■ Complete Guide to Machine Alignment
Machine alignment is essential for efficient, reliable, and safe operation of rotating equipment. This
guide provides in-depth knowledge, detailed checklists, and practical implementation steps with
illustrative diagrams.
1. What is Machine Alignment?
Machine alignment is the process of positioning two or more machines so that their rotational
centerlines are collinear. This is especially crucial for rotating machinery like motors and pumps.
2. Types of Alignment
- Shaft Alignment: Horizontal, Vertical, Parallel (Offset), Angular, Combined. - Bore/Geometric
Alignment: Ensures alignment of internal components. - Laser Alignment: Uses laser beams for
precise, real-time alignment feedback.
Figure 1: Types of Shaft Misalignment (Angular, Parallel, Combined)
3. Causes of Misalignment
Common causes include improper installation, thermal growth, foundation settling, pipe strain, and
wear over time.
4. Effects of Misalignment
- Increased vibration and noise - Bearing and seal failure - Energy inefficiency - Shaft fatigue and
eventual failure
5. Alignment Methods
- Straightedge & Feeler Gauge: Simple, rough method. - Dial Indicator: Accurate but manual and
time-consuming. - Laser Alignment: Fast, highly precise, with live correction feedback.
Figure 3: Dial Indicator Setup for Shaft Alignment
Figure 4: Laser Alignment Setup
6. Alignment Tolerances
Tolerances depend on machine type and speed. For 1500 RPM: Offset ≤ 0.05 mm, Angular ≤ 0.1
mm per 100 mm shaft length.
7. Alignment Process Steps
■ Step 1: Setup
• Lockout the motor & pump.
• Clean the base, shaft ends, and remove any old shims.
• Disconnect suction/discharge piping to check pipe strain.
■ Step 2: Check Soft Foot
• Loosen one foot at a time (motor side).
• Insert feeler gauge under each foot to detect gaps.
• Shim where needed (typically ≤0.05 mm gap acceptable).
■ Step 3: Rough Alignment
• Place a straightedge across motor and pump shaft coupling.
• Use feeler gauges to check vertical offset.
• Adjust motor position to make shafts approximately colinear.
■ Step 4: Dial Indicator Alignment
• Mount dial indicators on both couplings.
• Rotate shafts together to 0°, 90°, 180°, 270°.
• Record readings to determine offset and angular misalignment.
• Example: 0° = +0.10 mm, 180° = -0.05 mm ⇒ adjust shims.
■ If Using Laser Alignment Tool
• Fix brackets and target heads to both shafts.
• Use display to view Live Offset & Angular Misalignment.
• Use real-time guidance to adjust position.
■ Step 5: Correct Misalignment
• Shim front/rear motor feet to correct vertical misalignment.
• Use jacking bolts or pry bar to move motor horizontally.
• Retighten bolts and remeasure.
■ Step 6: Confirm Alignment
• Final tolerance for 1500 RPM: Offset <0.05 mm, Angular <0.1 mm/100 mm.
■ Step 7: Finalization
• Tighten all bolts to torque spec.
• Recheck soft foot and alignment one last time.
• Reconnect piping, ensuring no pipe strain.
• Run pump and monitor vibration/noise.
Figure 2: Soft Foot Condition - One Foot Not Touching Base
8. Tools Used in Alignment
| Tool | Use | |------|-----| | Feeler gauge | Rough alignment | | Dial indicator | Accurate TIR readings |
| Laser alignment tool | High-precision measurement | | Spirit level | Level checks | | Precision
straightedge | Visual checks | | Jack bolts | Controlled movement | | Shims | Elevation adjustments |
9. Alignment Best Practices
- Check soft foot first - Account for thermal growth - Use laser alignment tools if possible - Perform
vibration check after alignment - Align under operational conditions if feasible
■ Machine Alignment Checklist
■ Pre-Alignment Checks
Task Status
Ensure lockout/tagout is applied ■
Clean mounting surfaces, shaft ends, and couplings ■
Check for any visible damage or wear on couplings ■
Check for soft foot condition (use feeler gauge/shim method) ■
Confirm baseplate/foundation is rigid and level ■
Verify pipe strain is eliminated (disconnect pipe, observe movement) ■
■■ Rough Alignment (Initial Positioning)
Task Status
Use straightedge and feeler gauge between couplings ■
Ensure both shafts are roughly centered ■
Bolt machine loosely (not tightened fully) ■
■ Precision Alignment (Dial or Laser)
Task Status
Mount dial indicator or laser bracket ■
Measure horizontal & vertical offset and angularity ■
Record readings at 0°, 90°, 180°, and 270° (if using dial) ■
Calculate corrections (or get direct readout from laser tool) ■
Adjust motor position: sideways (horizontal), shim (vertical) ■
Re-tighten bolts and re-measure ■
Repeat until within acceptable tolerance ■
■ Final Checks
Task Status
Confirm all bolts are torqued properly ■
Recheck soft foot after final tightening ■
Verify final alignment within tolerance (e.g., <0.05 mm offset) ■
Document final readings ■
Run test for vibration or abnormal noise ■
