Shaft Alignment
Contents
Introduction
to alignment
Types of misalignment
Alignment Methods
Causes/Effects of misalignment
Couplings
Types of coupling
Shaft Alignment
Alignment
is a technique to bring rotational axis
of coupled machines co-linear.
Every
shaft, bent or straight, rotates about an
axis that forms a straight line.
Co-linearity
Shafts in this same straight line are
considered co-linear, or in the same
straight line.
Types of Misalignment
Offset, or Parallel the
shafts are parallel to each
other, but are not coplanar, or in the same
plane. This can be both
vertical and horizontal.
Angular the shafts are not in
the same plane, which causes a
difference in measurement
between measurements made
180 degrees opposite on the
coupling faces.
Its almost always a combination of both!
Parallel Offset
Parallel
offset between motor and pump
Angular Misalignment
Angular misalignment between motor and
pump
Shaft Alignment Methods
Straight Edge and Feeler gauge
Reverse Indicator Method
Face and Rim
Laser Alignment
Causes of Misalignment
Bearing
wearness
Failure of seals or mechanical seal
Extreme temperatures
Piping stresses
Distortion of base plate
Not aligned right from the begining
After effects of misalignment
Excessive
Vibration
Coupling Failure
Bearing Failure
Mechanical Seal / Packing Failure
Shaft Failure (Bent / Broken)
High Energy Consumption
Low Efficiency
Pre-alignment Assumptions
Can
shafts be rotated freely
Soft Footing
Soft foot can be offset, angular,
or both
Thermal
Growth
Misalignment affecting bearing life
Bearing life and misalignment
Misalignment affecting energy
consumption
Energy consumption and misalignment
Misalignment causing high
temperature
.
Misalignment a source of Vibration
Misalignment causing vibration
Misalignment is single greatest source of machine
vibration shown on the pie chart. Its
impact is dramatically shown in the two
thermographic images of the temperature of an
electric motor housing before and after shaft
alignment. The 30C degree temperature drop
represents several years of additional trouble-free
operating life for the motor.
Validity and Repeatability of data
Obtain two consecutive sets of data and
check data for repeatability.
For each set of data, ensure the data is
mathematically valid. If a set of data
obtained on the face or the rim is valid, the
sum of the top (12:00) and bottom
(6:00) readings will equal the sum of the side
(9:00) and side (3:00) readings
Straight Edge
Straight edge method
Better than doing nothing
Quick and easy
Accuracy varies greatly between users
Gives no real guidance on how to align
Face and Rim Method
Face and Rim
When using the rim-face method, one common source of error
specifically related to the validity and repeatability of the face
readings is error due to shaft end-play (axial movement.) Axial
movement of either shaft will adversely impact the accuracy of
the face readings.
Assuming that the source of end-play cannot be eliminated and
that the rim-face methodis to be used, the only accurate way to
determine the amount of error and correct for it isto set up two
face dials 180 degrees apart and obtain two sets of face data
permeasurement. Any difference in the numerical values, other
than the mathematicalsigns, which will obviously be reversed,
is due to axial movement. The error can be determined and
mathematically subtracted from measurements
Face and Rim Method
Now
suppose readings are
0
+.005
Rim
+0.010
+.005
-.007
Face
-.005
+.002
Face and Rim
Now measure following distances.
D=dia of hub where readings are being taken.
L1=distance from face of motor hub to center of front motor foot
L2=distance from face of motor hub to center of rear motor foot
TIRF= total indicator reading on face
R=rim reading which if+ will be added and subtracted if negative
y1=L1/D*TIRF+R/2
y2=L2/D*TIRF+R/2
s1=L1/D*TIRF+R/2
s2=L1/D*TIRF+R/2
if rim reading is + it must be added and if - it must be subtracted
Face and Rim
y1
= 12/6 X (-.005) + .010/2 = - 0.005 Take
out .005 shims from front foot.
y2 = 24/6 X (-.005) + .010/2 = - .015 Take
out .015 shims from rear foot.
Similarly 3 and 9 O clock readings will be
used to calculate s1 and s2
Reverse Indicator Method
Reverse Indicator Method
The reverse indicator method is an acceptable method, but it
does take a great deal of time.
Very accurate especially for small diameter flanges
Not affected by axial float.
Can be used with a flexible coupling in place.
You have to rotate both shafts
Reverse Indicator Method
Essentially, the fundamental principle of the reverse rim dial method and
laser systems is to determine shaft position based on two different offset
measurements (rim readings) taken at two different points along the length
of the shafts. Since no face readings are obtained with this method,
measurement inaccuracies due to shaft endplay are essentially eliminated.
Reverse Indicator Method
Pump in this example will be fixed and electric motor will be moved into
alignment with pump. The alignment can be done either with coupling
installed or coupling totally removed. Attach the dial indicator bracket
to the movable unit (motor) coupling hub or shaft whichever is more
convenient and rigid. Obtain the readings on the fixed unit (pump)
coupling hub or shaft.
Also attach the dial indicator bracket to the fixed unit (pump) coupling
hub or shaft and obtain the readings on the movable unit coupling hub
or shaft. All readings must be taken on the periphery of coupling hub
shaft. All indicator readings must be recorded as viewed from fixed unit
or stationary unit. Readings are taken by rotating shaft and noting dial
indicator at increments of 90 (i.e. starting at 12 o clock position and
taking readings at 3,6,9 o clock positions and ending at 12 o clock
where it was zeroed.
Reverse Indicator Method
Dial on pump
Dial on motor
0
-.015
-.005
-.02
+.004
-.006
+.01
Reverse Indicator
Total indicator readings are divided by two to get actual differences pump line is
our reference, reading on dial on pump will be plotted such that + reading will
be plotted above the graph and -ve below the graph centerline. Readings on
dial on motor will follow opposite convention i.e -ve above centerline and +ve
below. In this case -.020"/2 =-0.010 will be plotted below as it is negative and
+0.010"/2=+0.005" though positive will be plotted negative as this is reading
taken when dial is on motor.
motor
pump
c1
f1
f2
Reverse Indicator
Now measure following distances.
c
distance from first indicator riding on pump hub
to where the second
indicator is riding on motor
hub
f1 distance from first indicator on pump hub to
center of front feet of motor (movable unit)
f1 distance from first indicator on pump hub to
center of rear feet of motor(movable unit)
Suppose readings are
Reverse Indicator
Reverse Indicator
Laser Alignment
CSI 2130
The CSI 2130 can be
equipped with up to 7 different
applications:
Route-based vibration collection
Advanced vibration analysis
Dynamic balancing
Basic/advanced laser alignment
Transient analysis
ODS/Modal analysis
Cross-channel analysis
CSI2130
The CSI 8225 Laser Alignment system is designed to
get the job done quickly and accurately.provides a
confidence check for every alignment correction
before the machine is moved. Review alternate
solutions for a bolt bound machine with the touch of a
button. Adjust the laser heads to a convenient angle
to watch the real-time display of changes to
alignment. Instant feedback on tolerance is provided
in the formof an intuitive bulls-eye graphic.
When the job is complete, load the data to AMS
Suite: Machinery Health Manager for beforeandafter documentation and reporting.
CS
2130 Laser Heads
Laser Alignment
CS2130 LASER HEADS
NEW colour coded laser heads which match equipment
shown on the screen in the alignment program
Each laser head has its own inclinometer for
double the accuracy
Laser head takes a data point every 2 deg of rotation,
so 360 total data points for a full rotation
NEW NiMH batteries for increased power, battery
life and enhanced RF signal strength
Resetting the laser heads is simply done using the On/Off key
NEW Dual Live Mode allows
live simultaneous vertical and
horizontal alignment
NEW Auto Data Checker
validates alignment data as it is
dumped
The radial vibration caused by coupling misalignment is typically highly directional on
both the driver and driven units. Misalignment occurs in a certain direction and, as a result,
the radial forces are not uniformly applied in all radial directions like that from unbalance.
2. The vibration frequencies due to misalignment are usually 1 x, 2x and 3x RPM, and
may appear in any combination depending on the type and extent of misalignment.
Angular misalignment normally causes vibration at 1 x RPM, whereas offset or parallel
misalignment causes vibration predominantly at 2 x RPM. In fact, offset misalignment is
60
probably the most likely cause of a predominate 2 x RPM vibration. Combinations of
angular and offset misalignment may show combinations of 1x and 2 x RPM and in some
cases even 1x, 2x and 3 x RPM.
