Alignment

Alignment, primarily for rotating machinery is the

activity to check that centerlines of two rotating
shafts ( of Driver & Driven machine ) are in line i.e.
collinear with each other at operating conditions.
Rotating Machinery

Driver
Rotating Machinery

Driver Driven
Rotating Machinery

Driver Connector Driven

Rotating Machinery

Driver Connector Driven

Coupling

Motor Pump
Shaft Alignment Fundamentals, Techniques
& Execution Methods

Introduction to shaft alignment

Understanding alignment
Objectives of accurate alignment
Effect of misalignment
Types of misalignment
Misalignment tolerance guide
Pre alignment checks
Alignment techniques
Symptoms of misalignment
Dos & Donts of alignment
Conclusion
 Introduction to Shaft Alignment

Shaft misalignment is the deviation of relative

shaft position from a collinear axis of rotation
measured at the points of power transmission
when equipment is running at normal operating
condition.
 Introduction to Shaft Alignment

Prime interest of alignment is to set the

centerline of rotation of shaft for two or more
pieces of rotating machinery collinear. However,
in practice alignment check is performed on the
coupling & it is assumed that coupling hub bore
& shaft are concentric with each other. So its
necessary to ensure that coupling hub bores &
shaft centerlines are concentric to each other.
Understanding Alignment
Understanding Alignment
Understanding Alignment
Understanding Alignment
 Objectives of Accurate Alignment

Reduce excessive axial and radial forces on the

bearings to insure longer bearing life
Minimize the amount of shaft bending
Minimize the amount of wear in the coupling
components
Reduce mechanical seal failure
Maintain proper internal rotor clearances
Eliminate the possibility of shaft failure from cyclic
fatigue
Lower vibration levels in machine casings,
bearing housings, and rotors
Effect of Misalignment
Effect of Misalignment
Effect of Misalignment
Effect of Misalignment
Types of Misalignment
Types of Misalignment
Types of Misalignment
Types of Misalignment
Misalignment Tolerance
Misalignment Tolerance
 Pre Alignment Checks

Shaft run-out
Soft foot
Distance Between Shaft Ends
Rough Alignment
Piping strain
Tightening Sequence of foundation bolts
Pre Alignment Checks Shaft Run-out
 Pre Alignment Checks Soft Foot
Soft-Foot is
the term
commonly
applied to that
condition which
exists when all
four (4) of the
machine feet
are not
supporting the
weight of the
machine.
 Pre Alignment Checks Soft Foot

Set the machine in place, but do NOT tighten the

hold-down nuts
Attempt to pass a thin feeler gage check for gap
Tighten all hold-down nuts on the machine to be
aligned
Secure a dial indicator holder on one foot
Set the dial indicator to zero (0)
Completely loosen the hold-down nut(s) on that
foot only. Watch the dial indicator for foot
movement during the loosening
If the foot rises from the base when the hold-down
nut(s) is loosened, the leg is having soft foot
Pre Alignment Checks - DBSE
Pre Alignment Checks Rough Alignment
Pre Alignment Checks Piping Strain
Pre Alignment Checks Tightening Sequence
 Machine To Be Moved

The machine which is easy to move & can be

moved in least time with minimum effort is
preferred for movement i.e.

For Pump & Motor train, motor shall be preferred

for movement
For pump & turbine train, turbine shall be
preferred for movement
For compressor, G.box & Turbine train, first
fixing the G.box & carrying out adjustment on
turbine& compressor shall be preferred
 Alignment Techniques

Straight edge & feeler gauge

Shaft alignment using dial indicators :

- Face-Rim method
~ Two indicator method
~ Three indicator method
- Reverse indicator method

Laser alignment method

Alignment Techniques
 Straight Edge & Feeler Gauge Method

Advantages :

Simplest & cheapest of all methods.

Does not require too many tools.
Does not require specialized skills

Disadvantages:

Least accurate of all methods.

Too much Scope for human errors
Face-rim Dial Indicator Method
Face-rim Two Dial Indicator Method
Face-rim Three Dial Indicator Method
Reverse Indicator Method
Laser Alignment
 Symptoms of Misalignment

Premature bearing or Mech. seal failures

Excessive radial and axial vibration
High casing temperatures at or near the
bearings
Excessive amount of oil leakage at the bearing
seals
Loose foundation bolts
Loose or broken coupling bolts
Unusually high number of coupling failures
The shafts are breaking (or cracking) at or close
to the inboard bearings or coupling hubs
 Dos

Always use calibrated dial gauges

Adjust the plunger of the dial gauges so that they are
pressed half ways
Ensure that uniform conventions i.e. top, bottom, north
& south is followed throughout the procedure
Measure all the readings facing the same direction
Follow uniform practice for dial readings-division or mm
Before rotating the machine, ensure that bearings are
lubricated
Always use pre-cut SS shims
Ensure the correctness of readings by taking at least
two set of readings
Check the surfaces where measurements are to be
made are free from burrs or marks
 Donts

Do not hammer the machine feet directly for side

movement. Use side jackscrews for movement
Do not use poorly fabricated or rough alignment
brackets. Use properly machined & sturdy brackets
Never use magnetic dial stand for alignment
Dont use trial & error method for corrective
movements
Dont grind shank of the holding down bolts if
restricting the movement, enlarge the holes
Avoid using too many shims
While measuring the readings if you have passed
the 90 Deg. mark never rotate back, complete the
whole revolution
 Conclusion

Precision alignment
reduces maintenance
cost
Aligned equipment
run longer &
smoother
Always align to a
known tolerance
Dont skip the pre
alignment checks