Professional Documents
Culture Documents
Dial Guage - Alignment PDF
Dial Guage - Alignment PDF
WHITE PAPER
ALIGNMENT
by Greg Towsley
To provide an overview of alignment, the discussion in this article applies primarily to horizontal
centrifugal pumps that are operating in a general
service and driven by a separate driver through a
flexible coupling on a common baseplate.
Many of the terms and techniques described can
be used for other types of pumps and rotating
equipment, but the installation and operation
instructions should be followed as required by
the manufacturer.
This article is meant to be used as a primer only.
Extensive training and practice should be completed prior to aligning equipment that is in service.
GENERAL
The lack of alignment, or misalignment, is a
condition where the rotating centerlines of
two or more machinery shafts are not in line
with each other. This is not easy to detect when
machinery is running. The rotating equipment is
aligned following a series of detailed steps of a
few alignment techniques.
It can be said that the goal of alignment is to
position the equipment so that any deviations
of the shaft centerlines are below specified or
required criterion. Further, the objective is to
ALIGNMENT
ALIGNMENT
ALIGNMENT TERMS
There are a few basic terms used in alignment
that should be reviewed. The specific terms discussed in this section are important to a successful installation.
ALIGNMENT
ANGULAR MISALIGNMENT
Angular misalignment is the term used when two
shaft centerlines are at an angle to each other, as
shown in Figure 4. Angular misalign- ment can
occur in the horizontal or vertical plane of the
shafts. A typical objective is to obtain angular
misalignment to less than 1.
Figure 4. Angular Misalignment
PARALLEL MISALIGNMENT
When the equipment shaft centerlines are parallel, but are offset from each other, as shown in
Figure 5, it is called parallel misalignment. This
type of misalignment can also occur in the horizontal or vertical plane.
It is important to note that equipment shafts can
have angular and parallel misalignment simultaneously. Both must be considered for a successful
installation.
BOLT BOUND
The term bolt bound is used to describe a condition that occurs during the alignment process,
where the driver or pump cannot be moved any
further. The best method to resolve this problem
is to fill-weld the existing bolt hole, redrill in the
proper location, and retap. This problem can also
be resolved by removing the problem equipment
and increasing the diameter of the mounting
holes in the feet.
SHIMS
Shim stock or precut shims are used to raise the
driver during the alignment process. The proper
shimming of the driver should occur only after
the installation of the baseplate has been
finalized and the connection of the piping to the
pump is completed.
Typical of the baseplate manufacturers, a minimum of 0.125 shim under the driver feet will
allow for proper alignment. Although a minimum is recommended, it must be noted that too
many shims may make the installation springy.
A stack of the same size of shims, as shown in
Figure 6, should have five or fewer shims of the
same size. The precut shims should be sized to fit
the bolt of the equipment feet. The stack should
ALIGNMENT
The most common soft foot condition is a parallel air gap, or short foot. This condition is identified when there is an equal gap at all four corners
of a foot. A short foot can occur when one leg of
the driver is too short, when the foot mounting
pad is not in the same plane as the other(s), or
the foot has an inadequate amount of shim under it. If the alignment process has been started,
and an accurate or consistent alignment cannot
be obtained, it is likely that there is a soft foot
condition present.
To check for the parallel air gap, set up the dial
indicator on a foot and loosen mounting bolt. If
the foot moves more than 0.002, or the soft foot
standard defined by the user, the foot is considered soft and needs to be corrected. This should
be done for all feet and documented.
The following example is typical for correcting
parallel air gap or short foot. Figure 8 shows a
view of a motor with various parallel air gap
measurements at each foot. It should be assumed that the gap shown is the same under
each corner of the foot.
ALIGNMENT
To calculate the amount of shim to add to compensate for the short foot, the sum of the smaller
gap values are subtracted from the sum of the
larger gap values.
This amount is divided by two. Use 80% of the
quotient as the amount of shim that should be
added under each foot to remove the parallel air
gap. The equation can be shown as:
Shim to add under Foot #1 and Foot #4
DIAL INDICATORS
Dial indicators are used to measure the amount
of misalignment between the equipment. A dial
indicator (Figure 9) can assist in determining
alignment within 0.001. The dial indicators
come from the manufacturer pre-calibrated, and
must be rechecked on a regular schedule.
Shaft alignment kits are available starting at approximately $600.00. These kits will contain two
ALIGNMENT
(2) alignment frames, roller chain, two (2) dial indicator assemblies with swivel joints and mounting
rods, tubing of varying lengths, instruction manuals, alignment worksheets, and a sturdy carrying
case with handle. This type of kit will handle the
vast majority of shaft alignment situations.
When initially getting ready to use a dial indicator, make sure that it works properly and can
travel the full range of the indicator.
Upon installation of the indicators and at the
beginning of the process, note the direction that
the indicator travels. The indicator should be
adjusted to start at zero (0.000).
The indicator needle traveling clockwise is
considered positive, while counterclockwise is
considered negative travel.
During the alignment process and a full 360
sweep, the summation of the left and right side
readings should equal the summation of the top
and bottom readings.
In addition, the indicators should have read the
same reading (0.000) when it reaches the original position.
BAR SAG
Bar sag is a deflection that occurs in the overhung indicator bar due to the bars weight and
the weight of the indicator. Because of the precision that is required for alignment, the bar sag
must be compensated for.
To determine the amount of bar sag, mount the
indicator on a pipe in same approach, distance,
etc. as it will be mounted on equipment shaft.
Next, zero the indicator on top. Then roll the dial
indicator 180, so that it is located at the bottom.
Read the indicator.
During the alignment process, this bar sag
amount must be included in your alignment
calculations. Instead of zero on the top of the dial
indicator, dial in the positive value of the bar sag
reading. During the alignment process, the dial
indicator should read zero when rolled to bottom.
ALIGNMENT
ALIGNMENT
ALIGNMENT
ALIGNMENT
DEFINITIONS
IB
OB
TIR
FxB
IB Movement =
FxA
D
2.
3.
b.
c.
d.
ii.
R
2
OB Movement =
R
2
ii.
ALIGNMENT
Inches
A=
26
B=
16
D=
Horizontal
er
Mo
IBHorizontal =
Positive (+) = L
Negative (-) =
OBHorizontal =
Vertical
Mo
er
(Add or Remove
Positive (+) =
Negative (-) = emo
IBVertical =
IB = Inboard
OB = Outboard
OBVertical =
(FaceValue)xB
IBMovement =
D
(FaceValue)xA
(Rim Value)
2
OBMovement =
D
(Rim Value)
2
ALIGNMENT
4.
c.
ii.
ii.
e.
5.
6.
ALIGNMENT
ALIGNMENT
Moveable Front
Horizontal
Vertical
-0.005
0.011
Moveable Back
-0.007
0.025
2.
3.
b.
c.
ALIGNMENT
d.
e.
ii.
ALIGNMENT
g.
4.
b.
c.
ii.
ii.
e.
5.
6.
ALIGNMENT
ALIGNMENT
SPECIAL SERVICES
HIGH TEMPERATURE
Abnormally high temperatures can affect the alignment of a pump and its driver. These temperature
changes can be caused by friction in the bearings or
change that occurs with a process liquid.
The thermal growth can occur on pumps in a
hot service, such as in the petroleum industry or
power plants. When the pump is the equipment
in the hot operation, the pump is set and aligned
lower than the driver. This is called cold setting.
This will allow for the thermal growth.
The pump manufacturer will typically have a chart
available to assist in the proper alignment. The
manufacturers recommendations should always
be followed for the exact piece of equipment.
If the driver is the high temperature equipment,
such as with a steam turbine, the driver shaft
should be set lower than the pump shaft to compensate for vertical expansion of that equipment.
After the equipment reaches normal operating
temperatures, alignment should be verified.
VERTICAL PUMPS
For services located in process plants, alignment
of vertical pumps must be considered. This is
especially true if the driver thrust bearing carries
the load of the driver and the pump.
Because of the importance of the driver thrust
bearing in this pump and driver configuration,
accurate radial and angular alignment between
driver and the pump is essential.
As part of the precision alignment process of
vertical pumps, the driver shaft runout and
concentricity with the mounting fit must be
ALIGNMENT
REFERENCES
1. National Electrical Manufacturers Association
(NEMA), 1300 North 17th Street, Suite 1847,
Rosslyn, VA 22209; http://www.nema.org.
ACKNOWLEDGEMENTS
Figures 2, 6, 7, 9, 17, and 18:
Diagnostic Solutions, LLC.