
10
5

-7.5

S1 from graph is -5 (remove 5)

S2 from graph is 7.5 (add 7.5)
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Mathematical method a
A = distance between
dials “a” and dial “b”
Motor
b
B = distance between
dial “a” and front feet A = 200mm
C = distance between A
B = 400mm
dial “a” and rear feet B
C = 900mm
C
a-b a
B
S1= A ( 2 )- 2
=
400
200
( 30-20
2
)- 30
2
= -5

a-b a
C
S2= A ( 2 )- 2
=
900
200
30-20
2
-
30
2
= 7.5
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Some dial tricks
Sagging indicator brackets
Sticking / Jumping dial
Hands
Lower resolution=rounding
losses
Reading errors: +\- sign error
Parallax error &mirror
image
Play in mechanical
linkages
Tilted dial indicator=offset
error
Axial shaft play = gap
error
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2.3 Laser method.
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Soft foot using
laser method
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Alignment Tolerance
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Alignment Tolerance
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Machine train
alignment

Machine train alignment is

probably the most difficult and
demanding task of all
alignment engineering skills.
Often a machine train is part
of a critical production, the
most expensive and the most
costly to production loss when
it goes down.
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More than
2 feet ? A

B C D
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Soft Foot
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Soft Foot

Machine
Foot 0
5
10
10
Shims
5

5
feeler gauge set 5
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Detecting
Misalignment
Angular misalignment
causes axial vibration at
the running speed
frequency (1x).
Angular Misalignment, a
phase shift of 180º will
exist across the coupling
or machine, Axially.
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Detecting
Misalignmen
t
•Parallel misalignment
produces radial vibration
at twice the running
speed frequency (2x).
•A phase shift of 180º
will exist across the
coupling or machine in
radial direction.
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Detecting
Misalignment

• Infrared Thermograph