Eliminate Stray Losses

Stray losses contributes 10 – 15% of

motor losses
 What are the causes?
• Damaged to air gap surfaces.
• Uneven air gap (i.e., rotor eccentric with respect to stator
bore).
– Dismounting of bearings using cutting torch.
– Manner of how to repair rotor shaftings.
– Misalignment
• Damage to end laminations – the manner how to remove
burnt windings.
 There are several ways to return bearing fits
which include:
• Peening: the practice of punching or marring mechanical fits to create a tighter fit. This practice is
not recommended for repair as it is ‘uncontrolled.’
• Metalizing: consists of a one- or two-part spray process that requires metal to be removed first.
This process is susceptible to separation from the material to which it is bonded in instances of
non-symmetrical pressure or when the surfaces have not been properly prepared. This practice
should not be considered when world-class energy efficient motor repair and reliability are being
considered.
• Welding: similar to metalizing. However, it creates a stronger metal-to-metal bond when properly
applied. If a repair requires adding metal, this is the preferred method as compared to metalizing.
However, significant experience is required in order to prevent stress fractures in the material.
• Sleeving: the process of returning fits by machining and sleeving a motor shaft or housing. This is
the recommended method of motor repair as it is more controlled.
• Re-fabrication: while expensive, this method is the best for machining severely worn parts, shafts in
particular.

BROKEN SHAFT OR WORN OUT SHAFT MOST COMING IS THE

END RESULT OF MISALIGNMENT.
Shaft/Housing Interference fits
Shaft interference fit
Housing interference fit
• All of the mechanical fits on
the motor must be tested
using calibrated outside and
inside micrometers. The
critical areas that effect
efficiency include the
bearing journals and
housings. If the fits are too
loose or tight, both the
efficiency and the bearing
life will be reduced.
Check Shaft Run-out & Repair
Shaft Run-out
Common problems that can be detected & corrected

• Detection: Vibration
Analyzers. E.g.
OneproDMVP-2C of
01dB-Metravib/Areva.
• Corrective: Express
Alignment System of
Fixturlaser AB.
The Importance of Motor Shaft
Alignment
How precise is your alignment
How precise is your alignment
 Symptoms of misalignment
• Wearing of coupling inserts
• Broken coupling bolts
• Damage foundation
• Excessive vibration
Before cracks were rectified

Cracks found were rectified Coupled

28.48 mm/s

Uncoupled
6.09 mm/s

Broken coupling bolts

 Alignment Tolerance

Alignment Rotational Acceptable Tolerance Alignment Rotational Acceptable Tolerance

Condition Speed mils mm Condition Speed mils mm
Parallel 0 - 1000 5 0.13 Angular 0 - 1000 4 0.1
Offset 1 - 2000 4 0.1 Error 1 - 2000 3.5 0.08
2 - 3000 3 0.07 2 - 3000 2.5 0.07
3 - 4000 2 0.04 3 - 4000 2 0.06
4 - 5000 1.5 0.03 4 - 5000 1.5 0.05
5 - 6000 < 1.5 < 0.03 5 - 6000 1.5 0.04

We shall based our tolerance at a speed of 1000 – 2000 rpm.

•Parallel Offset tolerance = 0.10 mm
•Angular Error = 0.08 mm
Actual Alignment Result
 What is the problem?

Misalignment generates forces in the

coupling between the machines
 Rotational centers

All shafts, whether they are straight or bent, rotate on an axis

called the rotational center.

The rotational center forms a straight line.

 Misalignment

Misalignment - when the two shafts are not collinear.

 Types of misalignment
Offset misalignment

Angular misalignment
 Measuring Misalignment
Viewed from the top - Horizontal Misalignment

Viewed from the side - Vertical Misalignment

 Shaft alignment – basics
Measure and adjust the machines so there
rotational centers are colinear
Shaft alignment - basics
One of the machines is a reference–
Stationary machine
 Shaft alignment - basics
The second machine is adjusted
Moveable machine
 Shaft alignment - basics
The alignment system measure the position of the
moveable machine according to the stationary
 Shaft alignment - basics
Adjustments are done on the moveable
machine until the two rotational centers are
collinear.
Alignment tolerances
 Alignment Methods
With all alignment methods measurements are taken at the
shafts or couplings.
 Alignment Methods
Misalignment is corrected at the feet.
Alignment Methods
 Mechanical methods
Straight edge/feeler gauge method

Determine the direction and amount of offset using a

straight edge and feeler gauges.

Measure the gap at two points 180° apart to determine

the direction and amount of angular misalignment.
 Dial indicator methods
Rim-Face method

Reversed-Rim method
 Rim- Face Alignment method

The rim dial measures offset

The face dial measures angularity

Reversed- Rim alignment method

• Widely acknowledged as the

“preferred method” of shaft
alignment.

• Both dials measure offset on the

Rim. The Angular error is the
slope between the two offset
values.

• Easy to plot or calculate the feet

correction values.
 Laser systems
Single laser systems with a single or
double detectors.

Twin laser systems using the Reversed-

Rim method.
Misalignmet – the biggest single
cause to high vibration levels
Misalignment – is it common?

Studies has shown that up to

90% of all rotating machinery
runs outside recommended
alignment tolerances.
Shaft alignment – it is important!
• Key factor in successful
condition based maintenance
• Misaligned machines are the
single largest cause to high
vibration levels.
• Cause failure in bearings, seals
and couplings
• Will lead to machine breakage
and increased down-time if not
implemented
 Vibrations

General and coarse analyse of vibration results:

• Horizontal vibration indicates unbalance (H)
• Vertical vibrations indicates a weak or loose foundation(V)
• Axial vibrations indicates misalignment (A)

38
 Energy savings

Correctly aligned machines can save up to 15% in energy

consumption, sometimes more

39
 Wear of components

Bearings
Increased load will mean an exponential decrease in lifetime
on bearings.
Example: double the load, reduce the lifetime to 1/8

40
 Wear of components

Seals
Misalignment can reduce
lifetimes of mechanical seals
with 50-70%.

Leakage - a typical indication of

misalignment

41
 Production capacity

• A modern production process is extremely

depenent on availability.
• Cost for lost production is high, 10-100
kUSD/h
• The cost of a stop in production is normally a
lot higher than cost for, be several times…

42
 Product quality

• Decreased vibration levels can

directly give effect on product
quality.
• Example: products with high
level of surface treamment could
be directly effected by
misalignment.

43
 Implementation
Important factors:
•Increase the awareness and motivate– why?
•Choose an alignment system/procedure that makes it simple to
understand how to do it
•Stream-line and standardize procedures
•Train all people involved
•Demand that external companies performs alignment in your way.
•Document results (better prediction, justify costs)
 Impact if corrected
• Reduce energy consumption by 2 – 7% in
current drawn.
• Increase service life of motor bearings as well
the shaft.
• Reduce 10 – 15% stray load losses
 Use of precision alignment tools

Fixturlaser Pulley Alignment Tool

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http://www.fixturlaser.com